Subaru Impreza 2002

2002 Model Year
PDF Service Manual
GENERAL INFORMATION SECTION (Pub.No.G1840GE1)

ENGINE 1 SECTION (Pub.No.G1840GE2)
ENGINE 2 SECTION (Pub.No.G1840GE3)
TRANSMISSION SECTION (Pub.No.G1840GE4)
CHASSIS SECTION (Pub.No.G1840GE5)
BODY SECTION (Pub.No.G1840GE6)
WIRING SYSTEM SECTION (Pub.No.G1840GE7)
2002 IMPREZA 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.
G1840GE1
FOREWORD
FW
1.
Page
Foreword .....................................................................................................2
FOREWORD
FOREWORD
1. Foreword
A: FOREWORD
These manuals are used when performing maintenance, repair, or diagnosis of the Subaru IMPREZA.
Applied model: GG***** and GD***** from 2002MY.
The additional manuals below are also available:
AUTOMATIC TRANSMISSION SERVICE MANUAL (Pub. No. G0864ZE)
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

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
diagnosis information has also been added where
necessary.
2. INDEX
The first page has an index with tabs. And at the
end of each section is an alphabetical index.
3. COMPONENTS
For each component, a composition drawing is included.
4. SPECIFICATIONS
If necessary, specifications are also included.
5. INSPECTION
Inspections are included to be carried out before
and after maintenance.
6. MAINTENANCE
Maintenance instructions are provided for each
component. When multiple components comprise
one process, refer to the instructions for that process for each component.
7. DIAGNOSIS
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.
HU-2
SPECIFICATIONS
SPC
1.
Page
Impreza SA08731 .......................................................................................2
IMPREZA
SPECIFICATIONS
1. Impreza
SA08731
A: DIMENSIONS
SA08731G28
Model
Overall length
Overall width
Overall height (at C.W.)
Compartment
Wheelbase
Tread
Minimum road
clearance
Sedan
mm (in)
mm (in)
mm (in)
Length
Width
Height
mm (in)
mm (in)
mm (in)
Front
mm (in)
mm (in)
Rear
mm (in)
Without catalytic
converter
With catalytic
converter
mm (in)
mm (in)
1,730 (68.1)
1,440 (56.7)
1,890 (74.4)
1,180 (46.5),
1,125 (44.3)5
1,485 (58.5)
1,475 (58.1),
1,480 (58.3)3
150 (5.9),
155 (6.1)2
150 (5.9),
155 (6.1)3
Wagon
OUTBACK
4,405 (173.4)
1,695 (66.7)
1,710 (67.3)
1,465 (57.7),
1,475 (58.1),
1,485 (58.5)4
1,495 (58.9)4
1,845 (72.6)
1,380 (54.3)
1,200 (47.2),
1,200 (47.2),
1,150 (45.3)5
1,150 (45.3)5
2,525 (99.4)
1,460 (57.5)1,
1,460 (57.5)
1,465 (57.7)
1,450 (57.1)1,
1,455 (57.3)
1,455 (57.3)
150 (5.9),
160 (6.3)
155 (6.1)2
150 (5.9),
160 (6.3)
155 (6.1)3
1: 1.6 L
2: 2.0 L
3: 2.0 L Turbo
4: With roof rail
5: With sun roof
B: ENGINE
SA08731G29
Model
Engine type
Valve arrangement
Bore Stroke
Displacement
Compression ratio
Firing order
Idle speed at Park/Neutral
position
Maximum output
Maximum torque
mm (in)
cm3 (cu in)
rpm
1.6 L
Non-Turbo 2.0 L
Turbo 2.0 L
2.5 L
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Overhead camshaft type
87.9 65.8
92 75
99.5 79
(3.461 2.591)
(3.62 2.95)
(3.92 3.11)
1,597 (97.45)
1,994 (121.67)
2,475 (151.03)
10.0 0.2
8.0 0.2
1324
10.0 0.2
700 100
750 100
700 100
kW (HP)/rpm
70 (94)/5,200
92 (123)/5,600
160 (215)/5,600 112 (150)/5,600
Nm (kgf-m, ft-lb)/rpm 143 (14.6, 105.5) 184 (18.8, 136.0) 292 (29.8, 215.4) 223 (22.7, 164.5)
/3,600
/3,600
/3,600
/3,600
SPC-2
IMPREZA
SPECIFICATIONS
C: ELECTRICAL
Model
Ignition timing at
idling speed
Spark Type and
plug
manufacturer
SA08731G30
BTDC/rpm
Without
OBD
With OBD
Generator
Battery Type and
capacity
(5HR)
Model
Transmission type
Clutch type
Gear ratio
510/700
1010/700
1210/750
2.5 L
MT: 1010/700
AT: 1510/700
NGK: BKR6E (without
catalyst)
CHAMPION: RC10YC4
(with catalyst)
NGK: BKR5E-11 (with
catalyst)
NGK: BKR6E
(without catalyst)
CHAMPION:
RC10YC4
(with catalyst)
NGK: BKR5E-11
(with catalyst)
CHAMPION:
RC10YC4
NGK: PFR6G
Alternate
NGK: BKR5E-11
12V 75A
12V 48AH
(55D23L)
CHAMPION: RC10YC4
Alternate
NGK: BKR6E-11
MT: 12V 48AH
(55D23L)
AT: 12V 52AH
(75D23L)
MT: 12V 48AH (55D23L)

AT: 12V 52AH (65D23L)
12V 27AH (34B19L)
1.6 L
5MT
4AT
DSPD
TCC
Non-turbo 2.0 L
5MT
4AT
DSPD
TCC
3.454
2.785
3.454
2.785
2.062
1.545
2.062
1.545
1.448
1.000
1.448
1.000
1.088
0.694
1.088
0.694
0.825
0.825
0.738
Final
reduction
Reverse
Dual range
Type of gear
Gear ratio
Type of gear
Gear ratio
3.333
1.447
Hypoid
2.272
Helical
1.000
Hypoid
3.333
1.447
Hypoid
2.272
Helical
1.000
Hypoid
2.272
Helical
1.000
Hypoid
4.111
4.444
3.900
4.111
Transfer
reduction
Type of gear
Gear ratio
Helical
Helical
1.000
1.000
Final
reduction
Type of gear
Gear ratio
Hypoid
Hypoid
Hypoid
Hypoid
4.111
4.444
3.900
4.111
3.333
Hypoid
3.900,
4.4441
Helical
1.100,
1.0001
Hypoid
3.545,
4.4441
1st
3rd
4th
5th
Reduction
gear (Rear
drive)
Turbo 2.0 L
SA08731G31
2nd
Reduction
gear (Front
drive)
Non-turbo 2.0 L
NGK: BKR6E
(without catalyst)
CHAMPION:
RC8YC4
(with catalyst)
NGK: BKR6E-11
(with catalyst)
CHAMPION:
RC8YC4
Alternate
NGK: BKR6E-11
For
Europe
and South
America
Others
D: TRANSMISSION
1.6 L
1st
reduction
5MT: 5 forward speeds with synchromesh and 1-reverse

4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse
DSPD: Dry Single Plate Diaphragm
TCC: Torque Converter Clutch
1: Australia spec vehicle
SPC-3
Turbo 2.0 L
5MT
4AT
DSPD
TCC
3.454,
2.785
3.1661
1.947,
1.545
1.8821
1.366,
1.000
1.2961
0.972
0.694
2.5 L
5MT
4AT
DSPD
TCC
3.454
2.785
2.062
1.545
1.448
1.000
0.694
2.272
Helical
1.000
Hypoid
1.088
0.871,
0.7801
3.333
Hypoid
3.700,
4.1111
Helical
1.000
Hypoid
Hypoid
3.700,
4.1111
Hypoid
4.111
4.111
4.111
4.111
IMPREZA
SPECIFICATIONS
E: STEERING
SA08731G32
Model
Type
Turns, lock to lock
Turbo 2.0 L, 2.5 L
Minimum turning circle
m (ft)
F: SUSPENSION
Curb to curb
Wall to wall
3.0
3.2
10.8 (35.4)
11.6 (38.1)
10.4 (34.1)
11.2 (36.7)
Macpherson strut type, Independent, Coil spring

Dual-link type, Independent, Coil spring
G: BRAKE
SA08731G34
Model
Service brake system
Front
Rear
Parking brake
1.6 L
Non-turbo 2.0 L, 2.5 L
Turbo 2.0 L
Dual circuit hydraulic with vacuum suspended power unit
Ventilated disc brake
Drum brake
Disc brake
Ventilated disc brake
Mechanical on rear brakes
SA08731G35
Rim size
14 51/2JJ
Tire size
175/70R14 84T
185/70R14 88H
15 6JJ
CAPACITY
Model
16 61/2JJ
17 7JJ
185/65R15 88H
P205/55R16 89V
195/60R15 88H
205/50R16 87V
Steel belted radial, Tubeless
Type
I:
OTHERS
SA08731G33
Front
Rear
H: TIRE
RHD: 2.7
LHD: 3.0
11.0 (36.1)
12.0 (39.4)
OUTBACK
Rack and Pinion
215/45R17 87W
SA08731G36
1.6 L
5MT
4AT
50 (13.2, 11.0)
Fuel tank
2 (US gal, Imp gal)
Engine Total
2 (US qt, Imp qt)
oil
capacity
Engine
2 (US qt, Imp qt)
oil
amount
for refill
Transmission
2 (US qt, Imp qt)
3.5
gear oil
(3.7, 3.1),
4.0
(4.2, 3.5)
1
Automatic trans2 (US qt, Imp qt)
mission fluid
AT differential
2 (US qt, Imp qt)
gear oil
AWD rear differ2 (US qt, Imp qt)
ential gear oil
Power steering
2 (US qt, Imp qt)
fluid
Engine coolant
2 (US qt, Imp qt)
7.4
(7.8, 6.5)
Non-turbo 2.0 L
5MT
4AT
50 (13.2, 11.0)
Turbo 2.0 L
2.5 L
5MT
4AT
5MT
4AT
60 (15.9, 13.2)
4.5 (4.8, 4.0)
5.0 (5.3, 4.4)
4.5 (4.8, 4.0)
Approx. 4.5 (4.8, 4.0)
Approx.
5.0 (5.3, 4.4)
Approx.
4.5 (4.8, 4.0)
3.5
(3.7, 3.1),
4.0
(4.2, 3.5)
1
8.4
(8.9, 7.4)
1.2
(1.3, 1.1)
8.4
(8.9, 7.4)
1.2
(1.3, 1.1)
3.5
(3.7, 3.1)
9.3
(9.8, 8.2)
1.2
(1.3, 1.1)
3.5
(3.7, 3.1)
9.3
(9.8, 8.2)
1.2
(1.3, 1.1)
0.8 (0.8, 0.6)

0.7 (0.7, 0.6)
7.3
7.0
6.9
7.7
7.7
7.0
6.9
(7.7, 6.4) (7.4, 6.2) (7.3, 6.1) (8.1, 6.8) (8.1, 6.8) (7.4, 6.2) (7.3, 6.1)
1: Dual range
SPC-4
IMPREZA
SPECIFICATIONS
J: WEIGHT
SA08731G37
1. LHD VEHICLE
SA08731G3703
Sedan
Option code1
Model
Curb weight (C.W.)
Maximum permissible
axle weight (M.P.A.W.)
Maximum permissible
weight (M.P.W.)
Option
EC
Maximum permissible
Maximum permissible
weight (M.P.W.)
Option
K0
KS
1.6 L
AWD
TS
Front
kgf (lb)
Rear
kgf (lb)
Total
kgf (lb)
Front
kgf (lb)
Rear
kgf (lb)
Total
kgf (lb)
Air conditioner
Cruise control
ABS
Aluminium wheel
Rear spoiler
Spoiler pac
5MT
730
(1,609)
520
(1,146)
1,250
(2,755)
890
(1,962)
890
(1,962)
1,700
(3,748)
Option code1
Model
Curb weight (C.W.)
K4
4AT
750
(1,654)
520
(1,146)
1,270
(2,800)
890
(1,962)
890
(1,962)
1,700
(3,748)
5MT
750
(1,654)
520
(1,146)
1,270
(2,800)
890
(1,962)
890
(1,962)
1,700
(3,748)
EC
4AT
770
(1,698)
520
(1,146)
1,290
(2,844)
890
(1,962)
890
(1,962)
1,700
(3,748)
5MT
750
(1,654)
520
(1,146)
1,270
(2,800)
890
(1,962)
890
(1,962)
1,700
(3,748)
K4
4AT
770
(1,698)
520
(1,146)
1,290
(2,844)
890
(1,962)
890
(1,962)
1,700
(3,748)
5MT
740
(1,631)
535
(1,179)
1,275
(2,810)
890
(1,962)
890
(1,962)
1,700
(3,748)
K0
4AT
760
(1,676)
535
(1,179)
1,295
(2,855)
890
(1,962)
890
(1,962)
1,700
(3,748)
KS
2.0 L
AWD
GX
Front
kgf (lb)
Rear
kgf (lb)
Total
kgf (lb)
Front
kgf (lb)
Rear
kgf (lb)
Total
kgf (lb)
Air conditioner
Cruise control
ABS
Aluminium wheel
Rear spoiler
Spoiler pac
5MT
745
(1,643)
535
(1,179)
1,280
(2,822)
920
(2,028)
910
(2,006)
1,760
(3,880)
4AT
770
(1,698)
530
(1,168)
1,300
(2,866)
920
(2,028)
910
(2,006)
1,760
(3,880)
5MT
765
(1,687)
530
(1,168)
1,295
(2,855)
920
(2,028)
910
(2,006)
1,760
(3,880)
1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
SPC-5
4AT
790
(1,742)
525
(1,157)
1,315
(2,899)
920
(2,028)
910
(2,006)
1,760
(3,880)
5MT
760
(1,676)
525
(1,157)
1,285
(2,833)
920
(2,028)
910
(2,006)
1,760
(3,880)
4AT
795
(1,753)
530
(1,168)
1,325
(2,921)
920
(2,028)
910
(2,006)
1,760
(3,880)
5MT
750
(1,653)
550
(1,213)
1,300
(2,866)
920
(2,028)
910
(2,006)
1,760
(3,880)
4AT
780
(1,720)
545
(1,202)
1,325
(2,922)
920
(2,028)
910
(2,006)
1,760
(3,880)
IMPREZA
SPECIFICATIONS
Option code1
Model
EC
2.5 L
2.0 L Turbo
AWD
RS
Curb weight (C.W.)
Maximum permissible
Maximum permissible
weight (M.P.W.)
Option
Front
Rear
Total
Front
Rear
Total
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
Air conditioner
Cruise control
ABS
Aluminium wheel
Rear spoiler
Spoiler pac
5MT
760 (1,676)
535 (1,179)
1,295 (2,855)
930 (2,050)
910 (2,006)
4AT
785 (1,731)
530 (1,168)
1,315 (2,899)
930 (2,050)
910 (2,006)
WRX
5MT
815 (1,797)
550 (1,213)
1,365 (3,009)
970 (2,138)
920 (2,028)
1,780 (3,924)
1,780 (3,924)
1,850 (4,079)
SPC-6
IMPREZA
SPECIFICATIONS
Wagon
Option code1
Model
Curb weight (C.W.)
Maximum permissible
Maximum permissible
weight (M.P.W.)
Option
EC
Maximum permissible
Maximum permissible
weight (M.P.W.)
Option
K0
KS
1.6 L
AWD
TS
Front
kgf (lb)
Rear
kgf (lb)
Total
kgf (lb)
Front
kgf (lb)
Rear
kgf (lb)
Total
kgf (lb)
Air conditioner
Cruise control
ABS
Aluminium wheel
Rear spoiler
Spoiler pac
D/R
735
(1,620)
545
(1,202)
1,280
(2,822)
900
(1,984)
910
(2,006)
1,730
(3,814)
Option code1
Model
Curb weight (C.W.)
K4
4AT
750
(1,653)
545
(1,202)
1,295
(2,855)
900
(1,984)
910
(2,006)
1,730
(3,814)
D/R
755
(1,664)
545
(1,202)
1,300
(2,866)
900
(1,984)
910
(2,006)
1,730
(3,814)
EC
4AT
770
(1,698)
545
(1,202)
1,315
(2,900)
900
(1,984)
910
(2,006)
1,730
(3,814)
D/R
755
(1,664)
545
(1,202)
1,300
(2,866)
900
(1,984)
910
(2,006)
1,730
(3,814)
K4
4AT
770
(1,698)
545
(1,202)
1,315
(2,900)
900
(1,984)
910
(2,006)
1,730
(3,814)
D/R
745
(1,642)
560
(1,235)
1,305
(2,877)
900
(1,984)
910
(2,006)
1,730
(3,814)
K0
4AT
760
(1,676)
560
(1,235)
1,320
(2,911)
900
(1,984)
910
(2,006)
1,730
(3,814)
KS
2.0 L
AWD
GX
Front
kgf (lb)
Rear
kgf (lb)
Total
kgf (lb)
Front
kgf (lb)
Rear
kgf (lb)
Total
kgf (lb)
Air conditioner
Cruise control
ABS
Aluminium wheel
Rear spoiler
Spoiler pac
D/R
755
(1,664)
570
(1,257)
1,325
(2,921)
920
(2,028)
960
(2,116)
1,800
(3,969)
4AT
770
(1,698)
565
(1,246)
1,335
(2,944)
920
(2,028)
960
(2,116)
1,800
(3,969)
D/R
775
(1,709)
565
(1,246)
1,340
(2,955)
920
(2,028)
960
(2,116)
1,800
(3,969)
D/R: Dual range

SPC-7
4AT
790
(1,742)
560
(1,235)
1,350
(2,977)
920
(2,028)
960
(2,116)
1,800
(3,969)
D/R
780
(1,720)
570
(1,257)
1,350
(2,977)
920
(2,028)
960
(2,116)
1,800
(3,969)
4AT
795
(1,753)
565
(1,246)
1,360
(2,999)
920
(2,028)
960
(2,116)
1,800
(3,969)
D/R
760
(1,676)
580
(1,279)
1,340
(2,955)
920
(2,028)
960
(2,116)
1,800
(3,969)
4AT
780
(1,720)
575
(1,268)
1,355
(2,988)
920
(2,028)
960
(2,116)
1,800
(3,969)
IMPREZA
SPECIFICATIONS
Option code1
Model
Curb weight (C.W.)
Maximum permissible
Maximum permissible
weight (M.P.W.)
Option
EC
K4
2.0 L Turbo
AWD
WRX
5MT
Front
Rear
Total
Front
Rear
Total
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
Air conditioner
Cruise control
ABS
Aluminium wheel
Rear spoiler
Spoiler pac
805 (1,775)
585 (1,290)
1,390 (3,065)
970 (2,138)
950 (2,094)
825 (1,819)
585 (1,290)
1,410 (3,109)
970 (2,138)
950 (2,094)
1,860 (4,101)
1,860 (4,101)
D/R: Dual range

SPC-8
IMPREZA
SPECIFICATIONS
2. RHD VEHICLE
SA08731G3704
Sedan
Option code1
Model
Curb weight (C.W.)
Maximum permissible
Maximum permissible
weight (M.P.W.)
Option
EK
Front
Rear
Total
Front
Rear
Total
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
Air conditioner
Cruise control
ABS
Aluminium wheel
Rear spoiler
Spoiler pac
5MT
735 (1,621)
520 (1,146)
1,255 (2,767)
890 (1,962)
890 (1,962)
4AT
755 (1,665)
520 (1,146)
1,275 (2,811)
890 (1,962)
890 (1,962)
5MT
750 (1,654)
520 (1,146)
1,270 (2,800)
890 (1,962)
890 (1,962)
4AT
770 (1,698)
520 (1,146)
1,290 (2,844)
890 (1,962)
890 (1,962)
1,700 (3,748)
1,700 (3,748)
1,700 (3,748)
1,700 (3,748)
Option code1
Model
Curb weight (C.W.)
Maximum permissible
Maximum permissible
weight (M.P.W.)
Option
K1
1.6 L
AWD
TS
EK
K1
2.0 L
AWD
GX
Front
Rear
Total
Front
Rear
Total
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
Air conditioner
Cruise control
ABS
Aluminium wheel
Rear spoiler
Spoiler pac
5MT
765 (1,687)
535 (1,179)
1,300 (2,866)
920 (2,028)
910 (2,006)
4AT
790 (1,742)
530 (1,168)
1,320 (2,910)
920 (2,028)
910 (2,006)
5MT
770 (1,698)
535 (1,179)
1,305 (2,877)
920 (2,028)
910 (2,006)
4AT
795 (1,753)
530 (1,168)
1,325 (2,921)
920 (2,028)
910 (2,006)
1,760 (3,880)
1,760 (3,880)
1,760 (3,880)
1,760 (3,880)
SPC-9
IMPREZA
SPECIFICATIONS
Option code1
Model
2.0 L
KA
2.5 L
GX
RS
EK
2.0 L Turbo
AWD
Curb weight (C.W.)
Maximum permissible
Maximum permissible
weight (M.P.W.)
Option
Front
kgf (lb)
Rear
kgf (lb)
Total
kgf (lb)
Front
kgf (lb)
Rear
kgf (lb)
Total
kgf (lb)
Air conditioner
Cruise control
ABS
Aluminium wheel
Rear spoiler
Spoiler pac
5MT
750
(1,653)
535
(1,179)
1,285
(2,833)
920
(2,028)
910
(2,006)
1,760
(3,880)
4AT
775
(1,709)
530
(1,168)
1,305
(2,877)
920
(2,028)
910
(2,006)
1,760
(3,880)
5MT
780
(1,720)
540
(1,191)
1,320
(2,910)
930
(2,050)
910
(2,006)
1,780
(3,924)
SPC-10
4AT
805
(1,775)
535
(1,179)
1,340
(2,954)
930
(2,050)
910
(2,006)
1,780
(3,924)
5MT
830
(1,830)
560
(1,235)
1,390
(3,065)
970
(2,138)
920
(2,028)
1,850
(4,079)
WRX
4AT
855
(1,885)
555
(1,224)
1,410
(3,109)
970
(2,138)
920
(2,028)
1,850
(4,079)
5MT
830
(1,830)
560
(1,235)
1,390
(3,065)
970
(2,138)
920
(2,028)
1,850
(4,079)
IMPREZA
SPECIFICATIONS
Wagon
Option code1
Model
Curb weight (C.W.)
Maximum permissible
Maximum permissible
weight (M.P.W.)
Option
EK
Front
Rear
Total
Front
Rear
Total
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
Air conditioner
Cruise control
ABS
Aluminium wheel
Rear spoiler
Spoiler pac
D/R
740 (1,631)
545 (1,202)
1,285 (2,833)
900 (1,984)
910 (2,006)
4AT
755 (1,664)
545 (1,202)
1,300 (2,866)
900 (1,984)
910 (2,006)
D/R
755 (1,664)
545 (1,202)
1,300 (2,866)
900 (1,984)
910 (2,006)
4AT
770 (1,698)
545 (1,202)
1,315 (2,900)
900 (1,984)
910 (2,006)
1,730 (3,814)
1,730 (3,814)
1,730 (3,814)
1,730 (3,814)
Option code1
Model
Curb weight (C.W.)
Maximum permissible
Maximum permissible
weight (M.P.W.)
Option
K1
1.6 L
AWD
TS
EK
K1
2.0 L
AWD
GX
Front
Rear
Total
Front
Rear
Total
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
Air conditioner
Cruise control
ABS
Aluminium wheel
Rear spoiler
Spoiler pac
D/R
775 (1,709)
570 (1,257)
1,345 (2,965)
920 (2,028)
960 (2,116)
4AT
790 (1,742)
565 (1,246)
1,355 (2,987)
920 (2,028)
960 (2,116)
D/R
780 (1,720)
570 (1,257)
1,350 (2,977)
920 (2,028)
960 (2,116)
4AT
795 (1,753)
565 (1,246)
1,360 (2,999)
920 (2,028)
960 (2,116)
1,800 (3,968)
1,800 (3,968)
1,800 (3,968)
1,800 (3,968)
D/R: Dual range

SPC-11
IMPREZA
SPECIFICATIONS
Option code1
Model
KA
2.0 L
AWD
GX
Curb weight (C.W.)
Maximum permissible
Maximum permissible
weight (M.P.W.)
Option
Front
Rear
Total
Front
Rear
Total
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
Air conditioner
Cruise control
ABS
Aluminium wheel
Rear spoiler
Spoiler pac
Option code1
Model
Curb weight (C.W.)
Maximum permissible
Maximum permissible
weight (M.P.W.)
Option
OUT BACK
D/R
760 (1,676)
570 (1,257)
1,330 (2,932)
920 (2,028)
960 (2,116)
4AT
775 (1,709)
565 (1,246)
1,340 (2,954)
920 (2,028)
960 (2,116)
D/R
750 (1,653)
570 (1,257)
1,320 (2,910)
920 (2,028)
960 (2,116)
4AT
765 (1,687)
570 (1,257)
1,335 (2,943)
920 (2,028)
960 (2,116)
1,800 (3,968)
1,800 (3,968)
1,800 (3,968)
1,800 (3,968)
EX
Front
Rear
Total
Front
Rear
Total
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
Air conditioner
Cruise control
ABS
Aluminium wheel
Rear spoiler
Spoiler pac
KA
5MT
825 (1,819)
585 (1,290)
1,410 (3,109)
970 (2,138)
950 (2,094)
2.0 L Turbo
AWD
WRX
5MT
825 (1,819)
585 (1,290)
1,410 (3,109)
970 (2,138)
950 (2,094)
4AT
850 (1,874)
585 (1,290)
1,435 (3,164)
970 (2,138)
950 (2,094)
1,860 (4,101)
1,860 (4,101)
1,860 (4,101)
D/R: Dual range

SPC-12
PRECAUTION
PC
1.
Page
Precaution ...................................................................................................2
PRECAUTION
PRECAUTION
1. Precaution
7. AIRBAG MODULE
A: PRECAUTION
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
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.
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 individual parts. Doing
so could prevent the ABS system from operating
when needed or cause it to operate incorrectly and
result in injury.
2. BRAKE FLUID
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.
3. ELECTRIC FAN
The electric fan may rotate without warning, even
when the engine is not on. Do not place your hand,
cloth, tools, or other items near the fan at any time.
8. AIRBAG SPECIAL TOOLS

To prevent unexpected deployment, only use special tools.
9. WINDOW
Always wear safety glasses when working around
any glass to prevent glass fragments from damaging your eyes.
10.WINDOW ADHESIVE
Always use the specified urethane adhesive when
attaching glass to prevent it from coming loose and
falling, resulting in accidents and injury.
4. ROAD TESTS
Always conduct road tests in accordance with traffic rules and regulations to avoid bodily injury and
interrupting traffic.
5. AIRBAG
To prevent bodily injury from unexpected deployment of airbags and unnecessary maintenance, follow the instructions in this manual when performing
maintenance on airbag components or nearby, and
airbag wiring harnesses or nearby.
To prevent unexpected deployment, perform one of
the steps below and then wait at least 20 seconds
to discharge electricity before beginning work.
Step 1: Turn the ignition switch OFF.
Step 2: Disconnect the ground cable from battery.
6. AIRBAG DISPOSAL
To prevent bodily injury from unexpected airbag
deployment, do not dispose airbag modules in the
same way as other refuse. Follow the special instructions for disposal in this manual. Follow all
government regulations concerning disposal of
refuse.
PC-2
NOTE
NT
1.
Page
Note.............................................................................................................2
NOTE
NOTE
1. Note
A: NOTE
This is information that can improve efficiency of
maintenance and assure sound work.
1. FASTENER NOTICE
Fasteners are used to prevent parts from damage
and dislocation due to looseness. Fasteners must
be tightened to the specified torque.
Do not apply paint, lubricant, rust retardant, or other substances to the surface around bolts, fasteners, etc. Doing so will make it difficult to obtain the
correct torque and result in looseness and other
problems.
2. STATIC ELECTRICITY DAMAGE

Do not touch the ECM, connectors, logic boards,
and other such parts when there is a risk of static
electricity. Always use a static electricity prevention
cord or touch grounded metal before conducting
work.
3. IGNITION OFF BATTERY

When removing the battery cables, always be sure
to turn the ignition off to prevent electrical damage
to the ECM from rush current.
4. SERVICE PARTS
Use authentic service parts for maximum performance and maintenance, when conducting repairs.
Subaru/FHI will not be responsible for poor performance resulting from the use of parts not specified
by a genuine dealer.
NT-2
NOTE
NOTE
5. LIFTS AND JACKS

When using a lift or jack-ridged rack to raise a vehicle, always follow instructions concerning jack-up points
and weight limits to prevent the vehicle from falling, which could result in injury. Be especially careful to make
sure the vehicle is balanced before raising it.
Support locations
Without side sill cover

With side sill cover
Pantograph jack
Lift
Safety stand
GI0120
NT-3
NOTE
NOTE
Front
Front crossmember
Rear
Rear differential
GI0121
NT-4
NOTE
NOTE
6. TIE DOWNS
Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie downs only
to the specified points on the vehicle.
Hook for tie-down
Hook for towing
Hook for tie-down
Hook for towing

and tie-down
GI0122
NT-5
NOTE
NOTE
GI0103
20
20
20
20
20
20
20
20
45
45
45
: Tie-down range
45
GI0123
7. TOWING
Avoid towing vehicles except when the vehicle cannot be driven. For vehicles with AWD, AT, or VTD,
use a loader instead of towing. When towing other
vehicles, to prevent excessive weight from damaging the hook or vehicle:
Do not tow other vehicles with a front towing
hook.
Make sure the vehicle towing is heavier that the
vehicle being towed.
NT-6
NOTE
NOTE
8. FRONT HOOD STAY INSTALLATION

At the check and general maintenance
GI0175
When wider hood opening is necessary

Set stay into the hole of hood inner as shown in the figure below.
NOTE:
Before setting the hood in this position, remove the windshield washer hose attaching clip from the hood.
GI0176
9. TRAINING
10.GENERAL SCAN TOOL
For information about training, contact a dealer or

agent.
Using general scan tools will greatly improve efficiency of repairing engine electronic controls. The
Subaru Select Monitor can be used to diagnose the
engine and also the ABS, the air conditioner, and
other parts.
NT-7
NOTE
NOTE
NT-8
IDENTIFICATION
ID
1.
Page
Identification ................................................................................................2
IDENTIFICATION
IDENTIFICATION
1. Identification
A: IDENTIFICATION
1. IDENTIFICATION NUMBER AND LABEL LOCATIONS
The VIN (Vehicle Identification Numbers) is used to classify the vehicle.
Positioning of the plate label for identification
Vacuum hose piping label
Emisson control label
ID plate (Europe model)

ADR compliance plate
(Australia model)
Tire inflation pressure label

(Driver side) (Australia model)
Tire pressure label
(Driver side) (Except Australia model)
Vehicle identification number
Model number plate
Saudi Arabia plate (Saudi Arabia model)

Built date plate (Australia model)
GI0154
GI0007A
GI0008A
GI0009A
ID-2
IDENTIFICATION
IDENTIFICATION
GI0010A
GI0011A
ID-3
IDENTIFICATION
IDENTIFICATION
2. MEANING OF V.I.N.
The meaning of the VIN is as follows:
Europe, Australia and General (Except GCC)
]JF1GD5LJ31G002001[
The starting and ending brackets ( ][ ) are stop marks.
Digits
Code
1 to 3
4
5
JF1
G
D
10
11
12 to 17
G
002001
Meaning
Details
Manufacturer body area JF1: Passenger car, FHI made
Car line
IMPREZA
Body type
D: 4 Door Sedan
G: Wagon
Displacement
5: 1.6 L AWD
9: 2.0 L AWD
A: 2.0 L AWD Turbo
E: 2.5 L AWD
Steering position
K: RHD (Right-hand drive)
L: LHD (Left-hand drive)
Engine & transmission
R: SOHC MPI 4-speed AT
J: SOHC MPI Full-time AWD 5-speed MT
K: SOHC MPI Full-time AWD 5-speed MT Dual range
D: DOHC Turbo Full-time AWD 5-speed MT
P: DOHC Turbo 4-speed AT
Drive type
3: Full-time AWD Single range
4: Full-time AWD Dual range
5: AWD AT
Model year
2: 2002MY
3: 2003MY
Factory location
G: FHI (Gunma)
Serial number
GCC countries (Saudi Arabia, etc.)

]JF1GD33MX1G002001[
The starting and ending brackets ( ][ ) are stop marks.
Digits
Code
1 to 3
4
5
JF1
G
D
8
9
10
M
X
2
11
12 to 17
002001
Meaning
Details
Manufacturer body area JF1: Passenger car, FHI made
Car line
IMPREZA
Body type
D: 4 Door Sedan
G: Wagon
Displacement
4: 1.6 L AWD
8: 2.0 L AWD
Grade
5: TS
7: GX
Restraint
M: Manual belts, dual airbag
Check digit
Model year
2: 2002MY
3: 2003MY
Transmission type
G: Full-time AWD 5-speed MT single range
H: Full-time AWD 4-speed AT
J: Full-time AWD 5-speed MT dual range
Serial number
ID-4
IDENTIFICATION
IDENTIFICATION
3. MODEL NUMBER PLATE

The model number plate indicates: the applied model, the option code, the trim code, the engine type, the
transmission type, and the exterior color code. This information is helpful when placing orders for parts.
GD9AL7R
Digits
Code
Meaning
Series
Body style
1
2
G
D
4
5
A
L
Engine displacement
Drive system
Suspension system
Minor change
Destination
Grade
Transmission, fuel feed

system
Details
IMPREZA
D: 4 Door Sedan
G: Wagon
5: 1.6 L AWD
9: 2.0 L AWD
E: 2.5 L AWD
2002MY
K: Right-hand drive market
L: Left-hand drive market
4: TS
5: GX
6: RS
7: OUTBACK
8: WRX
K: SOHC MPI 5-speed MT
R: SOHC MPI 4-speed AT
P: DOHC B MPI 4-speed AT
J: SOHC MPI 5-speed MT AWD
D: DOHC B MPI 5-speed MT AWD
The engine and transmission type are as follows:

Engine
EJ161RX3AA
Digits
1 and 2
3 and 4
EJ
16
Code
Meaning
Engine type
Displacement
Fuel feed system
6
7
R
X
Detailed specifications
Transmission
8 to 10
3AA
Details
EJ: 4 cylinders
16: 1.6 L
20: 2.0 L
25: 2.5 L
1: D-MPI SOHC-A
5: MPI Turbo
Used when ordering parts. See the parts catalog for details.
W: MT
X: AT
ID-5
IDENTIFICATION
IDENTIFICATION
Transmission
TV1B4VYAAA
1
2
Digits
T
V
Code
Meaning
Transmission
Transmission type
3 and 4
1B
Classification
Series
Transmission specifications
7 to 10
YAAA
Details
T: Transmission
Y: Full-time AWD MT center differential
V: Full-time AWD AT center differential
Z: Full-time AWD AT MPT
75: MT
1B: AT
MT
4: 5MT
AT
4: AT
S: Part-time AWD 5-speed MT Single range
D: Part-time AWD 5-speed MT Dual range
V: Full-time AWD 5-speed MT with viscous coupling center differential single range
X: Full-time AWD 5-speed MT with viscous coupling center differential dual range
Z: Full-time AWD 4-speed AT with MPT
Y: Full-time AWD 4-speed AT with VTD
Rear differential 1
VA1REJ
Digits
Code
1
2
3
V
A
1
4
5
R
E
Meaning
For AWD
Type
Hypoid gear diameter
mm (in)
Installation position
Reduction gear ratio
Specification differences
Details
V: AWD
A: A type
1: 152 (6.0) dia.
2: 160 (6.3) dia.
R: Rear
B: 3.900
E: 4.111
F: 4.444
J: Case B
Rear differential 2
EG
Code
Reduction gear ratio
EG
ER
EM
3.900
3.700
4.444
EJ
EF
4.111
3.545
LSD
No
Viscous
SURETRAC
Viscous
Viscous
ID-6
IDENTIFICATION
IDENTIFICATION
Option code
ECPS
1 to 2
Digits
EC
Code
Meaning
Destination
Details
3 to 4
PS
Main option of vehicle
EC: EC
KO: KO
K4: K4
KS: KS
EK: EK
KA: KA
K1: K1
ID-7
IDENTIFICATION
IDENTIFICATION
ID-8
RM
1.
Page
Recommended Materials ............................................................................2
1. Recommended Materials
A: RECOMMENDED MATERIALS
1. GENERAL
To insure the best performance, always use the
specified oil, gasoline, adhesive, sealant, etc. or
that of equivalent quality.
2. FUEL
Always use a gasoline of the same or higher octane
value than specified in the owner's manual. Ignoring the specifications below will result in damage or
poor operation of the engine and fuel injection system. Use the specified gasoline to correct performance.
Unleaded gasoline
Use unleaded gasoline and not leaded gasoline on
vehicles with catalytic converter installed to reduce
air pollution. Using leaded gasoline will damage the
catalytic converter.
Leaded gasoline
On vehicles without catalytic converter, use gasoline with an octane value of 90 RON or higher.
RM-2
3. LUBRICANTS
Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the correct
SAE viscosity.
API: SH or SG
GY
NG
EN
ACEA Spec.
A1, A2 or A3
SERVICE S
PI
SAE
5W-30
R
Alternative
Engine oil
Recommended
API Spec.
CCMC Spec.
SL or SJ Grade Energy conserving
G4 or G5
VI
Lubricant
CONS E
B1M0495
GI0002
Manual transmission oil

Front differential
Rear differential
SAE viscosity
Engine oil
GL-5
GL-5
GL-5
SAE viscosity No. and applicable temperature SAE J300
GI0003A
RM-3
SAE viscosity
Manual transmission oil
SAE viscosity No. and applicable temperature SAE J300
Rear differential
GI0004A
Front differential
GI0005A
4. FLUID
Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid.
Fluid
Automatic transmission fluid
Power steering fluid
Brake fluid
Clutch fluid
Recommended
DEXRON III
DEXRON III
FMVSS No. 116 DOT3
FMVSS No. 116 DOT3
Alternative
FMVSS No. 116 DOT4

FMVSS No. 116 DOT4
Remarks
5. COOLANT
Use genuine coolant to protect the engine. The table below shows the ratio of coolant to distilled water.
Coolant
Coolant
Water for dilution
Recommended
SUBARU coolant
Distilled water
Item number
000016218
RM-4
Alternative
None
Tap water
6. REFRIGERANT
Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants.
Also, do not use any air compressor oil except for DH-PR.
Air conditioner
Refrigerant
Compressor oil
Recommended
HFC134a
DH-PR
Item number
Alternative
None
None
7. GREASE
Use the grease and supplementary lubricants shown in the table below.
Grease
Supplementary lubricants
Grease
Application point
O2 sensor
Bolts, etc.
MT main shaft
Clutch master cylinder
push rod
Steering shaft bearing
Gear shift bush
Steering gear box
Disc brake
Drum brake
Brake pad
Brake shoe
Front axle SFJ
Front EBJ
Rear axle EBJ
Rear axle BJ
Rear axle DOJ
Control cable
Throttle linkage
Water pump
Door latch
Door striker
Recommended
SUBARU CRC
Item number
004301003
Alternative
FX clutch grease
Slicolube G-40M
000040901
004404003
SUNLIGHT2
003602010
Valiant grease M-2

Niglube RX-2
Molykote No. 7439
Molykote AS-880N
003608001
725191040
72519460
26298AC000
SSG-6003
NTG 2218
28093TA000
28093AA000
Molylex No. 2
VU-3A702
Slicolube G-30M
723223010
23223GA050
004404002
8. ADHESIVES
Use the adhesives shown in the table below, or equivalent.
Adhesive
Adhesive
Application point
Windshield and body
Soft vinyl
Recommended
Essex Chemical Crops Urethane E
Cemedine 540
Momentary sealant
Cemedine 3000
Item number
RM-5
Alternative
Sunstar 580
3Ms EC-776 EC-847 or EC-1022
(Spray type)
Armstrongs Eastman 910
9. SEAL MATERIAL
Use seal material shown in the table below, or equivalent.
Seal material
Seal material
Application point
Engine case
Torque converter
clutch case
Transmission
Rear differential
Rear differential
Weatherstrip
Steering adjusting screw
SOHC cam cap
Recommended
Three Bond 1215
Item number
004403007
Alternative
Dow Cornings No. 7038
Three Bond 1217B

Three Bond 1324
Three Bond 1105
Starcalking B-33A
Three Bond 1102
Three Bond 1280B
K0877YA020
004403042
004403010
000018901
004403006
K0877YA018
Dow Cornings No. 7038

Butyl Rubber sealant
RM-6
PI
1.
Page
Pre-delivery Inspection................................................................................2
1. Pre-delivery Inspection
A: GENERAL
The purposes of the pre-delivery inspection (PDI)
are as follows.
Remove the additional parts used for ensuring
the vehicle quality during transportation and restore
the vehicle to its normal state.
Check if the vehicle before delivery is in a normal
state.
Check for any damage or missing parts that may
have taken place during transportation or storage.
Make sure to provide a complete vehicle to the
customer.
Because of the above reasons, all dealerships
must always carry out the PDIs before delivering a
vehicle.
In addition, all franchised shops and PDI centers
must check the status of every vehicle received to
identify who is responsible for any possible defects.
PI-2
B: PDI PROCEDURE
Follow the procedures shown in the table below.
Static Checks Just After Vehicle Receipt
Step
1. Appearance check
2. Tire check
3. Fuse installation
4. Connection of air conditioner harness
5. Check the doors for lock/unlock and open/close
operations.
6. Check the trunk lid for open/close operations.
7. Check the rear gate for lock/unlock and open/

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

lever
9. Accessory check
10. Operation check of hood lock release system

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

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

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

Step
41. ATF level
42. Power steering fluid level
43. Fluid leak check
44. Water leak check
45. Appearance check 2
Check point
(1) Check that the ATF level is normal.
(2) Check that the power steering fluid level is normal.
(3) Check for fluid/oil leaks.
(4) Spray the vehicle with water and check for water leaks.
(5) Remove the protective coating (if any).
(6) Check the body paints for damage and smears.
(7) Check the plated parts for damage and rust.
PI-4
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.
If there is no protective coating, check the body
paints for small areas of damage or stains and repair as necessary.
Check the window glass, door glass, and lights
for any cracks or damage and repair or replace the
parts as necessary.
Check the plated parts, such as the grilles and
door knobs, for damage or loss of gloss and repair
or replace the parts as necessary.
A vehicle just delivered has its air conditioner harness disconnected to protect the air conditioner
compressor. Connect the harness as shown in the
figure.
2. TIRE CHECK
Check the tire outer faces for any damage.
Check the tire air pressure by referring to the following table.
Tire size
175/70R14
185/70R14
195/60R15
205/50R16
215/45R17
GI0085
Tire inflation pressure

kPa (kg/cm2, psi)
Front
Rear
220 (2.2, 32)
220 (2.2, 32)
220 (2.2, 32)
220 (2.2, 32)
220 (2.2, 32)
220 (2.2, 32)
220 (2.2, 32)
220 (2.2, 32)
230 (2.3, 33)
220 (2.2, 32)
3. FUSE INSTALLATION
A vehicle just delivered has no fuse for the room
lamp circuit to prevent battery discharge. Attach a
15 A fuse (A) as shown in the figure.
GI0084A
PI-5
5. CHECK THE DOORS FOR LOCK/UNLOCK AND OPEN/CLOSE OPERATIONS.
6. CHECK THE TRUNK LID FOR OPEN/

CLOSE OPERATIONS.
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.
Operate the trunk lock release lever and verify

that the trunk lid opens.
Using the key, open the trunk lid several times to
check for normal operation.
Open and close the trunk lid several times for
smooth movement.
Unlock
Lock
GI0148
Vehicles with manual door locks:

Sit in the driver seat, close the door completely,
and move the lock lever to the lock position. Then,
pull the inside door handle to ensure the door will
not open.
Vehicles with power door locks:
GI0170
7. CHECK THE REAR GATE FOR LOCK/

UNLOCK AND OPEN/CLOSE OPERATIONS.
Sit in the driver seat, close the driver's door completely, and place the door lock knob (A) to the lock
position. Then pull all inside door handles (B) to ensure that all doors will not open.
For other doors, place the door lock knob (A) to the
lock positions and then pull the inside door handles
to ensure that the doors will not open.
Using the key, lock and unlock the rear gate several times to check for normal operation.
Open and close the rear gate several times for
smooth movement.
Lock
Unlock
GI0171
Operate the drivers side door lock knob to check

that the rear gate is locked and unlocked normally.
GI0079A
8. OPERATION CHECK OF FUEL LID

OPENER LOCK RELEASE LEVER
Operate the fuel lid opener and verify that the fuel
lid opens normally. Check that the filler cap is securely closed.
PI-6
9. ACCESSORY CHECK
10.OPERATION CHECK OF HOOD LOCK

RELEASE SYSTEM
Check that the following accessories are provided

in the luggage compartment or cargo area.
Owner's manual
Warranty booklet
Service booklet
Spare key
Jack
Tool set
Spare tire
Operate the hood release knob (A) and check that

the hood is unlocked normally.
Jack
GI0082A
Operate the lever (A) and check that the hood is

opened normally. Then support the hood with hood
stay.
Jack handle
GI0149
Jack
Jack handle
GI0150
(A)
GI0151
PI-7
11.BATTERY
15.AT FRONT DIFFERENTIAL OIL
Check the battery terminals to make sure that no

rust or corrosions due to fluid leaks are found.
Check that the battery caps are securely tightened.
Check the AT front differential oil amount. If the

amount is insufficient, check that no leaks are
found. Then, add the necessary amount of the
specified AT front differential oil.
GI0086A
GI0089A
12.BRAKE FLUID
16.COOLANT
Check the brake fluid amount. If the amount is insufficient, carry out a brake line test to identify
brake fluid leaks and check the brake operation. After that, refill the brake fluid tank with the specified
type of fluid.
Check the coolant amount on the reservoir. If the

found. Then, add the necessary amount of coolant
with the specified concentration.
13.ENGINE OIL
17.CLUTCH FLUID
Check the engine oil amount. If the amount is insufficient, check that no leaks are found. Then, add
the necessary amount of the specified engine oil.
Check the clutch fluid amount. If the amount is insufficient, check that no leaks are found. Then, add
the necessary amount of the specified fluid.
GI0087A
GI0090A
14.TRANSMISSION FLUID
(A) Reservoir tank

(B) MIN level
(C) MAX level
Check the transmission fluid amount. If the amount

is insufficient, check that no leaks are found. Then,
add the necessary amount of the specified fluid.
18.WINDOW WASHER FLUID

Check the window washer fluid amount. If the
found. Then, add the necessary amount of washer
fluid commercially available.
19.HOOD LATCH CHECK

Retract the hood stay and close the hood. Check
that the hood is securely latched.
GI0088A
PI-8
20.KEYLESS ENTRY SYSTEM
24.READ MEMORY AND TEST MODE CONNECTORS
Check the keyless entry system operations as follows.

Remove the key from the ignition switch and
close all the doors including rear gate (wagon).
Press the LOCK button on the transmitter momentarily once and check if all the doors are locked
and the hazard light flashes once.
Turn the ignition switch to ON and check that the

check-engine light starts blinking. If the light blinks,
return the ignition key to LOCK and disconnect the
test mode connector. Then, turn the ignition key to
ON again. If the check-engine light blinks at that
time in spite of the disconnected test mode connector, carry out an engine diagnosis.
With OBD MODEL
B5M1182
Press the OPEN button on the transmitter momentarily once and check if all doors are unlocked,
the hazard light flashes twice and the dome light illuminates.
Close all doors and rear gate, press the LOCK
button of the transmitter. Press the OPEN button
of the transmitter and wait for 30 seconds. Check
that all doors and the rear gate are automatically
locked again.
GI0095A
Without OBD MODEL
21.SEAT
Check that each seat provides full functionality in
sliding and reclining. Check all available functions
of the rear seat such as a trunk-through center arm
rest.
GI0119A
25.STARTING CONDITION
22.SEAT BELT
Start the engine and check that the engine starts

smoothly. If any battery voltage problems are
found, recharge or replace the battery. If any abnormal noises are observed, immediately stop the
engine and check and repair the necessary components.
Pull out the seat belt and then release it. Check that
the belt webbing retracts smoothly.
23.WHEEL ALIGNMENT
Check the wheel alignments. <Ref. to FS-8, Wheel
Alignment.> and <Ref. to RS-9, Wheel Alignment.>
26.EXHAUST SYSTEM
Listen to the exhaust noise to see if no abnormal
noises are observed.
27.INDICATOR LIGHT
Check that all the indicator lights are off.
28.CLOCK
Check the clock for normal operations and enough
accuracy.
29.RADIO
Check the radio for full functionality and normal
noise level. Also check the CD unit operations.
PI-9
30.CIGARETTE LIGHTER
36.PARKING BRAKE
Check the cigarette lighter operations.
Check the parking brake for normal operations.
31.LIGHTING SYSTEM
37.AT SHIFT CONTROL
Check the headlight operations.

Check the brake light operations.
Check the other lights for normal operations.
Set the AT select lever to each gear position while

checking that the demanded gear position is correctly attained.
32.WINDOW WASHER
Check that the window washer system injects
washer fluid to the specified area of windshield
shown in the figure.
Front injection position:
A: 350mm (13.78 in)
B: 162mm (5.91 in)
C: 300mm (11.81 in)
D: 500mm (23.62 in)
GI0113A
A
B
Selector
Position
D
3
2
1
C
1st
Yes
Yes
Yes
Yes
Gear Position
2nd
3rd
Yes
Yes
Yes
Yes
Yes
4th
Yes
38.HEATER & VENTILATION
Nozzle
Operate the heater and ventilation system to check

for normal airflow and heating capacity.
GI0152
Rear injection position:

A: 39 mm (2.36 in)
B: 72
39.AIR CONDITIONER
Operate the air conditioner. Check that the A/C
compressor operates normally and enough cooling
is provided.
Nozzle
40.CRUISE CONTROL
Operate the cruise control system. Check that the

system is activated and deactivated correctly.
41.ATF LEVEL
Check that the ATF level is normal. If insufficient,

check that no leaks are found. Then add the necessary amount of the specified ATF.
GI0153
33.WIPER
Check the front and rear wipers for normal operations.
34.POWER WINDOW OPERATION CHECK

Manipulate the power window switches one by one
to check that each of the power windows goes up
and down with no abnormal noises.
35.BRAKE TEST
GI0098A
Check the foot brake for normal operations.
PI-10
42.POWER STEERING FLUID LEVEL
44.WATER LEAK TEST
Check that the power steering fluid level is normal.

If insufficient, check that no leaks are found. Then
add the necessary amount of the specified power
steering fluid.
Spray the vehicle with water and check that no water enters the passenger compartment.
Before performing the water leakage test, remove anything that may obstruct the operation or
which must be kept dry.
Close all windows completely, and then close all
doors tightly. Close the hood and trunk lid before
starting the test.
Connect a hose to a tap, and spray water on the
vehicle. The rate of water discharge must be approx. 20 25 2 (5.3 6.6 US gal, 4.4 5.5 Imp
gal) per minute.
When spraying water on areas adjacent to the floor
and wheel house, increase the pressure. When directing water on areas other than the floor portion
and wheel house, decrease the pressure. But the
force of water must be made strong occasionally by
pressing the end of the hose.
GI0099A
(A) Reservoir tank

(B) MIN level
(C) MAX level
43.FLUID LEAK CHECK

Check the entire areas of the vehicle for any trace
of coolant/oil/fluid leaks.
NOTE:
Be sure to keep the hose at least 10 cm (3.9 in)
from the vehicle.
Check the following areas:
Front window and body framework mating portion
Door mating portions
Glass mating portions
Rear quarter window mating portions
Rear window and body framework mating portion
Around roof drips
If any dampness in the compartment is discovered
after the water has been applied, carefully check all
areas that may have possibly contributed to the
leak.
45.APPEARANCE CHECK 2
Check the vehicle body paints, plated faces, glass,
and lenses for any dirt or damage.
PI-11
PI-12
PM
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
Page
General Description ....................................................................................2
Schedule .....................................................................................................3
Engine Oil....................................................................................................6
Engine Oil Filter...........................................................................................8
Spark Plugs.................................................................................................9
Drive Belt(s) ..............................................................................................10
Camshaft Drive Belt ..................................................................................12
Fuel Line ...................................................................................................15
Fuel Filter ..................................................................................................16
Air Cleaner Element ..................................................................................17
Cooling System .........................................................................................18
Coolant......................................................................................................19
Idle Mixture................................................................................................21
Clutch System ...........................................................................................22
Hill-holder System .....................................................................................24
Transmission Oil .......................................................................................25
ATF ...........................................................................................................26
Front & Rear Differential Oil ......................................................................28
Brake Line .................................................................................................30
Brake Fluid ................................................................................................32
Disc Brake Pads and Discs.......................................................................33
Brake Linings and Drums..........................................................................34
Suspension ...............................................................................................36
Wheel Bearing...........................................................................................39
Axle Boots & Joints ...................................................................................40
Steering System (Power Steering)............................................................41
Supplemental Restraint System................................................................44
GENERAL DESCRIPTION
1. General Description
A: GENERAL
Be sure to perform periodic maintenance in order to
maintain vehicle performance and find problems
before they become serious.
PM-2
SCHEDULE
2. Schedule
A: MAINTENANCE SCHEDULE 1
1. MAINTENANCE SCHEDULE 1 (1)
For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by referring
to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set
of 50,000 km (30,000 miles) or 48 months.
1
2
Maintenance Interval
[Number of months or km (miles), whichever occurs first]
12
24
36
48
Remarks
5
12.5
25
37.5
50
3
7.5
15
22.5
30
R
R
R
R
R
R
R
R
Months
1,000 km
1,000 miles
Engine oil
Engine oil filter
2. MAINTENANCE SCHEDULE 1 (2)

For periodic maintenance of over 100,000 km (60,000 miles) or 48 months, carry out inspections by referring
to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set
of 100,000 km (60,000 miles) or 48 months.
Months
1,000 km
1,000 miles
Spark plugs
4
5
6
7
8
9
10
11
Drive belt(s)
Camshaft drive belt
Fuel line
Fuel filter
Air cleaner element
Cooling system
Coolant
Idle mixture
12
13
14
15
16
Clutch system
Hill-holder system
Transmission oil
ATF
Front & rear differential oil
Brake line
Brake fluid
Disc brake pads &
discs
Brake linings and
drums
Parking brake
Suspension
Wheel bearing
17
18
19
20
21
22
23
For Turbo
Others
12
24
36
48
Remarks
1.6
25
50
75
100
1
15
30
45
60
R
R
R
I
I
I
I
R
I
I
R
I
R
I
R
I
I
R
R
I
I
I
I
I
For models without catalyst converter
I
I
I
I
I
I
I
I
I
R
R
R
R
R
R
I
R
I
I
I
I
PM-3
I
I
I
R
I
I
I
I
I
I
(I)
SCHEDULE
24
25
Months
1,000 km
1,000 miles
Axle boots & joints
Steering system
(Power steering)
12
24
36
48
Remarks
1.6
25
50
75
100
1
15
30
45
60
I
I
I
I
I
I
I
I
Symbols used:
R: Replace
I: Inspection
(R) or (I): Recommended service for safe vehicle operation.
NOTE:
(1) Periodic inspection and replacement of the camshaft drive chains on the 3.0 liter models are not required.
(2) When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often.
(3) ATF filter is a maintenance free part. ATF filter needs replacement, when it is physically damaged or ATF leaked.
PM-4
SCHEDULE
B: MAINTENANCE SCHEDULE 2
Item
Every
Engine oil
Engine oil filter
Fuel line
Repeat short Repeat

distance drive rough/muddy
road drive
Extremely
cold weather
area
Replace
more frequently
Replace
more frequently
Replace
more frequently
Replace
more frequently
6 months
12,500 km
7,500 miles
Salt or other
corrosive
used or
coastal area
High humidity or mountain area
Replace
more frequently
Replace
more frequently
I
Transmission oil
Replace
more frequently
Replace
more frequently
Replace
more frequently
I
ATF
Front & rear differential oil

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

joints
Steering system
(Power steering)
6 months
12,500 km
7,500 miles
12 months
25,000 km
15,000 miles
6 months
12,500 km
7,500 miles
6 months
12,500 km
7,500 miles
6 months
12,500 km
7,500 miles
6 months
12,500 km
7,500 miles
6 months
12,500 km
7,500 miles
6 months
12,500 km
7,500 miles
Repeat towing trailer
PM-5
ENGINE OIL
3. Engine Oil
A: REPLACEMENT
1) Drain the engine oil by loosening engine oil drain
plug.
5) Fill engine oil through the filler pipe up to upper

point on level gauge. Make sure that the vehicle is
placed level when checking oil level. Use engine oil
of proper quality and viscosity, selected in accordance with the table in figure.
Engine oil amount for preparation
(Non-turbo model):
Approx. 4.5 2 (4.8 US qt, 4.0 Imp qt)
Engine oil amount for preparation
(Turbo model):
GI0012A
2) Open the engine oil filler cap for quick draining of

the engine oil.
GI0015A
The proper viscosity helps vehicle get good cold

and hot starting by reducing viscous friction and
thus increasing cranking speed.
GI0013A
3) Replace the drain plug gasket.

4) Tighten the engine oil drain plug after draining
engine oil.
Tightening torque:
44 Nm (4.5 kgf-m, 33 ft-lb)
NOTE:
When replenishing oil, it does not matter if the oil
to be added is a different brand from that in the engine; however, use oil having the API classification
and SAE viscosity No. designated by SUBARU.
If vehicle is used in desert areas with very high
temperatures or for other heavy duty applications,
the following viscosity oils may be used:
API classification: SL or SJ
SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W50
6) Close the engine oil filler cap.
7) Start the engine and warm it up for a time.
8) After the engine stops, recheck the oil level.
If necessary, add engine oil up to upper level on
level gauge.
GI0012A
GI0016A
PM-6
ENGINE OIL
B: INSPECTION
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.
5) After turning off the engine, wait a few minutes
for the oil to drain back into oil pan before checking
the level.
6) Just after driving or while the engine is warm, engine oil level may show in the range between the
F line and the notch mark. This is caused by thermal expansion of the engine oil.
7) To prevent overfilling the engine oil, do not add
oil above the F line when the engine is cold.
PM-7
ENGINE OIL FILTER

4. Engine Oil Filter

A: REPLACEMENT
1) Remove the oil filter with ST.
ST 498547000
OIL FILTER WRENCH
GI0012A
2) Get a new oil filter and apply a thin coat of engine

oil to the seal rubber.
3) Install the oil filter by turning it by hand, being
careful not to damage the seal rubber.
4) Tighten more (approx. 2/3 to 3/4 turn) after the
seal rubber contacts the oil pump case. Do not
tighten excessively, or oil may leak.
5) After installing the oil filter, run the engine and
make sure that no oil is leaking around seal rubber.
NOTE:
The filter element and filter case are permanently
joined; therefore, interior cleaning is not necessary.
6) Check the engine oil level. <Ref. to PI-3, PDI
PROCEDURE, Pre-delivery Inspection.>
PM-8
SPARK PLUGS
5. Spark Plugs
A: REPLACEMENT
1) Remove the intake duct and intake chamber.
2) Remove the washer tank and put it aside.
3) Disconnect the spark plug cord.
4) Remove the spark plug with a plug-wrench.
GI0018A
5) Set the new spark plug.

Recommended spark plug :
SOHC
CHAMPION: RC10YC4
CHAMPION: RC8YC4
NGK: BKR6E-11
DENSO: K20PR-U11
Spark plug gap
1.0 1.1 mm (0.039 0.043 in)
SOHC Without OBD
NGK: BKR6E (Without catalytic converter)
CHAMPION: RC10YC4 (With catalytic converter)
NGK: BKR5E-11 (With catalytic converter)
Spark plug gap
0.7 0.8 mm (0.028 0.031 in) (Without
catalytic converter)
1.0 1.1 mm (0.039 0.043 in) (With catalytic converter)
DOHC Turbo
NGK: PFR6B
Spark plug gap
0.7 0.8 mm (0.028 0.031 in)
6) Tighten the spark plug lightly with hand, and
then secure with a plug-wrench to the specified
torque.
Tightening torque:
20.6 Nm (2.10 kgf-m, 15.19 ft-lb)
NOTE:
Be sure to place the gasket between the cylinder
head and spark plug.
If a torque wrench is not available, tighten the
spark plug until gasket contacts cylinder head; then
tighten further 1/4 to 1/2 turns.
PM-9
DRIVE BELT(S)
6. Drive Belt(s)
B: REPLACEMENT
A: INSPECTION
1. V-BELT COVER
1) Replace the belts, if cracks, fraying or wear is

found.
2) Check the drive belt tension and adjust it if necessary by changing the generator installing position
and/or idler pulley installing position.
1) Remove the V-belt cover.
Belt tension
(A)
replaced: 7 9 mm (0.276 0.354 in)
reused: 9.0 10.0 mm (0.354 0.394 in)
(B)*
replaced: 7.5 8.5 mm (0.295 0.335 in)
reused: 9.0 10.0 mm (0.354 0.394 in)
*: There is no belt (B) on models without an air conditioner.
GI0020
2. FRONT SIDE BELT (DRIVING POWER

STEERING OIL PUMP AND GENERATOR)
NOTE:
Wipe off any oil or water on the belt and pulley.
1) Loosen the lock bolt (A).
2) Loosen the slider bolt (B).
3) Remove the front side belt (C).
4) Install a new belt, and tighten the slider bolt so as
to obtain the specified belt tension.
5) Tighten the slider bolt (B).
6) Tighten the lock bolt (A).
GI0019A
C/P
GEN
P/S
A/C
I/P
Crankshaft pulley
Generator
Power steering oil pump pulley
Air conditioning compressor pulley
Idler pulley
Tightening torque:
Lock bolt, through bolt:
25 Nm (2.5 kgf-m, 18 ft-lb)
Slider bolt:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
GI0021A
PM-10
DRIVE BELT(S)
3. REAR SIDE BELT (DRIVING AIR CONDITIONER)

NOTE:
Before removing the rear side belt, remove the
front side belt.
1) Loosen the lock nut (A).
3) Remove the rear side belt.
4) Install a new belt, and tighten the slider bolt so as
to obtain the specified belt tension.
6) Tighten the lock nut (A).
Tightening torque:
22.6 Nm (2.3 kgf-m, 16.6 ft-lb)
GI0022A
PM-11
CAMSHAFT DRIVE BELT

7. Camshaft Drive Belt
10) Turn the crankshaft and align alignment marks

on crankshaft, and right and left camshaft sprockets with notches of belt cover and cylinder block.
ST 499987500
CRANKSHAFT SOCKET
A: REPLACEMENT
1. SOHC MODEL
1) Remove the radiator fan <Ref. to CO-10, Radiator Main Fan System.> and air conditioner fan.
<Ref. to CO-18, Radiator Sub Fan System.>
GI0020
3) Remove the V-belts. <Ref. to ME-44, V-belt.>

4) Remove the air conditioning compressor drive
belt tensioner.
5) Remove the pulley bolt. To lock the crankshaft,
use ST.
ST 499977100
CRANKSHAFT PULLEY
WRENCH
GI0025A
11) Remove the belt idler.

12) Remove the belt idler (No. 2).
GI0024A
6) Remove the crankshaft pulley.

7) Remove the left side belt cover.
8) Remove the front belt cover.
9) Remove the timing belt guide. (MT vehicle only)
GI0026
13) Remove the timing belt.

14) Remove the automatic belt tension adjuster assembly.
S2M0294
GI0027
PM-12
CAMSHAFT DRIVE BELT

2. DOHC MODEL
1) Remove the radiator fan and air conditioner fan.
10) Turn the crankshaft and align alignment marks

on crankshaft, and right and left camshaft sprockets with notches of belt cover and cylinder block. To
turn the crankshaft, use ST.
ST 499987500
CRANKSHAFT SOCKET
Notch
GI0137
2) Remove the V-belts. <Ref. to ME(TURBO)-44,

V-belt.>
belt tensioner.
4) Remove the pulley bolt. To lock the crankshaft
use ST.
ST 499977300
CRANKSHAFT PULLEY
WRENCH
Notch
Alignment
mark
Alignment
mark
Alignment
mark
Notch
Alignment
mark
Notch
Alignment
mark
Alignment
mark
Alignment
mark
BO0139
11) Remove the belt idler.
ST
GI0138

belt tensioner.
7) Remove the belt cover (LH).
8) Remove the belt cover (RH).
GI0140

GI0141
PM-13
CAMSHAFT DRIVE BELT

B: INSTALLATION
C: INSPECTION
1. SOHC MODEL
1. SOHC MODEL
Install in the reverse order of removal. <Ref. to ME49, Timing Belt Assembly.>
1) Remove the belt covers (RH) and (LH).

2) While cranking the 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.
2. DOHC MODEL
Install in the reverse order of removal. <Ref. to
ME(TURBO)-48, Timing Belt Assembly.>
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.
GI0142
4) Install the belt covers (RH) and (LH).
2. DOHC MODEL
1) Remove the belt covers (RH) and (LH).
2) While cranking the 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 belt covers (RH) and (LH).
GI0143
PM-14
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 bands, etc. If
faulty parts are found, repair or replace them. <Ref.
to FU-71, Fuel Delivery, Return and Evaporation
Lines.> or <Ref. to FU(w/oOBD)-68, Fuel Delivery,
Return and Evaporation Lines.> or <Ref. to
FU(TURBO)-68, Fuel Delivery, Return and Evaporation Lines.>
PM-15
FUEL FILTER
9. Fuel Filter
A: REPLACEMENT
For fuel filter replacement procedures, refer to FU
section.
<Ref. to FU-68, Fuel Filter.> or <Ref. to FU(w/
oOBD)-65, Fuel Filter.> or <Ref. to FU(TURBO)65, Fuel Filter.>
PM-16
AIR CLEANER ELEMENT

10.Air Cleaner Element
2. TURBO MODEL
A: REPLACEMENT
NOTE:
Do not attempt to clean the air cleaner element.
The filter paper of the element is wetted with a special non-inflammable slow-evaporating viscous liquid. It is resistant to cold weather and has a long
service life. Dirt adhering to this filter paper forms
porous laminations with the viscous liquid, which
function as a filtration layer to reduce dust penetration into the filter paper. If this filter paper is
cleaned, the filtration layer thus formed will be lost
along with the viscous liquid.
GI0126
1) Remove the clip (B) above the air cleaner case.
1. NON-TURBO MODEL
(B)
GI0127
2) Remove the air cleaner.

3) Install in the reverse order of removal.
GI0032
1) Remove the bolt (A) which installs air cleaner

case to stays.
2) Remove the clip (B) above the air cleaner case.
CAUTION:
Before installing the air cleaner upper cover,
align holes with protruding portion of air cleaner lower case, then secure the upper cover to
lower case.
H2M2947A
3) Remove the air cleaner.

EN0906
CAUTION:
Fasten with a clip after inserting the lower tab
of the case.
PM-17
COOLING SYSTEM
11.Cooling System
2) Check the radiator cap valve open pressure using radiator cap tester.
A: INSPECTION
1) Check the radiator for leakage, filling it with coolant and attach the radiator cap tester to filler neck.
Then apply a pressure of 157 kPa (1.6 kg/cm2, 23
psi) and check the following points:
Each portion of radiator for leakage
Hose joints and other connections for leakage
NOTE:
When attaching or detaching tester and when
operating tester, use special care not to deform radiator filler neck.
Non-TURBO model
Cap tester
NOTE:
Rust or dirt on the cap may prevent the 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 5 to 6
seconds. The radiator cap is normal if a pressure
above the service limit value has been maintained
for this period.
Radiator cap valve open pressure
Standard value:
93 123 kPa (0.95 1.25 kg/cm2, 14 18
psi)
Service limit:
83 kPa (0.85 kg/cm2, 12 psi)
GI0124
TURBO model
Cap tester
GI0034
GI0125
When performing this check, be sure to keep the

engine stationary and fill the radiator with coolant.
Wipe off check points before applying pressure.
Use care not to spill coolant when detaching the
tester from radiator.
GI0035A
3) If the coolant temperature exceeds 76.0 to

80.0C (169 to 176F) while radiator is not so hot,
check thermostat. If the thermostat does not open
at 76.0 to 80.0C (169 to 176F), replace it with a
new one.
4) If the electric fan does not operate when coolant
temperature exceeds 90 to 94C (194 to 201F),
check the thermoswitch or fan motor.
PM-18
COOLANT
12.Coolant
8) Slowly pour the prepared coolant from radiator

filler port to neck of filler, then pour into reservoir
tank up to FULL level.
A: REPLACEMENT
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.
2) Remove the under cover.
3) Place a container under drain pipe.
4) Loosen and remove the drain screw to drain engine coolant into container.
EN0073
5) For quick draining, open the radiator cap.

CAUTION:
Be careful not to spill coolant on the floor.
6) Drain the coolant from reservoir tank.
7) Tighten the radiator drain screw securely after
draining coolant.
Coolant capacity (fill up to FULL level)

1.6 L AT model:
1.6 L MT model:
2.0 L Non-turbo AT model:
2.0 L Non-turbo MT model:
2.0 L Turbo AT model:
2.0 L Turbo MT model:
2.5 L AT model:
2.5 L 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.
9) Securely install the radiator cap.
10) Run the engine for more than 5 minutes at
2,000 to 3,000 rpm. (Run the engine until radiator
becomes hot in order to purge the air trapped in
cooling system.)
11) 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.
12) After adding coolant, securely install the radiator and reservoir tank caps.
PM-19
COOLANT
2. RELATIONSHIP OF SUBARU COOLANT

CONCENTRATION AND FREEZING TEMPERATURE
The concentration and safe operating temperature
of the SUBARU coolant is shown in the diagram.
Measuring the temperature and specific gravity of
the coolant will provide this information.
[Example]
If the coolant temperature is 25C (77F) and its
specific gravity is 1.054, the concentration is 35%
(point A), the safe operating temperature is 14C
(7F) (point B), and the freezing temperature is
20C (4F) (point C).
3. PROCEDURE TO ADJUST THE CONCENTRATION OF THE COOLANT

To adjust the concentration of the coolant according to temperature, find the proper fluid concentration in the above diagram and replace the
necessary amount of coolant with an undiluted solution of SUBARU genuine coolant (concentration
50).
The amount of coolant that should be replaced can
be determined using the diagram.
[Example]
Assume that the coolant concentration must be increased from 25% to 40%. Find point A, where the
25% line of coolant concentration intersects with
the 40% curve of the necessary coolant concentration, and read the scale on the vertical axis of the
graph at height A. The quantity of coolant to be
drained is 2.1 liters (2.2 US qt, 1.8 Imp qt). Drain
2.1 liters (2.2 US qt, 1.8 Imp qt) of coolant from the
cooling system and add 2.1 liters (2.2 US qt, 1.8
Imp qt) of the undiluted solution of SUBARU coolant.
If a coolant concentration of 50% is needed, drain
all the coolant and refill with the undiluted solution
only.
GI0037A
GI0038A
PM-20
IDLE MIXTURE
13.Idle Mixture
A: INSPECTION AND ADJUSTMENT
1. IDLE MIXTURE
Before measuring the idle mixture, make sure that
the ignition timing and the engine idle speed are
within specifications.
1) Set the gear position at Neutral for MT, or N
or P for AT.
2) Warm up the engine sufficiently until cooling fan
starts to operate.
3) Measure the idle mixture using CO meter.
Engine idle speed
700100 rpm
CO
1.00.5%
4) If out of specification, adjust the idle mixture using CO adjusting screw of mass air flow sensor.
5) After adjusting the CO value, check and adjust
the increment coefficient of CO resistor by using
Select Monitor.
(1) Select Current data display & Save on the
select monitor.
(2) If out of specified data, adjust the increment
coefficient of CO resistor while rotating the CO
adjusting screw.
Specified data:
0.28 4.22 V
GI0114A
NOTE:
If driving the vehicle on out of specified data, the
trouble code 49 is indicated in many case.
PM-21
CLUTCH SYSTEM
14.Clutch System
1. MECHANICAL CLUTCH TYPE
1) Inspect the free play of clutch pedal by operating
pedal by hand.
If it is out of the specified value, adjust it by turning
wing nut on engine side of clutch cable at release
fork.
Tightening torque
(Adjusting nut on release fork):
4.4 7.4 Nm
(0.45 0.75 kgf-m, 3.3 5.4 ft-lb)
2) Pedal-to-floor plate gap in disengaged position.

(1) With the engine idling, pull the parking brake
lever completely.
(2) Slowly depress the clutch pedal while moving shift lever into reverse.
(3) Stop depressing the clutch pedal when
gearshifting is complete. With the clutch pedal in
this position, measure the distance between the
upper side of pedal pad and the lower end of
front panel (intersection of front panel with floor).
Check that the measured value is within the
specified standard.
Standard:
80 mm (3.15 in) or more
3) Pedal height
Check that the clutch pedal pad surface is level
with or higher than brake pedal pad surface.
Standard free play:

AT clutch pedal
10 20 mm (0.39 0.79 in)
2. HYDRAULIC CLUTCH TYPE

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.
Non-TURBO model
Release lever
Push rod
Free play:
10 20mm(0.39
0.79in)
GI0144
Fork lever free play allowance:

2 4 mm (0.08 0.16 in)
Free play:
2 4mm
(0.08 0.16in)
Full stroke:
25.5mm(1 in)
Operating cylinder
GI0128
TURBO model
Release lever
Operating cylinder
Lock nut
Adjusting nut
Release fork
GI0145
Push rod
GI0129
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-41, Clutch Pedal.>
4) Inspect the underside of master cylinder, clutch
damper and operating cylinder for clutch system,
hoses, piping and their couplings for fluid leaks.
If fluid leaks are found, correct them by retightening
their fitting bolt and/or replacing their parts.
PM-22
CLUTCH SYSTEM
5) Check the fluid level using the scale on the outside of the clutch master cylinder tank (A). If the level is below MIN (B), add clutch fluid to bring it up
to MAX (C).
Recommended clutch fluid:
FMVSS No. 116, fresh DOT3 or DOT4 brake
fluid
NOTE:
Avoid mixing different brakes of brake fluid to
prevent degradation of the fluid.
Be careful not to allow dirt or dust to get into the
reservoir tank.
GI0040A
PM-23
HILL-HOLDER SYSTEM
15.Hill-holder System
1) Confirm the stopping and starting performance
by activating the hill-holder on an uphill road of 3
or higher inclination.
(1) When the vehicle does not stop;
Tighten the adjusting nut of PHV cable.
(2) When the vehicle does not start properly;
A; When the hill-holder is released later than engagement of clutch (engine tends to stall): Loosen the adjusting nut gradually until smooth
starting is enabled.
B; When the hill-holder is released earlier than
engagement to clutch (vehicle slips down slightly): Tighten the adjusting nut so that hill-holder is
released later than engagement of clutch (status
in A). Then make adjustment the same as in A.
NOTE:
Whenever turning the adjusting nut, hold the inner cable with pliers to prevent it from turning.
Replace the pressure hold valve (PHV), return
spring of PHV or PHV cable with a new one, if they
are defective and/or damaged.
GI0115A
PM-24
TRANSMISSION OIL
16.Transmission Oil
A: REPLACEMENT
1. MANUAL TRANSMISSION
1) Drain the gear oil by removing drain plug after allowing the engine to cool for 3 to 4 hours.
NOTE:
Before starting work, cool off the engine well.
GI0041
2) Reinstall the drain plug after draining gear oil

and tighten it to the specified torque.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
NOTE:
Be sure to place a gasket between the transmission case and drain plug.
Replace the gasket with a new one.
Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands.
3) Fill transmission gear oil through the oil level
gauge hole up to the upper point of level gauge.
Gear oil capacity:
Single range model
3.5 2 (3.7 US qt, 3.1 Imp qt)
Dual range model
4.0 2 (4.2 US qt, 3.5 Imp qt)
GI0042A
PM-25
ATF
17.ATF
A: INSPECTION
1) Raise the ATF temperature to 70 to 80C (158 to
176F) from 20 to 30C (68 to 86F) (when cold) by
driving a distance of 5 to 10 km (3 to 6 miles).
NOTE:
The level of ATF varies with fluid temperature. Pay
attention to the fluid temperature when checking oil
level.
4) Fluid temperature rising speed

By idling the engine
Time for temperature rise to 70C (158F) with atmospheric temperature of 0C (32F): More than
25 minutes
<Reference>
Time for temperature rise to 30C (86F) with atmospheric temperature of 0C (32F): Approx. 8 minutes
By running the vehicle
10 minutes
5) Method for checking fluid level upon delivery or
at periodic inspection
Check the fluid level after a warm-up run of approx.
10 minutes. During the warm-up period, the automatic transmission functions can also be checked.
B3M1020B
(A) ATF level gauge

(B) Upper level
(C) Lower level
2) Make sure the vehicle is level. After selecting all

positions (P, R, N, D, 3, 2, 1), set the select lever in
P range. Measure the fluid level with engine
idling.
NOTE:
After running, idle the engine for 1 or 2 minutes before measurement.
3) If the fluid level is below the center between upper and lower marks, add the recommended ATF
until the fluid level is found within the specified
range (above the center between upper and lower
marks). When the transmission is hot, the level
should be above the center of upper and lower
marks, and when it is cold, the level should be
found below the center of these two marks.
CAUTION:
Use care not to exceed the upper limit level.
ATF level varies with temperature. Remember that the addition of fluid to the upper limit
mark when the transmission is cold will result
in the overfilling of fluid.
PM-26
ATF
B: REPLACEMENT
2. ATF FILTER
1. AUTOMATIC TRANSMISSION FLUID
NOTE:
ATF filter is a maintenance free part. ATF filter
needs replacement, when it has physically damaged or ATF leaked.
For the replacement procedures of the ATF filter:
<Ref. to AT-45, ATF Filter.>
1) Drain the ATF (Automatic Transmission Fluid)

by removing drain plug after allowing the engine to
cool for 3 to 4 hours.
NOTE:
GI0043A
2) Reinstall the drain plug after draining ATF, and

tighten it to the specified torque.
Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
3) Fill ATF up to the middle of the COLD side on
level gauge by using the gauge hole.
Recommended fluid:
Dexron III type automatic transmission fluid
Fluid capacity:
Fill the same amount drained from ATF drain
plug hole.
4) Run the vehicle until the ATF temperature rises
to 60 to 80C (140 to 176F) and check the ATF
level.
GI0044A
PM-27
FRONT & REAR DIFFERENTIAL OIL

18.Front & Rear Differential Oil
3. REAR DIFFERENTIAL
A: REPLACEMENT
1) Drain the oil by removing drain plug.

2) Remove the filler plug for quick draining oil.
3) Reinstall the drain plug after draining oil.
1. FRONT DIFFERENTIAL (MANUAL

TRANSMISSION)
For MT vehicle, manual transmission oil works as
differential oil to lubricate differential. Refer to
Transmission Oil. <Ref. to PM-25, Transmission
Oil.>
NOTE:
Apply fluid packing to the drain plug threads before installation in Except Non-turbo AT model.
Non-turbo AT model uses a new aluminum gasket.
2. FRONT DIFFERENTIAL (AUTOMATIC

TRANSMISSION)
Fluid packing:
Three Bond 1105
1) Drain the differential gear oil by removing drain

plug after allowing the engine to cool for 3 to 4
hours.
Tightening torque:
Except 1.6 L and Non-turbo AT model:
49.0 Nm (5.0 kgf-m, 36.2 ft-lb)
1.6 L and Non-turbo AT model:
34 Nm (3.5 kgf-m, 25.3 ft-lb)
4) After installing the drain plug onto rear differential gear case firmly, fill oil up fully to the mouth of
filler plug.
1.6 L and Non-turbo AT MODEL
NOTE:
Filler bolt
GI0045
2) Reinstall the drain plug after draining differential

gear oil and tighten it to the specified torque.
Drain bolt
GI0173
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
Except 1.6 L and Non-turbo MODEL
NOTE:
Be sure to place a gasket between the transmission case and drain plug.
3) Fill differential gear oil through the oil level
gauge hole up to the upper point of level gauge.
Filler plug
Differential gear oil capacity:

1.1 1.3 2 (1.2 1.4 US qt, 1.0 1.1 lmp qt)
Drain plug
GI0174
Oil capacity:
0.8 2 (0.8 US qt, 0.7 lmp qt)
NOTE:
GI0046A
PM-28
FRONT & REAR DIFFERENTIAL OIL

5) Install the filler plug onto rear differential gear

case firmly.
NOTE:
Apply fluid packing to the filler plug before installation in Except Non-turbo AT model.
Non-turbo AT model uses a new aluminum gasket.
Fluid packing:
Three Bond 1105
Tightening torque:
Except 1.6 L and Non-turbo AT model:
49.0 Nm (5.0 kgf-m, 36.2 ft-lb)
1.6 L and Non-turbo AT model:
34 Nm (3.5 kgf-m, 25.3 ft-lb)
PM-29
BRAKE LINE
19.Brake Line
B: CHECKING
A: INSPECTION
1. SERVICE BRAKE
1. BRAKE LINE
1) Check the free play of brake pedal with a force of

less than 10 N (1 kgf, 2 lb).
1) Check scratches, swelling, corrosion and/or

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 the master cylinder, wheel cylinder and pressure control valve.
NOTE:
When the brake fluid level in the reservoir tank is
lower than the specified limit, the brake fluid warning light on the combination meter will come on.
Visually check the brake hose (using a mirror
where it is difficult to see) for any damage.
GI00148A
Brake pedal free play:

1 3 mm (0.04 0.12 in)
GI0050A
2) If the free play is out of specifications above, adjust the brake pedal as follows:
(1) Be 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.
[Depress brake pedal pad with a force of less
than 10 N (1 kgf, 2 lb) to a stroke of 1 to 3 mm
(0.04 to 0.12 in).]
(3) Depress the surface of brake pad by hand.
(4) If there is no free play between clevis pin
and clevis, turn the brake switch adjusting nut
until the clearance between stopper and screw
of brake switch becomes 0.3 mm (0.012 in).
Rear brake hoses
Rear brake pipe

GI0156
GI0051A
PM-30
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 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 95 mm (3.74 in). If the distance is
more than specified, there is possibility of air inside
the hydraulic unit.
4) Check valve is built into the vacuum hose. Disconnect the vacuum hose to inspect function of
check valve.
Blow air into the vacuum hose from its brake booster side end: Air must flow out of engine side end of
hose. Next blow air into the hose from engine side:
Air should not flow out of hose.
Replace both check valve and vacuum hose if the
check valve is faulty. Engine side of vacuum hose
is indicated by marking ENGINE as shown.
Brake pedal reserve distance: A

more than 95 mm (3.74 in)/ 490 N (50 kgf, 110
lb)
GI0053A
5) Check the vacuum hose for cracks or other damage.

GI0052A
4) Check to see if air is in the hydraulic brake line

by the feel of pedal operation. If air appears to exist
in the line, bleed it from the system.
5) Check for even operation of all brakes, using a
brake tester or by driving the vehicle for a short distance on a straight road.
NOTE:
When installing the vacuum hose on the engine
and brake booster, do not use soapy water or lubricating oil on their connections.
6) Check vacuum hose to make sure it is tight and
secure.
2. BRAKE SERVO SYSTEM

1) With the engine off, depress the brake pedal
several times applying the same pedal force: Make
sure the travel distance should not change.
2) With the brake pedal depressed, start the engine: Make sure the pedal should move slightly toward the floor.
3) With the brake pedal depressed, stop the engine
and keep the pedal depressed for 30 seconds:
Make sure the pedal height should not change.
PM-31
BRAKE FLUID
20.Brake Fluid
A: REPLACEMENT
1) Either jack-up the vehicle and place a safety
stand under it, or lift-up the vehicle.
2) Remove both front and rear wheels.
3) Draw out the brake fluid from master cylinder
with syringe.
4) Refill the reservoir tank with recommended
brake fluid.
Recommended brake fluid:
FMVSS No. 116, fresh DOT3 or 4 brake fluid
NOTE:
Avoid mixing different brands of brake fluid to
prevent degrading the quality of the fluid.
Be careful not to allow dirt or dust to get into the
reservoir tank.
Bleeding sequence (1) (2) (3) (4)
NOTE:
Add brake fluid as necessary while performing the
air bleed operation, in order to prevent the tank
from running short of brake fluid.
9) After completing the bleeding operation, hold
brake pedal depressed and tighten the screw and
install bleeder cap.
GI0054A
(1)
(2)
(3)
(4)
(5)
(6)
NOTE:
Cover the bleeder with waste cloth, when loosening it, to prevent brake fluid from being splashed
over surrounding parts.
During bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate entry of
air.
Brake pedal operation must be very slow.
For convenience and safety, it is advisable to
have two men working.
The amount of brake fluid required is 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 approx. 1/4 turn until a
small amount of brake fluid drains into container,
and then quickly tighten the screw.
8) Repeat steps 6) and 7) above until there are no
air bubbles in the drained brake fluid and new fluid
flows through vinyl tube.
Front right
Rear left
Front left
Rear right
Secondary
Primary
5) Install one end of a vinyl tube onto the air bleeder

and insert the other end of the tube into a container
to collect the brake fluid.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
10) Bleed air from each wheel cylinder by following
the previous 5 steps.
11) Depress 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 make sure
that 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
make sure that brakes are operating properly.
GI0055
PM-32
DISC BRAKE PADS AND DISCS

21.Disc Brake Pads and Discs
3) Check the disc rotor, and correct or replace if it is

damaged or worn.
Non-turbo MODEL
A: INSPECTION
1. DISC BRAKE PAD AND DISC
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.
Non-turbo MODEL
Standard
Wear limit
Brake disc thickness

Front
24 (0.94)
22 (0.87)
mm (in)
Rear
10 (0.39)
8.5 (0.335)
Turbo MODEL
Standard
Wear limit
Brake disc thickness

Front
24 (0.94)
22 (0.87)
mm (in)
Rear
18 (0.71)
16 (0.63)
4) Measure the disc rotor runout at a point less than

5 mm (0.20 in) from the outer periphery of the rotor.
Disc rotor runout limit:
Front: 0.070 mm (0.0028 in)
Rear: 0.075 mm (0.0030 in)
GI0056A
Pad thickness including back metal

mm (in)
Front
Rear
Standard
17 (0.67)
14 (0.55)
Service limit
7.5 (0.295)
6.5 (0.256)
NOTE:
When replacing a pad, always replace the pads for
both the right and left wheels at the same time. Also
replace the pad clips if they are twisted or worn.
Turbo MODEL
GI0147
Inspection
hole
GI0146
Pad thickness including back metal

mm (in)
Front
Rear
Standard
14.5 (0.570)
16 (0.629)
Service limit
6.0 (0.236)
6.0 (0.236)
GI0057A
PM-33
BRAKE LININGS AND DRUMS

22.Brake Linings and Drums

A: INSPECTION
1. REAR DRUM BRAKE
1) Remove the brake drum, and check that there is
no fluid leakage from wheel cylinder.
If there is fluid leakage from wheel cylinder, replace
it.
2) Inspect the brake shoes for damage or deformities and check brake linings for wear.
NOTE:
Always replace both leading and trailing brake
shoes for the right and left wheels at the same time.
When either the right and left brake assembly is
replaced, always replace the leading shoe and trailing shoe of the other.
The cotter pin, once removed, cannot be reused.
3) Check the brake drum for wear, dents or other

damage.
If the inside surface of brake drum is streaked, correct the surface with emery cloth (#200 or more). If
it is unevenly worn, tapered, or the outside surface
of brake drum is damaged, correct or replace it.
Brake drum inner diameter
Standard value: 228.6 mm (9.000 in)
Service limit: 230.6 mm (9.079 in)
If deformation or wear of back plate, shoe, etc. is
noticeable, replace the affected parts.
Thickness of lining (except back metal)

Service limit: 1.5 mm (0.059 in)
GI0060A
2. PARKING BRAKE (REAR DISC BRAKE)

Inspect the brake linings and drums of both sides of
the rear brake at the same time by removing brake
drums.
1) Inspect the brake shoes for damage or deformation and check brake linings for wear.
NOTE:
Always replace both primary and secondary brake
shoes for the right and left wheels at the same time.
GI0059A
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Brake lining thickness excluding back metal

Wear limit: 1.5 mm (0.059 in)
Rotational direction of drum (Forward)

Wheel cylinder
Upper shoe return spring
Adjusting lever
Trailing shoe
Lower shoe return spring
Leading shoe
To replace the trailing shoe, remove the cotter pin.

Clevis pin should also be replaced if worn.
GI0061A
PM-34
BRAKE LININGS AND DRUMS

2) Check the brake drum for wear, dents or other

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

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 a slot-type screwdriver as shown in illustration.
GI0062A
3) If the deformation or wear of back plate, shoe,

etc. is noticeable, replace them.
4) When the shoe return spring tension is excessively weakened, replace it, taking care to identify
upper and lower springs.
GI0063A
3) Turn back (downward) the adjuster 3 to 4 notches.

4) Install the cover (rubber) at original position correctly.
PM-35
SUSPENSION
23.Suspension
A: INSPECTION
1. SUSPENSION BALL JOINT
1) Jack-up the vehicle until front wheels are off
ground.
2) Next, grasp the bottom of tire and move it in and
out. If relative movement is observed between the
brake disc cover and end of transverse link, ball
joint may be excessively worn.
3) Next, grasp the end of transverse link and move
it up and down. Relative movement between the
housing and transverse link boss indicates ball joint
may be excessively worn.
4) If relative movement is observed in the immediately preceding two steps, remove and inspect the
ball joint. If free play exceeds standard, replace the
ball joint. <Ref. to FS-18, Front Ball Joint.>
5) Damage of dust seal

Visually inspect the ball joint dust seal. If it is damaged, remove the transverse link. <Ref. to FS-16,
Front Transverse Link.> And measure free play of
ball joint. <Ref. to FS-18, Front Ball Joint.>
(1) When looseness exceeds standard value,
replace the ball joint.
(2) If the dust seal is damaged, replace with the
new ball joint.
NOTE:
When the transverse link ball joint has been 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.>
GI0066A
2. TRANSVERSE LINK'S REAR BUSHING

GI0064A
Check oil leaks at around liquid-filled bushing. If oil

leaks, replace the bushing.
GI0067A
GI0065A
PM-36
SUSPENSION
3. WHEEL ARCH HEIGHT

1) Unload cargoes and set the vehicle in curb
weight (empty) condition.
2) Then, check the wheel arch height of front and
rear suspensions to ensure that they are within
specified values.
3) When the wheel arch height is out of standard,
visually inspect the following components and replace deformed parts.
Suspension components [Front strut assembly
and rear shock absorber assembly]
Body parts to which suspensions are installed.
4) When no components are deformed, adjust the
wheel arch height by replacing coil spring in the
suspension which wheel arch height is out of standard. <Ref. to FS-8, Wheel Alignment.> <Ref. to
RS-9, Wheel Alignment.>
4. WHEEL ALIGNMENT OF FRONT SUSPENSION

1) Check the alignment of front suspension to ensure that following items conform to standard values.
Toe-in
Camber angle
Caster angle
Steering angle
<Ref. to FS-8, Wheel Alignment.>
2) When the caster angle does not conform to standard value, visually inspect the following components and replace deformed parts.
Suspension components [Strut assembly, crossmember, transverse link, etc.]
3) When the toe-in and camber are out of standard
value, adjust them so that they conform to respective service standard.
4) When the right-and-left turning angles of tire are
out of standard, adjust to standard value.
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 angle
Thrust angle
<Ref. to RS-9, Wheel Alignment.>
2) When the camber angle does not conform to
standard value, visually inspect parts listed below.
If deformation is observed, replace the damaged
parts.
Suspension components [Shock absorber, link
F, link R, link UPR, arm R, sub frame, etc.]
3) When the toe-in and thrust angle are out of standard value, adjust them so that they conform to respective service standard.
6. OIL LEAKAGE OF STRUT AND SHOCK

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

Check the bolts and nuts shown in the figure for
looseness. Retighten the bolts and nuts to specified torque. If the self-lock nuts and bolts are removed, replace them with new ones.
Front suspension: <Ref. to FS-2, General Description.>
Rear suspension: <Ref. to RS-2, General Description.>
PM-37
SUSPENSION
8. DAMAGE TO SUSPENSION PARTS

1) Check the following parts and the fastening portion of the vehicle body for deformation or excessive rusting which impairs the suspension. If
necessary, replace the damaged parts with new
ones. If minor rust formation, pitting, etc. are noted,
remove the rust and apply remedial anti-corrosion
measures.
Front suspension
Transverse link
Crossmember
Strut
Rear suspension
Crossmember
Lateral links
Trailing link
Strut
In the district where salt is sprayed to melt snow
on a road in winter, check suspension parts for
damage caused by rust every 12 months after
lapse of 60 months. Take rust prevention measure
as required.
PM-38
WHEEL BEARING
24.Wheel Bearing
A: INSPECTION
1. FRONT WHEEL BEARING
NOTE:
Inspect the condition of front wheel bearing grease.
1) Jack-up the front 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 front wheel.
4) If bearing free play exists in step 2) above, attach a dial gauge to the hub and measure axial displacement in axial direction.
6) While supporting the rear drive shaft horizontally

with one hand, turn the hub COMPL with the other
to check for noise or binding.
If the hub COMPL is noisy or binds, disassemble
the rear axle and check condition of oil seals, bearings, etc.
Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the bolts and self-locking nuts, and extract transverse link from front crossmember.
6) While lightly hammering the spring pin which secures S.F.J. to transmission spindle, remove it.
7) Extract the S.F.J. from transmission spindle.
<Ref. to DS-18, Front Axle.>
8) While supporting the front drive shaft horizontally with one hand, turn the hub with the other to
check for noise or binding.
If the hub is noisy or binds, disassemble the front
axle and check condition of oil seals, bearing, etc.
Inner oil seal
Hub bolt
Snap ring
Bearing
Housing
Outer oil seal
Hub
GI0133
2. REAR WHEEL BEARING

1) Jack-up the rear 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 rear wheel.
4) If the bearing free play exists in step 2) above,
attach a dial gauge to the hub COMPL and measure axial displacement in axial direction.
Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the DOJ of rear drive shaft from rear differential. <Ref. to DS-39, Rear Drive Shaft.>
PM-39
Inner oil seal

Rear housing
Tone wheel
(With ABS only)
Bearing
Snap ring
Outer oil seal
Hub bolt
Socket bolt
(With ABS only)
Hub
GI0134
AXLE BOOTS & JOINTS

25.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-33, Front
Drive Shaft.> <Ref. to DS-39, Rear Drive Shaft.>
GI0070A
(B)
GI0135
2. PROPELLER SHAFT
Inspect the propeller shaft for damage or failure. If
faulty, replace with a new one. <Ref. to DS-15, Propeller Shaft.>
PM-40
STEERING SYSTEM (POWER STEERING)

26.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 right and
left 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.
1) 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)
GI0075A
3. GEARBOX
GI0074A
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) Pull to one side:
Steering wheel should not be pulled to either
side while driving on a level surface.
(3) Wheel runout:
Steering wheel should not show any sign of
runout.
(4) Return factor:
Steering wheel should return to its original position after it has been turned and then released.
Maximum permissible play:
0.5 mm (0.020 in)
1) With wheels placed on a level surface, turn the

steering wheel 90 in both the right and left 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)
GI0076A
2) Check the boot for damage, cracks or deterioration.

3) With the vehicle on a level surface, quickly turn
the steering wheel to the right and left.
While the steering wheel is being rotated, check the
gear backlash. If any unusual noise is noticed, adjust the gear backlash in the following manner.
(1) Tighten the adjusting screw to 7.4 Nm (0.75
kgf-m, 5.4 ft-lb) and then loosen. Repeat this operation twice.
(2) Retighten the adjusting screw to 7.4 Nm
(0.75 kgf-m, 5.4 ft-lb) and back off 25.
PM-41

(3) Apply liquid packing to at least 1/3 of entire

perimeter of adjusting screw thread.
5. POWER STEERING FLUID LEVEL

NOTE:
The fluid level must be checked when the temperature of reservoir tank surface is approx. 20C
(68F).
1) Place the vehicle with engine OFF on a flat and
level surface.
2) Check the fluid level using the scale on the outside of reservoir tank (A). If the level is below MIN
(B), add fluid to bring it up to MAX (C).
GI0077A
(4) Install the lock nut. While holding the adjusting screw with a wrench, tighten the lock nut using ST.
ST 926230000
SPANNER
Tightening torque (Lock nut):
39 Nm (4.0 kgf-m, 29 ft-lb)
Hold the adjusting screw with a wrench to prevent it from turning, while tightening the lock nut.
4. TIE-ROD
1) Check the tie-rod and tie-rod ends for bends,
scratches or other damage.
GI0014A
NOTE:
If the fluid level is at MAX level or above, drain fluid
to keep the level in specified range of indicator by
using a syringe or the like.
Recommended fluid:
Dexron IIE or III
Fluid capacity:
0.7 2 (0.7 US qt, 0.6 Imp qt)
6. POWER STEERING FLUID FOR LEAKS
GI0105A
2) Check the connections of knuckle ball joints for

play, inspect for damage on dust seals, and check
free play of ball studs. If the castle nut is loose, retighten it to the specified torque, then tighten further
up to 60 until the cotter pin hole is aligned.
Tightening torque:
27 Nm (2.75 kgf-m, 19.9 ft-lb)
3) Check the lock nut on tie-rod end for tightness. If
it is loose, retighten it to the specified torque.
Inspect the underside of oil pump and gearbox for

power steering system, hoses, piping and their
couplings for fluid leaks.
If fluid leaks are found, correct them by retightening
their fitting bolts (or nuts) and/or replacing their
parts.
NOTE:
Wipe the leakage fluid off after correcting fluid
leaks, or a wrong diagnosis is taken later.
Also pay attention to clearances between hoses
(or pipings) and other parts when inspecting fluid
leaks.
Tightening torque:
83 Nm (8.5 kgf-m, 61.5 ft-lb)
PM-42

7. HOSES OF OIL PUMP FOR DAMAGES

Check the pressure hose and return hose of oil
pump for crack, swell or damage. Replace the hose
with a new one if necessary.
NOTE:
Prevent the hoses from revolving and/or turning
when installing hoses.
GI0017
8. POWER STEERING PIPES FOR DAMAGE

Check the power steering pipes for corrosion and
damage.
Replace the pipes with a new one if necessary.
9. GEARBOX BOOTS
Inspect both sides of gearbox boots as follows, and
correct the defects if necessary.
1) (A) and (B) positions of gearbox boot are fitted
correspondingly in (A) and (B) grooves of gearbox
and the rod.
2) Clips are fitted outside of (A) and (B) positions of
boot.
3) Boot does not have crack and hole.
NOTE:
Rotate (B) the position of gearbox boot against
twist of it produced by adjustment of toe-in, etc.
GI0023A
10.FITTING BOLTS AND NUTS

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.
PM-43
SUPPLEMENTAL RESTRAINT SYSTEM

27.Supplemental Restraint System

A: INSPECTION
Check the airbag system in accordance with the result of the self-diagnosis. <Ref. to AB-2, Basic Diagnostic
Procedure.>
1) Ensure that airbag connectors are connected. If not, properly connect. When the ignition switch is turned
ON with the connector(s) disconnected, the airbag warning light blinks to identify the fault.
GI0136
2) Turn the ignition switch to ON, and connect the airbag diagnosis terminal of the service connector (located
below lower cover) to ground terminal.
3) The warning light blinks to indicate a trouble code (a fault is identified). When the airbag system is in good
order (no trouble codes are stored in the memory), the warning light blinks on and off at 0.6 second intervals
(as long as the diagnosis terminal is connected to ground terminal).
4) When the warning light indicates a trouble code, check the airbag system in accordance with the troubleshooting procedure. <Ref. to AB-2, Basic Diagnostic Procedure.>
PM-44
ENGINE 1 SECTION

of SUBARU vehicles.
FUEL INJECTION (FUEL SYSTEMS)
FU
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES)
EC
INTAKE (INDUCTION)
IN
MECHANICAL
ME
EXHAUST
EX
COOLING
CO
LUBRICATION
LU
SPEED CONTROL SYSTEMS
SP
IGNITION
IG
STARTING/CHARGING SYSTEMS
SC
ENGINE (DIAGNOSTICS)
EN

approval.
G1840GE2
FU
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Page
Throttle Body.............................................................................................16
Intake Manifold..........................................................................................17
Engine Coolant Temperature Sensor........................................................31
Crankshaft Position Sensor.......................................................................32
Camshaft Position Sensor.........................................................................33
Knock Sensor............................................................................................34
Throttle Position Sensor............................................................................35
Intake Air Temperature and Pressure Sensor...........................................37
Atmospheric Pressure Sensor ..................................................................38
Idle Air Control Solenoid Valve .................................................................39
Air Assist Injector Solenoid Valve .............................................................40
Fuel Injector ..............................................................................................41
Front Oxygen (A/F) Sensor .......................................................................47
Rear Oxygen Sensor.................................................................................49
Engine Control Module..............................................................................51
Main Relay ................................................................................................52
Fuel Pump Relay.......................................................................................53
Fuel ...........................................................................................................54
Fuel Tank ..................................................................................................55
Fuel Filler Pipe ..........................................................................................58
Fuel Pump.................................................................................................62
Fuel Level Sensor .....................................................................................65
Fuel Sub Level Sensor..............................................................................66
Fuel Filter ..................................................................................................68
Fuel Cut Valve...........................................................................................69
Fuel Damper Valve ...................................................................................70
Fuel Delivery, Return and Evaporation Lines............................................71
Fuel System Trouble in General ...............................................................75
GENERAL DESCRIPTION
A: SPECIFICATIONS
Model
Fuel tank
Fuel pump
Capacity
Location
Type
Shutoff discharge pressure
Discharge flow
Fuel filter
1600 cc and 2000 cc

2500 cc
50 2 (13.2 US gal, 11.0 Imp gal)
60 2 (15.9 US gal, 13.2 Imp gal)
Under rear seat
Impeller
370 677 kPa (3.77 6.9 kg/cm2, 53.6 98 psi)
More than 65 2 (17.2 US gal, 14.3 Imp gal)/h
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
Cartridge type
FU-2
GENERAL DESCRIPTION
FU-3
GENERAL DESCRIPTION
B: COMPONENT
1. INTAKE MANIFOLD
(25)
(2)
T7
(26)
T4
(21)
T3
(4)
T7
T5
(3)
T7
(5)
(9)
(8)
(6)
T8
(2)
T6
(7)
T3
T2
(27)
(14)
T7
T7
(10)
T6
(21)
(4)
T8
(3)
(15)
(5)
T8
(6)
(17)
T8
(1)
(24)
(23)
(11)
T3
T8
T7
T7
T4
T3
(22)
(28)
(20)
(16)
T1
T3
T1
T1
(19)
(12)
(19)
(24)
T1
(13)
(18)
(20)
T1
(20)
T1
T7
T3
(19)
EN1383
FU-4
GENERAL DESCRIPTION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Intake manifold gasket RH

Fuel injector pipe
Fuel injector
O-ring
O-ring
O-ring
Plug
PCV valve
Purge control solenoid valve
Nipple
Intake manifold
Intake manifold gasket LH
Fuel pipe protector LH
Intake air temperature and pressure sensor
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
O-ring
Plug cord holder LH
Fuel pipe protector RH
Fuel pipe ASSY
Fuel hose
Clip
Clip
Air assist injector solenoid valve
bracket
(24)
(25)
Guide pin
Atmospheric pressure sensor
bracket
(26)
(27)

Plug cord holder RH
FU-5
(28)
Accelerator cable bracket
Tightening torque: Nm (kgf-m, ft-lb)

T1: 1.5 (0.15, 1.1)
T2: 3.4 (0.35, 2.5)
T3: 5.0 (0.51, 3.7)
T4: 6.4 (0.65, 4.7)
T5: 7.4 (0.75, 5.4)
T6: 17(1.7, 12.5)
T7: 19 (1.9, 14.0)
T8: 25 (2.5, 18.4)
GENERAL DESCRIPTION
2. AIR INTAKE SYSTEM
B2M3455C
(1)
(2)
(3)
Gasket
Throttle position sensor
Idle air control solenoid valve
(4)
Throttle body
FU-6

T1: 1.6 (0.16, 1.2)
T2: 22 (2.2, 16.2)
GENERAL DESCRIPTION
3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS
B2M2282B
(1)
(2)
Crankshaft position sensor

Knock sensor
(3)
(4)
Camshaft position sensor

Camshaft position sensor support
FU-7

T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)
GENERAL DESCRIPTION
4. FUEL TANK
1600 CC and 2000 CC MODEL
T1
T1
(9)
(25)
(16)
(10)
(8)
(6)
(11)
(11)
D
A
(11)
(14)
(13)
(7)
(24)
T1
(12)
(24)
(11)
C
(9)
(11)
(8)
(5)
(15)
(11)
(17)
(19) (18)
(20)
A
(4)
(11)
(21)
(11)
(22)
(2)
T3
(18)
T3
(19)
(3)
(11)
(23)
(2)
T2
T2
(1)
T2
EN0439
FU-8
GENERAL DESCRIPTION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Heat shield cover

Fuel tank band
Protector RH
Fuel tank
Fuel pump gasket
Fuel pump ASSY
Fuel meter unit
Fuel cut valve gasket
Fuel cut valve
Evaporation hose A
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Clip
Evaporation hose B
Joint pipe
Evaporation hose C
Evaporation pipe ASSY
Evaporation pipe
Evaporation hose D
Retainer
Quick connector
Evaporation hose E
FU-9
(21)
(22)
(23)
(24)
(25)
Fuel pipe ASSY

Evaporation hose F
Fuel return hose B
Evaporation hose G
Evaporation hose H

T1: 4.4 (0.45, 3.3)
T2: 7.4 (0.75, 5.4)
T3: 33 (3.4, 24.3)
GENERAL DESCRIPTION
2500 CC MODEL
T1
T1
(30)
(17)
(10)
(11)
(9)
(7)
(12)
(12)
D
(12)
(8)
(15)
(14)
T1
(29)
(13)
T1
D
(9)
(12)
(8)
(28)
(6)
(29)
(12)
(16)
E
B
(12)
(12)
(18)
(21) (20)
(5)
(22)
(19)
(27)
(12)
(12)
(26)
(23)
(12)
(24)
(2)
T3
(20)
T3
(12)
(25)
(4)
(2)
T2
T2
(1)
T2
(3)
T2
EN1503
FU-10
GENERAL DESCRIPTION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Heat shield cover

Fuel tank band
Protector LH
Protector RH
Fuel tank
Fuel pump gasket
Fuel pump ASSY
Fuel meter unit
Fuel cut valve
Evaporation hose A
Clip
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
Evaporation hose B
Joint pipe
Evaporation hose C
Evaporation pipe
Evaporation hose D
Fuel return hose A
Retainer
Quick connector
Evaporation hose E
Fuel pipe ASSY
Evaporation hose F
FU-11
(25)
(26)
(27)
(28)
(29)
(30)
Fuel return hose B

Fuel sub meter gasket
Jet pump filter
Fuel sub meter unit
Evaporation hose G
Evaporation hose H

T1: 4.4 (0.45, 3.3)
T2: 7.4 (0.75, 5.4)
T3: 33 (3.4, 24.3)
GENERAL DESCRIPTION
5. FUEL LINE
(19)
B
(24)
(18)
(20)
(17)
(16)
(15)
(24)
(25)
(22)
(21) (13)
T
(23)
(14)
B
C
A
(1)
(1)
C
(12)
(8)
(1) (1) (10)
(9)
(1)
(1)
(1)
(1)
(10)
(11)
(7)
(1)
(6)
(2)
(1)
(5)
(4)
(3)
EN0440
FU-12
GENERAL DESCRIPTION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Clip
Fuel delivery hose A
Fuel filter bracket
Fuel filter holder
Fuel filter cup
Fuel filter
Evaporation hose
Fuel damper
Fuel delivery hose B
Fuel return hose
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Fuel pipe ASSY

Grommet
Canister hose A
Canister
Canister bracket plate
Cushion
Canister bracket spacer
Rear canister bracket
Two-way valve return hose
Two-way valve
FU-13
(21)
(22)
(23)
(24)
(25)
Two-way valve drain hose A

Connector
Two-way valve drain hose B
Clamp
Front canister bracket

T: 23 (2.3, 17.0)
GENERAL DESCRIPTION
6. FUEL FILLER PIPE
(9)
(8)
(10)
(11)
T
(1)
(3)
(2)
(5)
T
(3)
T
(6)
T
(4)
(3)
(7)
EN0441
(1)
(2)
(3)
(4)
(5)
Fuel filler pipe ASSY

Evaporation hose holder
Clip
Clamp
Air vent hose
(6)
(7)
(8)
(9)
(10)
Air vent pipe

Air vent pipe holder
Filler pipe packing
Filler ring
Filler cap
FU-14
(11)
Filler pipe protector

T: 7.5 (0.76, 5.53)
GENERAL DESCRIPTION
C: CAUTION
Wear working clothing, including a cap, protective goggles, and protective shoes during operation.
Remove contamination including dirt and corrosion before removal, installation or disassembly.
Keep the disassembled parts in order and protect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.
Be careful not to burn your hands, because each

part on the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Before disconnecting electrical connectors of
sensors or units, be sure to disconnect 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
24082AA190
(Newly adopted
tool)
DESCRIPTION
CARTRIDGE
REMARKS
Troubleshooting for electrical system.
SELECT MONITOR KIT
Troubleshooting for electrical systems.

English: 22771AA030 (Without printer)
German: 22771AA070 (Without printer)
French: 22771AA080 (Without printer)
Spanish: 22771AA090 (Without printer)
B2M3876
22771AA030
B2M3877
FU-15
THROTTLE BODY
2. Throttle Body
6) Disconnect the air by-pass hose from air assist

injector solenoid valve.
A: REMOVAL
1) Disconnect the ground cable from battery.
B2M3457A
(A) Throttle position sensor

(B) Idle air control solenoid valve
(C) Air by-pass hose from air assist injector solenoid valve
G6M0095
2) Remove the air cleaner case.
7) Disconnect the engine coolant hoses from throttle body.
H2M2947
3) Disconnect the accelerator cable (A).

4) Disconnect the cruise control cable (B). (With
cruise control model)
B2M4255
8) Remove the bolts which install throttle body to

intake manifold.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Always use a new gasket.
B2M4254A
5) Disconnect the connectors from idle air control

solenoid valve and throttle position sensor.
Tightening torque:
Throttle body;
22 Nm (2.2 kgf-m, 16.2 ft-lb)
Air cleaner case;
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
FU-16
INTAKE MANIFOLD
3. Intake Manifold
(3) Remove the bolts which hold power steering

pipes onto intake manifold protector.
A: REMOVAL
1) Release the fuel pressure.
<Ref. to FU-54, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>
2) Open the fuel flap lid and remove fuel filler cap.
NOTE:
Do not disconnect the power steering hose.
B2M4126
(4) Remove the bolts which install power steering pump bracket.
G6M0095
4) Remove the air intake duct and air cleaner assembly.

<Ref. to IN-7, REMOVAL, Air Intake Duct.> and
<Ref. to IN-6, REMOVAL, Air Cleaner Case.>
B2M3151
(5) Disconnect the connector from power steering pump switch.
B2M4254A
7) Remove the power steering pump and tank from

brackets.
(1) Remove the resonator chamber.
<Ref. to IN-8, REMOVAL, Resonator Chamber.>
(2) Remove the front side V-belt.
<Ref. to ME-44, REMOVAL, V-belt.>
EN0360
(6) Remove the power steering tank from the

bracket by pulling it upwards.
EN0361
FU-17
INTAKE MANIFOLD
(7) Place the power steering pump and tank on

right side wheel apron.
12) Remove the air cleaner case stay RH and engine harness bracket, and disconnect the engine
harness connectors from bulkhead harness connectors.
EN0208
8) Disconnect the spark plug cords from spark

plugs.
9) Disconnect the PCV hose from intake manifold.
B2M4260
13) Disconnect the connectors from engine coolant

temperature sensor.
B2M4258
10) Disconnect the engine coolant hose from throttle body.
B2M4261
14) Disconnect the knock sensor connector.
B2M4262
B2M4255
11) Disconnect the brake booster hose.
15) Disconnect the connector from crankshaft position sensor.
B2M4259
B2M1252
FU-18
INTAKE MANIFOLD
16) Disconnect the connector from oil pressure

switch.
19) Remove the bolts which hold intake manifold

onto cylinder heads.
B2M1253
B2M4128
17) Disconnect the connector from camshaft position sensor.
20) Remove the intake manifold.
B2M0160
B2M4263
B: INSTALLATION
18) Disconnect the fuel hoses from fuel pipes.
1) Install the intake manifold onto cylinder heads.
WARNING:
Do not spill fuel.
Catch the fuel from hoses in a container or
cloth.
NOTE:
Always use new gaskets.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
S2M0500F
B2M4128
(A) Fuel delivery hose

(B) Return hose
(C) Evaporation hose
FU-19
INTAKE MANIFOLD
2) Connect the fuel hoses.
6) Connect the knock sensor connector.
S2M0500F
B2M4262
7) Connect the connectors to engine coolant temperature sensor.

(B) Return hose
3) Connect the connector to camshaft position sensor.
B2M4261
8) Install the air cleaner case stay RH and engine

harness bracket, and connect the engine harness
connectors to bulkhead connectors.
B2M4263
4) Connect the connector to oil pressure switch.
B2M4260
9) Connect the brake booster hose.

B2M1253
5) Connect the connector to crankshaft position

sensor.
B2M4259
B2M1252
FU-20
INTAKE MANIFOLD
10) Connect the engine coolant hose to throttle

body.
(3) Tighten the bolts which install power steering pump on bracket.
Tightening torque:
22 Nm (2.2 kgf-m, 16.2 ft-lb)
B2M4255
11) Connect the PCV hose to intake manifold.

B2M3151
(4) Install the power steering pipes onto right

side intake manifold protector.
B2M4258
12) Connect the spark plug cords to spark plugs.

13) Install the power steering pump and tank on
brackets.
(1) Install the power steering tank on bracket.
B2M4126
(5) Install the front side V-belt.

<Ref. to ME-44, INSTALLATION, V-belt.>
(6) Install the resonator chamber.
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
EN0361
(2) Connect the connector to power steering

pump switch.
B6M1237
14) Connect the accelerator cable (A).
EN0360
FU-21
INTAKE MANIFOLD
15) Connect the cruise control cable (B). (With

cruise control models)
C: DISASSEMBLY
1) Disconnect the engine ground cable from intake
manifold.
B2M4254A
16) Install the air intake duct and air cleaner assembly.
<Ref. to IN-7, INSTALLATION, Air Intake Duct.>
and <Ref. to IN-6, INSTALLATION, Air Cleaner
Case.>
17) Connect the connector to fuel pump relay.
B2M4265
2) Disconnect the connector from ignition coil and

ignitor assembly.
B2M3472
3) Remove the ignition coil and ignitor assembly.

EN0344
18) Connect the battery ground cable to battery.
B2M3473
G6M0095
4) Disconnect the connector from intake air temperature and pressure sensor.
B2M3474
FU-22
INTAKE MANIFOLD
5) Remove the intake air temperature and pressure

sensor from intake manifold.
10) Disconnect the air by-pass hoses from air assist solenoid valve.
B2M3475
B2M4266
6) Disconnect the connectors from throttle position

sensor and idle air control solenoid valve.
11) Remove the air assist injector solenoid valve

from intake manifold.
B2M3479
B2M3478
7) Disconnect the air by-pass hose from throttle

body.
12) Disconnect the pressure regulator vacuum

hose from intake manifold.
B2M3480
H2M2961
8) Remove the throttle body.
13) Remove the fuel pipe protector LH.
H2M2951
B2M4129
9) Disconnect the connector from air assist injector

solenoid valve.
FU-23
INTAKE MANIFOLD
14) Remove the fuel pipe protector RH.
20) Remove the purge control solenoid valve.
B2M4130
B2M3487
15) Disconnect the connectors from fuel injectors.
21) Remove the bolt which installs injector pipe on

intake manifold as shown in the figure.
B2M4270
16) Disconnect the connector from purge control

solenoid valve.
H2M2965

intake manifold.
B2M3485
17) Disconnect the air by-pass hose from purge

control solenoid valve.
18) Remove the harness bands (A) and harness
bracket (B) which hold engine harness onto intake
manifold.
H2M2966
23) Remove the two bolts which hold fuel pipes on

the left side of intake manifold.
B2M4272
B2M4271A
19) Remove the engine harness from intake manifold.
FU-24
INTAKE MANIFOLD
24) Remove the fuel injectors.

(1) Remove the fuel injector securing clip.
27) Loosen the clamp which holds front right side

fuel hose to injector pipe, and remove the pipe from
fuel hose.
B2M3488
(2) Remove the fuel injector while lifting up the

fuel injector pipe.
B2M4274
28) Remove the fuel injector pipe.
H2M2975
H2M2970
25) Disconnect the air by-pass hoses from intake

manifold.
29) Remove the bolt which installs fuel pipes on intake manifold.
B2M3491
B2M4149A
26) Loosen the clamp which holds front left side

fuel hose.
30) Remove the fuel pipe assembly and pressure

regulator from intake manifold.
B2M4273
FU-25
INTAKE MANIFOLD
D: ASSEMBLY
1) Install the fuel pipe assembly and pressure regulator, etc. to intake manifold.
2) Tighten the bolt which installs fuel pipes on intake manifold.
5) Connect the left side fuel hose to injector pipe,

and tighten the clamp screw.
Tightening torque:
5.0 Nm (0.51 kgf-m, 3.7 ft-lb)
B2M4273
6) Connect the air assist hoses.
B2M3491
3) Connect the right side fuel hose to injector pipe,

B2M4149A
B2M4274
4) Install the fuel injector pipe.
H2M2975
FU-26
INTAKE MANIFOLD
7) Install the fuel injectors.
9) Tighten the two bolts which install fuel pipes on

NOTE:
Always use new O-rings.
Tightening torque:
5.0 Nm (0.51 kgf-m, 3.7 ft-lb)
B2M3492G
B2M4272
(A) O-ring
(B) Fuel injector
10) Tighten the bolt which installs injector pipe on

intake manifold.
NOTE:
Do not forget to install the fuel injector securing clip.
Tightening torque:
5.0 Nm (0.51 kgf-m, 3.7 ft-lb)
B2M3488
H2M2966
8) Tighten the bolt which installs injector pipe on intake manifold.
11) Install the purge control solenoid valve.
Tightening torque:
5.0 Nm (0.51 kgf-m, 3.7 ft-lb)
B2M3487
H2M2965
FU-27
INTAKE MANIFOLD
12) Connect the hoses to purge control solenoid

valve.
CAUTION:
Carefully connect the evaporation hoses.
16) Install the fuel pipe protector RH.

Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
B2M4130
B2M1893E
17) Install the fuel pipe protector LH.
(A) To fuel pipe

(B) To intake manifold
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
13) Install the engine harness onto intake manifold.

Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
14) Connect the connectors to fuel injectors and
purge control solenoid valve.
15) Hold the engine harness by harness band (A)
and harness bracket (B).
B2M4129
18) Connect the pressure regulator vacuum hose

to intake manifold.
B2M4271A
NOTE:
Do not use the harness band on harnesses where
they are supposed to be protected by the fuel pipe
protector.
H2M2961
FU-28
INTAKE MANIFOLD
19) Install the air assist injector solenoid valve to

bracket.
23) Connect the connector to throttle position sensor and idle air control solenoid valve.
Tightening torque:
5.0 Nm (0.51 kgf-m, 3.7 ft-lb)
B2M3479
24) Connect the air by-pass hose to throttle body.

B2M3478
20) Connect the air by-pass hoses to air assist solenoid valve.
B2M3480
25) Install the intake air temperature and pressure

sensor.
B2M4266
21) Connect the connector to air assist solenoid

valve.
22) Install the throttle body to intake manifold.
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
NOTE:
Tightening torque:
22 Nm (2.2 kgf-m, 16.2 ft-lb)
B2M3475
NOTE:
Replace the O-ring with a new one.
H2M2951
H2M2999
FU-29
INTAKE MANIFOLD
26) Connect the connector to intake air temperature and pressure sensor.
27) Install the ignition coil and ignitor assembly.
B2M3473
28) Connect the connector to ignition coil and ignitor assembly.

29) Install the engine ground cable to intake manifold.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
B2M2779
E: INSPECTION
Make sure the fuel pipe and fuel hoses are not
cracked and that connections are tight.
FU-30
ENGINE COOLANT TEMPERATURE SENSOR

4. Engine Coolant Temperature

Sensor
B: INSTALLATION
A: REMOVAL
Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
B2M4275
G6M0095
2) Remove the air intake duct and air cleaner assembly.

3) Disconnect the connector from engine coolant
temperature sensor.
B2M4261
4) Remove the engine coolant temperature sensor.
FU-31
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)
G6M0095
2) Remove the bolt which installs crankshaft position sensor to cylinder block.
G2M0408
3) Remove the crankshaft position sensor, and disconnect the connector from it.
G2M0409
FU-32
B2M1252B
CAMSHAFT POSITION SENSOR

6. Camshaft Position Sensor
5) Remove the camshaft position sensor and camshaft position sensor support as a unit.
6) Remove the camshaft position sensor itself.
A: REMOVAL
B2M2322
G6M0095
B: INSTALLATION
Tightening torque:
Camshaft position sensor support;
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
Camshaft position sensor;
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
B2M4263
3) Remove the bolt which installs camshaft position

sensor to camshaft position sensor support.
B2M2375

sensor support to camshaft cap LH.
B2M2321
FU-33
KNOCK SENSOR
7. Knock Sensor
B: INSTALLATION
A: REMOVAL
1) Install the knock sensor to cylinder block.
Tightening torque:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
NOTE:
The extraction area of the knock sensor cord must
be positioned at a 60 angle relative to engine rear.
G6M0095

H2M3511C
H2M2947

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

H2M2947
S2M1673
G6M0095
FU-34
THROTTLE POSITION SENSOR

8. Throttle Position Sensor
B: INSTALLATION
A: REMOVAL

Tightening torque:
1.6 Nm (0.16 kgf-m, 1.2 ft-lb)
CAUTION:
When installing the throttle position sensor, adjust to the specified data.
G6M0095
2) Disconnect the connector from throttle position

sensor.
H2M2979
C: ADJUSTMENT
1) Turn the ignition switch to OFF.
2) Loosen the throttle position sensor holding
screws.
B2M3493
3) Remove the throttle position sensor holding

screws, and remove it.
B2M3765
H2M2979
3) When using the voltage meter;

(1) Take out the ECM.
(2) Turn the ignition switch to ON.
(3) Adjust the throttle position sensor to proper
position to allow the voltage signal to ECM to be
in specification.
Connector & terminal/Specified voltage
(B136) No. 15 (B136) No. 17/0.45 0.55 V
[Fully closed.]
B2M4131A
FU-35

(4) Tighten the throttle position sensor holding

screws.
(4) Connect the Subaru Select Monitor to data

link connector.
Tightening torque:
1.6 Nm (0.16 kgf-m, 1.2 ft-lb)
B2M3148
B2M3765
4) When using the Subaru Select Monitor;

(1) Turn the ignition switch to OFF.
(2) Loosen the throttle position sensor holding
screws.
5) Turn the ignition switch to ON, and Subaru Select Monitor switch to ON.
6) Select the {2. Each System Check} in Main
Menu.
7) Select the {Engine Control System} in Selection
Menu.
8) Select the {1. Current Data Display & Save} in
Engine Control System Diagnosis.
9) Select the {1.12 Data Display} in Data Display
Menu.
10) Adjust the throttle position sensor to the proper
position to match with the following specifications.
Condition: Throttle fully closed
Throttle opening angle 0.00 %
Throttle sensor voltage 0.50 V
11) Tighten the throttle position sensor holding
screws.
B2M3765
NOTE:
For detailed operation procedures, refer to the Subaru Select Monitor Operation Manual.
(3) Insert the cartridge to Subaru Select Monitor.
Tightening torque:
1.6 Nm (0.16 kgf-m, 1.2 ft-lb)
B2M3765
S2M0286A
FU-36
INTAKE AIR TEMPERATURE AND PRESSURE SENSOR

9. Intake Air Temperature and

Pressure Sensor
B: INSTALLATION
A: REMOVAL
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
B2M3497
G6M0095
2) Disconnect the spark plug cord from ignition coil

and ignitor assembly.
NOTE:
H2M2999
B2M3495
B2M4276

sensor.
B2M3497
FU-37
ATMOSPHERIC PRESSURE SENSOR

10.Atmospheric Pressure Sensor
B: INSTALLATION
A: REMOVAL
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
EN1001
G6M0095
2) Disconnect the connector from atmospheric

pressure sensor.
3) Remove the atmospheric pressure sensor from
bracket.
EN1001
FU-38
IDLE AIR CONTROL SOLENOID VALVE

11.Idle Air Control Solenoid

Valve
B: INSTALLATION
NOTE:
A: REMOVAL
Tightening torque:
1.6 Nm (0.16 kgf-m, 1.2 ft-lb)
G6M0095
2) Disconnect the connector from idle air control

solenoid valve.
B2M3500
3) Remove the idle air control solenoid valve from

throttle body.
B2M3501
FU-39
B2M3501
AIR ASSIST INJECTOR SOLENOID VALVE

12.Air Assist Injector Solenoid

Valve
B: INSTALLATION
A: REMOVAL
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
B2M3503
G6M0095
2) Disconnect the connector from air assist injector

solenoid valve and disconnect the air by-pass hoses.
B2M4266
3) Remove the air assist injector solenoid valve

B2M3503
FU-40
FUEL INJECTOR
13.Fuel Injector
(3) Remove the bolts which install power steering pump to bracket.
A: REMOVAL
1. RH SIDE
2) Open the fuel filler flap lid and remove fuel filler
cap.
B2M3151
G6M0095
4) Remove the resonator chamber.

<Ref. to IN-8, REMOVAL, Resonator Chamber.>
5) Remove the spark plug cords from spark plugs
(#1 and #3 cylinders).
EN0360

B2M4127

brackets.
EN0361

the right side wheel apron.
EN0208
B2M4126
FU-41
FUEL INJECTOR
10) Remove the fuel injector from intake manifold.

B2M4130
B2M4283
8) Disconnect the connector from fuel injector.

fuel injector pipe.
B2M4280
9) Remove the bolts which hold injector pipe to intake manifold.
B2M4281
B2M4282
FU-42
B2M3509
FUEL INJECTOR
2. LH SIDE
cap.
8) Move the washer tank, and secure it away from

working area.
B2M3140

G6M0095
4) Remove the two bolts which install washer tank

on body.
B2M4287
B2M3139
5) Disconnect the connector from front window

washer motor.
6) Disconnect the connector from rear gate glass
washer motor.
B2M4129
B6M0562
7) Disconnect the rear window glass washer hose

from washer motor, then plug connection with a
suitable cap.
FU-43
B2M4294
FUEL INJECTOR
12) Remove the bolt which installs injector pipe to

intake manifold.

fuel injector pipe.
B2M4133
H2M3241
B: INSTALLATION
1. RH SIDE
NOTE:
Replace the O-rings with a new one.
H2M2994
13) Remove the bolt which holds fuel pipe on the

left side intake manifold.
B2M3492G
(A) O-ring
(B) Fuel injector
Tightening torque:
5.0 Nm (0.51 kgf-m, 3.7 ft-lb)
H2M2995

B2M4282
H2M2997
FU-44
FUEL INJECTOR
2. LH SIDE
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)

NOTE:
B2M4132
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
B2M3492G
(A) O-ring
(B) Fuel injector
Tightening torque:
5.0 Nm (0.51 kgf-m, 3.7 ft-lb)
B2M4130
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
H2M2994
Tightening torque:
5.0 Nm (0.51 kgf-m, 3.7 ft-lb)
B6M1237
H2M2995
FU-45
FUEL INJECTOR
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
B2M4133
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
B2M4129
FU-46
FRONT OXYGEN (A/F) SENSOR

14.Front Oxygen (A/F) Sensor
B: INSTALLATION
A: REMOVAL
1) Before installing the 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 by JET LUBE
CAUTION:
Never apply anti-seize compound to the protector of front oxygen (A/F) sensor.
G6M0095
2) Disconnect the connector from front oxygen (A/

F) sensor.
G2M0412
2) Install the front oxygen (A/F) sensor.

Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
B2M4243

4) Apply SUBARU CRC or its equivalent to the
threaded portion of front oxygen (A/F) sensor, and
leave it for 1 minute or more.
SUBARU CRC (Part No. 004301003)
5) Remove the front oxygen (A/F) sensor.
CAUTION:
When removing the oxygen (A/F) sensor, wait
until the exhaust pipe cools, otherwise it will
damage exhaust pipe.
G2M0411
3) Lower the vehicle.

4) Connect the connector of front oxygen (A/F)
sensor.
G2M0411
B2M4243
FU-47

G6M0095
FU-48
REAR OXYGEN SENSOR

15.Rear Oxygen Sensor
B: INSTALLATION
A: REMOVAL
1) Before installing the rear oxygen sensor, apply

anti-seize compound only to the threaded portion of
rear oxygen sensor to make the next removal easier.
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to the protector of rear oxygen sensor.
G6M0095
2) Disconnect the connector from rear oxygen sensor.
B2M0742A
2) Install the rear oxygen sensor.

Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
B2M4244

threaded portion of rear oxygen sensor, and leave
it for 1 minute or more.
5) Remove the rear oxygen sensor.
CAUTION:
When removing the oxygen sensor, wait until
the exhaust pipe cools, otherwise it will damage exhaust pipe.
B2M0741

4) Connect the connector to rear oxygen sensor.
B2M4244
B2M0741
FU-49
REAR OXYGEN SENSOR

G6M0095
FU-50
ENGINE CONTROL MODULE

16.Engine Control Module
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.
G6M0095
2) Remove the lower inner trim of passenger side.

<Ref. to EI-45, REMOVAL, Lower Inner Trim.>
3) Detach the floor mat of front passenger seat.
4) Remove the protect cover.
EN0532
5) Remove the nuts (A) which hold ECM to bracket.

6) Remove the clip (B) from bracket.
(A)
(A)
(B)
EN0533
7) Disconnect the ECM connectors and take out

the ECM.
FU-51
MAIN RELAY
17.Main Relay
B: INSTALLATION
A: REMOVAL
G6M0095
2) Remove the passengers side front side sill cover.

3) Remove the bolt which holds main relay bracket
on body.
4) Disconnect the connectors from main relay.
EN0534
FU-52
FUEL PUMP RELAY

18.Fuel Pump Relay
B: INSTALLATION
A: REMOVAL
G6M0095

3) Remove the bolt which holds fuel pump relay
bracket on body.
4) Disconnect the connector from fuel pump relay.
EN0535
5) Remove the fuel pump relay from mounting

bracket.
FU-53
FUEL
19.Fuel
5) Drain fuel from the fuel tank.

Set a container under the vehicle and remove the
drain plug from fuel tank.
1600 cc and 2000 cc MODEL
A: OPERATION
1. RELEASING OF FUEL PRESSURE
WARNING:
EN0999
2500 cc MODEL
EN0344
2) Start the engine and run it until it stalls.

3) After the engine stalls, crank it for 5 more seconds.
2. DRAINING FUEL
WARNING:
1) Set the vehicle on a lift.
EN0839
6) Tighten the fuel drain plug.

Tightening torque:
26 Nm (2.7 kgf-m, 19.2 ft-lb)
G6M0095
EN0999
cap.
2500 cc MODEL
EN0839
FU-54
FUEL TANK
20.Fuel Tank
9) Loosen the clamp and disconnect the fuel filler

hose and air vent hose from fuel filler pipe.
A: REMOVAL
WARNING:
<Ref. to FU-54, DRAINING FUEL, OPERATION,
Fuel.>
4) Remove the rear seat.
5) Disconnect the connector (A) of fuel tank cord to
rear harness.
6) Push the grommet (B) which holds fuel tank cord
on floor panel into under the body.
EN0539
10) Move the clips, and disconnect quick connector.

<Ref. to FU-71, REMOVAL, Fuel Delivery, Return
and Evaporation Lines.>
11) Disconnect the fuel hoses.
(B)
(A)
EN0540
EN0537
7) Remove the rear crossmember. <Ref. to RS-21,

REMOVAL, Rear Crossmember.>
8) Disconnect the two-way valve hose (A) from
two-way valve and disconnect the canister hose (B)
from canister.
(A)
12) Support the fuel tank with transmission jack,

and remove the bolts from bands and dismount fuel
tank from the vehicle.
WARNING:
A helper is required to perform this work.
(B)
EN0840
EN0541
FU-55
FUEL TANK
B: INSTALLATION
1) Support the fuel tank with transmission jack and
push the fuel tank harness into access hole with
grommet.
2) Set the fuel tank and temporarily tighten the
bolts of fuel tank bands.
5) Connect the fuel hoses, and secure them with

clips and quick connector.
<Ref. to FU-73, INSTALLATION, Fuel Delivery,
Return and Evaporation Lines.>
WARNING:
EN0540
6) Tighten the band mounting bolts.

Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
EN0541
3) Connect the two-way valve hose (A) to two-way

valve and connect the canister hose (B) to canister.
(A)
(B)
EN0541
EN0840
4) Connect the fuel filler hose and air vent hose.
7) Install the rear crossmember. <Ref. to RS-21,

INSTALLATION, Rear Crossmember.>
8) Connect the connector (A) to fuel tank cord and
plug the service hole with gromment (B).
(B)
(A)
EN0539
9) Set the rear seat and floor mat.
FU-56
EN0537
FUEL TANK
EN0344
C: INSPECTION
1) Make sure there are no cracks, holes, or other
damage on the fuel tank.
2) Make sure that the fuel hoses and fuel pipes are
not cracked and that connections are tight.
FU-57
FUEL FILLER PIPE

21.Fuel Filler Pipe

A: REMOVAL
WARNING:
cap.
9) Drain fuel from the fuel tank. Set a container under the vehicle and remove the drain plug from fuel
tank.
EN0999
2500 cc MODEL
G6M0095
5) Remove the screws holding packing in place.

EN0839
10) Tighten the fuel drain plug and then install the
front right side tank cover.
Tightening torque:
26 Nm (2.7 kgf-m, 19.2 ft-lb)
EN0542
6) Remove the rear right side wheel nuts.

8) Remove the rear right side wheel.
EN0999
2500 cc MODEL
B2M1748
EN0839
FU-58
FUEL FILLER PIPE

11) Remove the fuel filler pipe protector.
16) Move the clip and separate air vent hose (B).
(A)
(B)
EN0548
EN0544
12) Separate the evaporation hoses from clip of

fuel filler pipe.
17) Remove the fuel filler pipe to under side of the

vehicle.
18) Remove the air vent pipe together with clip
from body.
EN0545
13) Disconnect the air vent hose from fuel filler

pipe.
EN0549
B: INSTALLATION
1) Hold the fuel filler flap open.
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 cup
(B), and tighten the screws.
NOTE:
If the edges of rubber packing are folded toward inside, straighten it with a screwdriver.
EN0546
14) Remove the bolt which holds fuel filler pipe

bracket on body.
B2M1196A
EN0547
15) Loosen the clamp and separate fuel filler hose

(A) from fuel filler pipe.
FU-59
FUEL FILLER PIPE

4) Install the air vent pipe.
7) Insert the air vent hose approx. 25 to 30 mm

(0.98 to 1.18 in) into the lower end of air vent pipe
and hold clip.
L = 27.52.5 mm (1.0830.098 in)
EN0549
5) Connect the air vent hose to fuel filler pipe.

B2M1195A
(1) Hose
(2) Clip
(3) Pipe
8) Tighten the bolt which holds fuel filler pipe bracket on body.
Tightening torque:
7.5 Nm (0.75 kgf-m, 5.4 ft-lb)
EN0546
6) Insert the fuel filler hose (A) approx. 35 to 40 mm

(1.38 to 1.57 in) over the lower end of fuel filler pipe
and tighten the clamp.
CAUTION:
Do not allow clips to touch the air vent hose (B)
and rear suspension crossmember.
(A)
(B)
EN0547
9) Tighten the bolts which hold evaporation hoses

onto clip of fuel filler pipe.
EN0548
EN0545
FU-60
FUEL FILLER PIPE

10) Install the fuel filler pipe protector.
EN0544
11) Install the rear right wheel.
B2M1748

13) Tighten the wheel nuts.
EN0344
G6M0095
FU-61
FUEL PUMP
22.Fuel Pump
A: REMOVAL
Tightening torque:
26 Nm (2.7 kgf-m, 19.2 ft-lb)
WARNING:
NOTE:
Fuel pump assembly consists of fuel pump and fuel
level sensor.
cap.
EN0999
7) Raise the rear seat and turn floor mat up.

8) Remove the access hole lid.
EN0553
G6M0095

tank.
9) Disconnect the connector from fuel pump.
EN0554
EN0999
10) Disconnect the quick connector and then disconnect fuel delivery hose (A).
<Ref. to FU-71, REMOVAL, Fuel Delivery, Return
FU-62
FUEL PUMP
11) Move the clip and then disconnect the fuel return hose (B).
tank.
(A)
(B)
EN0555
12) Remove the nuts which install fuel pump assembly onto fuel tank.
EN0839

Tightening torque:
26 Nm (2.7 kgf-m, 19.2 ft-lb)
EN0556
13) Take off the fuel pump assembly from fuel tank.
2500 cc MODEL
1) Release the fuel pressure. <Ref. to FU-54, RELEASING OF FUEL PRESSURE, OPERATION,
Fuel.>
cap.
EN0839

EN0553

G6M0095
S2M0172
FU-63
FUEL PUMP
10) Disconnect the quick connector and then disconnect fuel delivery hose (A). <Ref. to FU(TURBO)-68, Fuel Delivery, Return and Evaporation
Lines.>
11) Move the clips, and then disconnect the fuel return hose (B) and jet pump hose (C).
2500 cc MODEL
S2M0063A
C: INSPECTION
Connect the lead harness to connector terminal of
fuel pump and apply battery power supply to check
whether the pump operates.
S2M0060A
WARNING:
Wipe off the fuel completely.
Keep the battery as far apart from fuel pump
as possible.
Be sure to turn the battery supply ON and
OFF on battery side.
Do not run the fuel pump for a long time under non-load condition.
S2M0061
3 2 1
6 5 4
B: INSTALLATION
Install in the reverse order of removal. Do the following:
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or foreign particles before installation.
(3) Tighten the nuts in alphabetical sequence
shown in the figure to specified torque.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
(A)
(C)
(E)
(H)
(G)
(F)
(B)
(D)
EN0557
FU-64
EN1502
FUEL LEVEL SENSOR

23.Fuel Level Sensor
3) Remove the bolt which installs fuel level sensor

on mounting bracket.
A: REMOVAL
;;;;
;
;
WARNING:
NOTE:
Fuel level sensor is built in the fuel pump assembly.
1) Remove the fuel pump assembly.
<Ref. to FU-62, REMOVAL, Fuel Pump.>
2) Disconnect the connector from fuel pump bracket.
EN0560
2500 cc MODEL
EN0559
2500 cc MODEL
EN0846
S2M0145
B: INSTALLATION
S2M0145
FU-65
FUEL SUB LEVEL SENSOR

24.Fuel Sub Level Sensor
6) Remove the service hole cover.
A: REMOVAL
NOTE:
Fuel sub level sensor is equipped to only 2500 cc
model.
WARNING:
G2M0863
7) Disconnect the connector from fuel sub meter.

8) Disconnect the fuel jet pump hose.
G6M0095

tank.
S2M0151
9) Remove the bolts which install fuel sub meter

unit on fuel tank.
EN0839
S2M0152
Tightening torque:
26 Nm (2.7 kgf-m, 19.2 ft-lb)
10) Remove the fuel sub meter unit.
S2M0153
EN0839
FU-66

B: INSTALLATION
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
B2M3178
FU-67
FUEL FILTER
25.Fuel Filter
A: REMOVAL
WARNING:
2) Disconnect the fuel delivery hoses from fuel filter.
S2M0195
3) Remove the filter from holder.
B: INSTALLATION
CAUTION:
If fuel hoses are damaged at the connecting
portion, replace it with a new one.
If clamps are badly damaged, replace with
new ones.
2) Tighten the hose clamp screws.
Tightening torque:
1.25 Nm (0.13 kgf-m, 0.94 ft-lb)
S2M0195
C: INSPECTION
1) Check the inside of fuel filter for dirt and water
sediment.
2) If it is clogged, or if replacement interval has
been reached, replace it.
3) If water is found in it, shake and expel the water
from inlet port.
FU-68
FUEL CUT VALVE

26.Fuel Cut Valve
B: INSTALLATION
A: REMOVAL
WARNING:
1) Remove the fuel tank.
<Ref. to FU-55, REMOVAL, Fuel Tank.>
2) Move the clip and disconnect the evaporation
hose from fuel cut valve.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
S2M0177
S2M0176
3) Remove the bolts which install fuel cut valve.
FU-69
FUEL DAMPER VALVE

27.Fuel Damper Valve
B: INSTALLATION
A: REMOVAL

2) Remove the fuel damper valve from fuel return
line.
EN0852
FU-70
FUEL DELIVERY, RETURN AND EVAPORATION LINES

28.Fuel Delivery, Return and

Evaporation Lines
A: REMOVAL
cap.
4) Remove the floor mat. <Ref. to EI-53, REMOVAL, Floor Mat.>
5) Remove the fuel delivery pipes and hoses, fuel
return pipes and hoses, evaporation pipes and hoses.
EN0564
FU-71

6) In the engine compartment, detach the fuel delivery hoses, return hoses and evaporation hose.
9) Separate the quick connector on fuel delivery

and return line.
(1) Clean the pipe and connector, if they are
covered with dust.
(2) Hold the connector (A) and push retainer (B)
down.
(3) Pull out the connector (A) from retainer (B).
NOTE:
Replace the retainer with new ones.
S2M0500F

(B) Return hose

from canister.
(A)
S2M0228A
(A) Connector
(B) Retainer
(C) Pipe
(B)
EN0840
FU-72

B: INSTALLATION
1) Connect the quick connector on fuel delivery
line.
NOTE:
Always use a new retainer.
Make sure that the connected portion is not damaged or has dust. If necessary, clean the seal surface of pipe.
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 any leakage of fuel.
S2M0231A
S2M0229A
(A) Connector
(B) Retainer
(C) Pipe
(1) Set the new retainer (B) to connector (A).

(2) Push the pipe into connector completely.
NOTE:
At this time, two clicking sounds are heard.
2) Connect the fuel delivery hose to pipe with an

overlap of 20 to 25 mm (0.79 to 0.98 in).
Type A: When the fitting length is specified.
Type B: When the fitting length is not specified.
2 : 2.51.5 mm (0.0980.059 in)
L: 22.52.5 mm (0.8860.098 in)
S2M0230A
(A) Connector
(B) Retainer
(C) Pipe
B2M1194B
(1) Fitting
(2) Clamp
(3) Hose
FU-73

3) Connect the evaporation hose to pipe by approx.

15 mm (0.59 in) from the hose end.
L = 17.52.5 mm (0.6890.098 in)
CAUTION:
B2M1195A
(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 tight.
FU-74
FUEL SYSTEM TROUBLE IN GENERAL

29.Fuel System Trouble in General

A: INSPECTION
Trouble and possible cause
1. Insufficient fuel supply to the injector
1)
Fuel pump will not operate.
Corrective action
Inspect connections, especially ground, and tighten

securely.
Replace the fuel pump.
Replace the 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 the air breather tube or pipe.
Replace.
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 breather tube or pipe.
7)
Damaged diaphragm of pressure regulator.
2. Leakage or blow out fuel
1)
Loosened joints of the fuel pipe.
2)
Cracked fuel pipe, hose and fuel tank.
3)
Defective welding part on the fuel tank.
4)
Defective drain packing of the fuel tank.
5)
Retightening.
Replace.
Replace.
Replace.
Clean, correct or replace the air breather tube or air vent
tube.
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
1)
filler pipe.
2)
Defective packing air tightness on the fuel saucer.
3)
Cracked fuel separator.
4)
Inoperative fuel pump modulator or circuit.
4. Defective fuel meter indicator
1)
Defective operation of fuel meter unit.
2)
Defective operation of fuel meter.
5. Noise
1)
Large operation noise or vibration of fuel pump.
NOTE:
When the vehicle is left unattended for an extended period of time, water may accumulate in the
fuel tank.
To prevent water condensation.
(1) Top off the fuel tank or drain the fuel completely.
(2) Drain water condensation from the fuel filter.
Refilling the fuel tank.
Refill the fuel tank while there is still some fuel left in
the tank.
Protecting the fuel system against freezing and
water condensation.
(3) Cold areas
In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures
drop below 0C (32F) throughout the winter
season, use an anti-freeze solution in the cooling system. Refueling will also complement the
effect of anti-freeze solution each time the fuel
level drops to about one-half. After the winter
Retightening.
Correct or replace the packing.
Replace the separator.
Replace.
Replace.
Replace.
Replace.
season, drain water which may have accumulated in the fuel filter and fuel tank in the manner
same as that described under Affected areas
below.
(4) Affected areas
When water condensation is notched in the fuel
filter, drain water from both the fuel filter and fuel
tank or use a water removing agent (or antifreeze solution) in the fuel tank.
Observe the instructions, notes, etc., indicated
on the label affixed to the anti-freeze solution (water removing agent) container before use.
FU-75

FU-76
EMISSION CONTROL
EC
1.
2.
3.
4.
5.
6.
Page
Front Catalytic Converter ............................................................................3
Rear Catalytic Converter.............................................................................6
Canister.......................................................................................................7
Purge Control Solenoid Valve .....................................................................8
Two-way Valve............................................................................................9
GENERAL DESCRIPTION
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
A: CAUTION
points.
cable from battery.
EC-2
FRONT CATALYTIC CONVERTER

2. Front Catalytic Converter
7) Separate the center exhaust pipe from rear exhaust pipe.
A: REMOVAL
CAUTION:
Be careful, the exhaust pipe is hot.

B2M3109
G6M0095
3) Disconnect the front oxygen (A/F) sensor connector.
8) Remove the nuts which hold front exhaust pipe

B2M3200
B2M4243
4) Disconnect the connector from rear oxygen sensor connector.
9) Remove the front and center exhaust pipe from

hanger bracket.
CAUTION:
Be careful not to pull down the front exhaust
pipe and center exhaust pipe.
B2M4244

B2M3111
EC-3

10) Separate the front catalytic converter from front

exhaust pipe.
3) Tighten the nuts which hold front exhaust pipe

NOTE:
The rear catalytic converter is integrated with front
catalytic converter. Therefore, the procedure for removing rear catalytic converter is the same as the
description above.
Tightening torque:
30 Nm (3.1 kgf-m, 22.4 ft-lb)
B2M3200
4) Tighten the bolts which install front and center

exhaust pipe to rear exhaust pipe.
S2M0923
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
B: INSTALLATION
NOTE:
Replace gaskets with new ones.
1) Install the front catalytic converter to front exhaust pipe.
Tightening torque:
30 Nm (3.1 kgf-m, 22.4 ft-lb)
B2M3109
5) Tighten the bolt which holds front and center exhaust pipe assembly to hanger bracket.
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
S2M0923
2) Install the front and center exhaust pipe assembly to the vehicle. And temporarily tighten the bolt
which installs center exhaust pipe to hanger bracket.
B2M3111
6) Install the under cover.
B2M3111
EC-4


8) Connect the front oxygen (A/F) sensor connector.
B2M4243
9) Connect the connector to rear oxygen sensor

connector.
B2M4244
G6M0095
NOTE:
The rear catalytic converter is integrated with front
catalytic converter. Therefore, the procedure for installing rear catalytic converter is the same as the
description above.
C: INSPECTION
1) Make sure there are no exhaust leaks from connections and welds.
2) Make sure there are no holes or rusting.
EC-5
REAR CATALYTIC CONVERTER

3. Rear Catalytic Converter

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

(B) Rear catalytic converter
B: INSTALLATION
the same as the ones described under front catalytic converter. <Ref. to EC-4, INSTALLATION, Front
Catalytic Converter.>
B2M4164A

C: INSPECTION
EC-6
CANISTER
4. Canister
A: REMOVAL
2) Loosen the two clamps which hold two canister
hoses, and disconnect the three evaporation hoses
from canister.
EN0898
3) Remove the canister from body.
B2M4166
B: INSTALLATION
Tightening torque:
23 Nm (2.3 kgf-m, 17 ft-lb)
B2M4166
C: INSPECTION
Make sure the canister and canister hoses are not
cracked or loose.
EC-7
PURGE CONTROL SOLENOID VALVE

5. Purge Control Solenoid Valve
B: INSTALLATION
A: REMOVAL

Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
G6M0095
2) Remove the bolt which installs purge control solenoid valve onto intake manifold.
H2M2985
CAUTION:
H2M2985
B2M1893E
3) Take out the purge control solenoid valve

through the bottom of intake manifold.
4) Disconnect the connector and hoses from purge
A: To fuel pipe
B: To intake manifold
C: INSPECTION
Make sure hoses are not cracked or loose.
H2M2986
EC-8
TWO-WAY VALVE
6. Two-way Valve
A: REMOVAL
2) Remove the canister from body. <Ref. to EC-7,
REMOVAL, Canister.>
3) Remove the two-way valve with bracket as a single unit from body.
EN0901
4) Remove the two-way valve from bracket.
B: INSTALLATION
C: INSPECTION
1) Make sure that the hoses are not cracked or
loose.
EC-9
TWO-WAY VALVE
EC-10
INTAKE (INDUCTION)
IN
1.
2.
3.
4.
5.
Page
Air Cleaner Element ....................................................................................5
Air Cleaner Case.........................................................................................6
Air Intake Duct.............................................................................................7
Resonator Chamber....................................................................................8
GENERAL DESCRIPTION
INTAKE (INDUCTION)
A: COMPONENT
T3
T3
(5)
(7)
(4)
(6)
(3)
T3
(9)
(8)
T1
(2)
T4
(1)
T3
(11)
T2
(11)
(20)
T2
(19)
(20)
(13)
(19)
(11)
(14)
(10)
(12)
(16)
T5
T6
T5
(18)
T5
(17)
(15)
EN1336
IN-2
GENERAL DESCRIPTION
INTAKE (INDUCTION)
(1)
(2)
(3)
(4)
(5)
Spacer
Bush
Resonator chamber
Cushion rubber
Air intake duct A (1600 cc and
2000 cc model)
(6)
(7)
(8)
(9)
(10)
Air intake duct A (2500 cc model)

Air intake duct B
Holder
Cushion
Air cleaner case A
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
Clip
(20) Spacer
Air cleaner element
Air cleaner case B
Air cleaner case stay LH (MT vehiT1: 33 (3.4, 24.6)
cles)
T2: 6.5 (0.66, 4.8)
Air cleaner case stay LH (AT vehiT3: 7.5 (0.76, 5.5)
cles)
T4: 14 (1.4, 10)
Air cleaner case stay RH
T5: 16 (1.6, 11.6)
Engine harness bracket
T6: 3 (0.3, 2.2)
Clamp
Bush
IN-3
GENERAL DESCRIPTION
INTAKE (INDUCTION)
B: CAUTION
points.
sensor or units, be sure to disconnect the ground
cable from battery.
IN-4
AIR CLEANER ELEMENT

INTAKE (INDUCTION)
2. Air Cleaner Element

A: REMOVAL
1) Remove the clip (A) above the air cleaner case.
H2M2947B
2) Remove the air cleaner element.
B: INSTALLATION
CAUTION:
Fasten with a clip after inserting the lower tab
of the case.
C: INSPECTION
Replace if excessively damaged or dirty.
IN-5
AIR CLEANER CASE

INTAKE (INDUCTION)
3. Air Cleaner Case

A: REMOVAL
1) Loosen the clamp which connects air cleaner
case to throttle body.
H2M2946
2) Disconnect the hoses and intake duct from air

cleaner case.
3) Remove the bolts which install air cleaner case
to stays.
H2M2947
B: INSTALLATION
C: INSPECTION
Inspect for cracks and loose connections.
IN-6
AIR INTAKE DUCT

INTAKE (INDUCTION)
4. Air Intake Duct
2500 cc MODEL
A: REMOVAL
1) Remove the bolts which install air intake duct A
on the front side of body.
B6M1224
B: INSTALLATION
C: INSPECTION
EN0061
1) Inspect for cracks and loose connections.

2) Inspect that no foreign objects are mixed in the
air intake duct.
2500 cc MODEL
B6M1222
2) Remove the bolt which installs air intake duct B

on body.
EN1004
3) Remove the air intake ducts as a unit.

EN0063
IN-7
RESONATOR CHAMBER
INTAKE (INDUCTION)
5. Resonator Chamber
B: INSTALLATION
A: REMOVAL

Tightening torque:
33 Nm (3.4 kgf-m, 24.6 ft-lb)
1) Remove the air intake duct. <Ref. to IN-7, REMOVAL, Air Intake Duct.>
2) Remove the resonator chamber.
B6M1237
B6M1237
C: INSPECTION
Inspect for cracks and loose connections.
IN-8
MECHANICAL
ME
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 .............................................................................................24
Idle Speed .................................................................................................25
Ignition Timing...........................................................................................26
Intake Manifold Vacuum............................................................................27
Engine Oil Pressure ..................................................................................28
Fuel Pressure............................................................................................29
Valve Clearance........................................................................................30
Engine Assembly ......................................................................................34
Engine Mounting .......................................................................................42
Preparation for Overhaul...........................................................................43
V-belt.........................................................................................................44
Crankshaft Pulley ......................................................................................46
Belt Cover .................................................................................................48
Timing Belt Assembly................................................................................49
Camshaft Sprocket....................................................................................54
Crankshaft Sprocket..................................................................................56
Valve Rocker Assembly ............................................................................57
Camshaft...................................................................................................59
Cylinder Head Assembly...........................................................................63
Cylinder Block ...........................................................................................71
Engine Trouble in General ........................................................................95
Engine Noise...........................................................................................101
GENERAL DESCRIPTION
MECHANICAL
A: SPECIFICATIONS
Model
Type
Valve arrangement
Engine
Bore x Stroke
mm (in)
Displacement
cm3 (cu in)
1600 cc
2000 cc
2500 cc
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline
engine
Belt driven, single over-head camshaft, 4-valve/cylinder
87.9 x 65.8
99.5 x 79.0
92 x 75 (3.62 x 2.95)
(3.46 x 2.591)
(3.917 x 3.110)
Compression ratio
Compression pressure (at 200 300
kPa (kg/cm2, psi)
rpm)
Number of piston rings
Opening
Intake valve timing
Closing
Opening
Exhaust valve timing
Closing
Intake
mm (in)
Valve clearance
Exhaust
mm (in)
Idling speed [At neutral position
on MT, or P or N position on
rpm
AT]
Firing order
Ignition timing
BTDC/rpm
NOTE:
STD: Standard
Belt
tensioner
adjuster
I.D.: Inner Diameter
1,597 (97.45)
1,020 1,275 (10.4 13.0, 148 185)
Valve
rocker arm
Clearance between shaft and arm
1 BTDC
51 ABDC
50 BBDC
6 ATDC
700100 (No load)

850100 (A/C switch ON)
510/700
Protrusion of adjuster rod
Side clearance of spacer
Pressure ring: 2, Oil ring: 1

4 BTDC
48 ABDC
48 BBDC
4 ATDC
0.200.02 (0.00790.0008)
0.250.02 (0.00980.0008)
10 BTDC
46 ABDC
42 BBDC
10 ATDC
O.D.: Outer Diameter
Clearance between spacer and bush
2,457 (150)
10.0
1324
1010/700
US: Undersize
OS: Oversize
5.2 6.2 mm (0.205 0.244 in)
Spacer O.D.
Tensioner bush I.D.
Belt
tensioner
1,994 (121.67)
STD
Limit
STD
Limit
STD
Limit
ME-2
17.955 17.975 mm (0.7069 0.7077 in)

18.00 18.08 mm (0.7087 0.7118 in)
0.025 0.125 mm (0.0010 0.0049 in)
0.175 mm (0.0069 in)
0.20 0.55 mm (0.0079 0.0217 in)
0.81 mm (0.0319 in)
0.020 0.054 mm (0.0008 0.0021 in)
0.10 mm (0.0039 in)
GENERAL DESCRIPTION
MECHANICAL
Bend limit
Thrust clearance
Intake
1600 cc
Exhaust
Intake
Camshaft
Cam lobe height
2000 cc
Exhaust
Intake
2500 cc
Exhaust
STD
Limit
STD
Limit
STD
Limit
STD
Limit
STD
Limit
STD
Limit
STD
Limit
Camshaft journal O.D.

Camshaft journal hole I.D.
STD
Limit
Oil clearance
Cylinder
head
Valve seat
Surface warpage limit

Surface grinding limit
Standard height
Refacing angle
Intake
Contacting width
Exhaust
STD
Limit
STD
Limit
Inner diameter
Valve guide
Protrusion above head

Intake
Head edge thickness
Exhaust
Valve
Stem diameter
Stem oil clearance
STD
Limit
Overall length
Intake
Exhaust
STD
Limit
STD
Limit
Intake
Exhaust
Intake
Exhaust
Intake
Exhaust
Free length
Squareness
Valve
spring
Tension/spring height
ME-3
0.025 mm (0.0010 in)

0.030 0.090 mm (0.0012 0.0035 in)
0.10 mm (0.0039 in)
39.378 39.478 mm (1.5503 1.5542 in)
39.278 mm (1.5464 in)
39.565 39.665 mm (1.5577 1.5616 in)
39.465 mm (1.5537 in)
38.732 38.832 mm (1.5249 1.5288 in)
38.632 mm (1.5209 in)
39.257 39.357 mm (1.5455 1.5495 in)
39.157 mm (1.5416 in)
39.485 39.585 mm (1.5545 1.5585 in)
39.385 mm (1.5506 in)
39.257 39.357 mm (1.5455 1.5495 in)
39.157 mm (1.5416 in)
31.928 31.945 mm (1.2570 1.2577 in)
32.000 32.018 mm (1.2598 1.2605 in)
0.055 0.090 mm (0.0022 0.0035 in)
0.10 mm (0.0039 in)
0.05 mm (0.0020 in)
0.1 mm (0.004 in)
97.5 mm (3.84 in)
90
1.0 mm (0.039 in)
1.7 mm (0.067 in)
1.4 mm (0.055 in)
2.1 mm (0.083 in)
6.000 6.012 mm (0.2362 0.2367 in)
20.0 20.5 mm (0.787 0.807 in)
16.5 17.0 mm (0.650 0.669 in)
1.0 mm (0.039 in)
0.6 mm (0.024 in)
1.2 mm (0.047 in)
0.6 mm (0.024 in)
5.950 5.965 mm (0.2343 0.2348 in)
5.945 5.960 mm(0.2341 0.2346 in)
0.035 0.062 mm (0.0014 0.0024 in)
0.040 0.067 mm (0.0016 0.0026 in)
0.15 mm (0.0059 in)
120.6 mm (4.75 in)
121.7 mm (4.79 in)
54.30 mm (2.1378 in)
2.5, 2.4 mm (0.094 in)
214 246 N (21.8 25.1 kgf, 48.1 55.3 lb)/
45.0 mm (1.772 in)
526 582 N (53.6 59.3 kgf, 118.3 130.8 lb)/
34.7 mm (1.366 in)
GENERAL DESCRIPTION
MECHANICAL
Cylinder
block
Piston
Piston pin
Surface warpage limit (mating with cylinder head)

A
1600 cc
STD
B
A
Cylinder bore
2000 cc
STD
B
A
2500 cc
STD
B
STD
Taper
Limit
STD
Out-of-roundness
Limit
STD
Piston clearance
Limit
Enlarging (boring) limit
A
STD
B
0.25
mm
(0.0098
in)
1600 cc
OS
0.50 mm (0.0197 in)
OS
A
STD
B
0.25
mm
(0.0098
in)
Outer diameter
2000 cc
OS
0.50 mm (0.0197 in)
OS
A
STD
B
0.25 mm (0.0098 in)
2500 cc
OS
0.50 mm (0.0197 in)
OS
Standard inner diameter of piston pin hole
Outer diameter
Standard clearance between piston pin and hole in piston
88.125 88.135 mm (3.4695 3.4699 in)

88.375 88.385 mm (3.4793 3.4797 in)
91.985 91.995 mm (3.6214 3.6218 in)
91.975 91.985 mm (3.6211 3.6214 in)
92.225 92.235 mm (3.6309 3.6313 in)
92.475 92.485 mm (3.6407 3.6411 in)
99.485 99.495 mm (3.9167 3.9171 in)
99.475 99.485 mm (3.9163 3.9167 in)
99.725 99.735 mm (3.9262 3.9266 in)
99.975 99.985 mm (3.9360 3.9364 in)
23.000 23.006 mm (0.9055 0.9057 in)
22.994 23.000 mm (0.9053 0.9055 in)
0.004 0.008 mm (0.0002 0.0003 in)
STD
Limit
STD
Limit
STD
Limit
STD
Limit
STD
Limit
Piston pin must be fitted into position with thumb at 20C

(68F).
0.20 0.35 mm (0.0079 0.0138 in)
1.0 mm (0.039 in)
0.35 0.50 mm (0.0138 0.0197 in)
1.0 mm (0.039 in)
0.20 0.50 mm (0.0079 0.0197 in)
1.5 mm (0.059 in)
0.055 0.090 mm (0.0022 0.0035 in)
0.15 mm (0.0059 in)
0.030 0.070 mm (0.0012 0.0028 in)
0.15 mm (0.0059 in)
Bend twist per 100 mm (3.94

in) in length
Limit
0.10 mm (0.0039 in)
Side clearance
STD
Limit
0.070 0.330 mm (0.0028 0.0130 in)

0.4 mm (0.016 in)
Degree of fit
Top ring
Piston ring gap
Piston ring
Second
ring
Oil ring
Clearance
between piston
ring and piston
ring groove
Connecting
rod
0.05 mm (0.0020 in)

0.1 mm (0.004 in)
87.905 87.915 mm (3.4608 3.4612 in)
87.895 87.905 mm (3.4604 3.4608 in)
92.005 92.015 mm (3.6222 3.6226 in)
91.995 92.005 mm (3.6218 3.6222 in)
99.505 99.515 mm (3.9175 3.9179 in)
99.495 99.505 mm (3.9171 3.9175 in)
0.015 mm (0.0006 in)
0.050 mm (0.0020 in)
0.010 mm (0.0004 in)
0.050 mm (0.0020 in)
0.010 0.030 mm (0.0004 0.0012 in)
0.050 mm (0.0020 in)
0.5 mm (0.020 in)
87.885 87.895 mm (3.4600 3.4604 in)
87.875 87.885 mm (3.4596 3.4600 in)
Top ring
Second
ring
ME-4
GENERAL DESCRIPTION
MECHANICAL
Oil clearance
1600 cc
2000 cc
2500 cc
1600 cc
2000 cc
Connecting
rod bearing
Thickness at
center portion
2500 cc
Connecting
rod bushing
Clearance between piston pin

and bushing
STD
Limit
STD
Limit
STD
0.03 mm (0.0012 in)
US
0.05 mm (0.0020 in)
US
0.25 mm (0.0098 in)
US
STD
0.03 mm (0.0012 in)
US
0.05 mm (0.0020 in)
US
0.25 mm (0.0098 in)
US
STD
Limit
Bend limit
Crank pin and
crank journal
Crank pin outer

diameter
Crankshaft
Crank journal
outer diameter
Thrust clearance
Oil clearance
Out-of-roundness
Grinding limit
STD
0.03 mm (0.0012 in)
US
1600 cc
0.05 mm (0.0020 in)
US
0.25 mm (0.0098 in)
US
STD
0.03 mm (0.0012 in)
US
2000 cc
0.05 mm (0.0020 in)
2500 cc
US
0.25 mm (0.0098 in)
US
STD
0.03 mm (0.0012 in)
US
#1, #3
0.05 mm (0.0020 in)
US
0.25 mm (0.0098 in)
US
STD
0.03 mm (0.0012 in)
US
#2, #4, #5 0.05 mm (0.0020 in)
US
0.25 mm (0.0098 in)
US
STD
Limit
STD
Limit
ME-5
0.010 0.038 mm (0.0004 0.0015 in)

0.05 mm (0.0020 in)
0.012 0.037 mm (0.0005 0.0015 in)
0.05 mm (0.0020 in)
1.492 1.501 mm (0.0587 0.0591 in)
1.510 1.513 mm (0.0594 0.0596 in)
1.520 1.523 mm (0.0598 0.0600 in)
1.620 1.623 mm (0.0638 0.0639 in)
1.490 1.502 mm (0.0587 0.0591 in)
1.504 1.512 mm (0.0592 0.0595 in)
1.514 1.522 mm (0.0596 0.0599 in)
1.614 1.622 mm (0.0635 0.0639 in)
0 0.022 mm (0 0.0009 in)
0.030 mm (0.0012 in)
0.035 mm (0.0014 in)
0.020 mm (0.0008 in) or less
0.250 mm (0.0098 in)
47.984 48.000 mm (1.8880 1.8898 in)
47.954 47.970 mm (1.8879 1.8886 in)
47.934 47.950 mm (1.8872 1.8878 in)
47.734 47.750 mm (1.8793 1.8799 in)
51.984 52.000 mm (2.0466 2.0472 in)
51.954 51.970 mm (2.0454 2.0461 in)
51.934 51.950 mm (2.0446 2.0453 in)
51.734 51.750 mm (2.0368 2.0374 in)
59.992 60.008 mm (2.3619 2.3625 in)
59.962 59.978 mm (2.3607 2.3613 in)
59.942 59.958 mm (2.3599 2.3605 in)
59.742 59.758 mm (2.3520 2.3527 in)
59.992 60.008 mm (2.3619 2.3625 in)
59.962 59.978 mm (2.3607 2.3613 in)
59.942 59.958 mm (2.3599 2.3605 in)
59.742 59.758 mm (2.3520 2.3527 in)
0.030 0.115 mm (0.0012 0.0045 in)
0.25 mm (0.0098 in)
0.010 0.030 mm (0.0004 0.0012 in)
0.040 mm (0.0016 in)
GENERAL DESCRIPTION
MECHANICAL
#1, #3
Crankshaft
bearing
Crankshaft bearing thickness
#2, #4, #5
STD
0.03 mm (0.0012 in)
US
0.05 mm (0.0020 in)
US
0.25 mm (0.0098 in)
US
STD
0.03 mm (0.0012 in)
US
0.05 mm (0.0020 in)
US
0.25 mm (0.0098 in)
US
ME-6
1.998 2.011 mm (0.0787 0.0792 in)

2.017 2.020 mm (0.0794 0.0795 in)
2.027 2.030 mm (0.0798 0.0799 in)
2.127 2.130 mm (0.0837 0.0839 in)
2.000 2.013 mm (0.0787 0.0793 in)
2.019 2.022 mm (0.0795 0.0796 in)
2.029 2.032 mm (0.0799 0.0800 in)
2.129 2.132 mm (0.0838 0.0839 in)
GENERAL DESCRIPTION
MECHANICAL
B: COMPONENT
1. TIMING BELT
B2M3122A
(1)
(2)
Belt cover No. 2 (RH)

Timing belt guide (MT vehicles
only)
(3)
(4)
(5)
(6)
(7)
(8)
Crankshaft sprocket
Belt cover No. 2 (LH)
Camshaft sprocket No. 1
Belt idler (No. 1)
Tensioner bracket
Belt idler (No. 2)
(9)
Automatic belt tension adjuster

ASSY
(10)
(11)
(12)
(13)
(14)
(15)
Belt idler No. 2

Camshaft sprocket No. 2
Timing belt
Front belt cover
Belt cover (LH)
Crankshaft pulley (1600 cc and
2000 cc model)
(16)
Crankshaft pulley (2500 cc model)
ME-7

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-46, Installation,
Crankshaft Pulley.>
Crankshaft Pulley.>
GENERAL DESCRIPTION
MECHANICAL
2. CYLINDER HEAD AND CAMSHAFT
B2M1954D
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Rocker cover (RH)

Intake valve rocker ASSY
Exhaust valve rocker ASSY
Camshaft cap (RH)
Oil seal
Camshaft (RH)
Plug
Spark plug pipe gasket
Cylinder head (RH)
Cylinder head gasket
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
Cylinder head (LH)

Camshaft (LH)
Camshaft cap (LH)
Oil filler cap
Gasket
Oil filler pipe
O-ring
Rocker cover (LH)
Stud bolt
ME-8

Cylinder Head Assembly.>
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
B2M1956A
(1)
(2)
(3)
(4)
(5)
Intake valve rocker arm

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

Exhaust rocker shaft
Exhaust valve rocker arm
ME-9

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
B2M1955D
(1)
(2)
(3)
(4)
Exhaust valve
Intake valve
Valve guide
Valve spring seat
(5)
(6)
(7)
(8)
Intake valve oil seal

Valve spring
Retainer
Retainer key
ME-10
(9)
Exhaust valve oil seal
GENERAL DESCRIPTION
MECHANICAL
5. CYLINDER BLOCK
EN1498
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Oil pressure switch

Cylinder block (RH)
Service hole plug
Gasket
Oil separator cover
Water by-pass pipe
Oil pump
Front oil seal
Rear oil seal
O-ring
Service hole cover
Cylinder block (LH)
Water pump
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
Baffle plate
Oil filter connector
Oil strainer
Gasket
Oil pan
Drain plug
Metal gasket
Oil level gauge guide
Water pump sealing
Oil filter
Gasket
Water pump hose
ME-11

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: 47 (4.8, 34.7)
T6: 69 (7.0, 50.6)
T7: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
T8:
T9:
T10:
T11:
16 (1.6, 11.6)
44 (4.5, 33)
25 (2.5, 18.1)
54 (5.5, 39.8)
GENERAL DESCRIPTION
MECHANICAL
6. CRANKSHAFT AND PISTON
B2M3429A
ME-12
GENERAL DESCRIPTION
MECHANICAL
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Flywheel (MT)
Reinforcement (AT)
Drive plate (AT)
Top ring
Second ring
Oil ring
Piston
Piston pin
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Circlip
Connecting rod bolt
Connecting rod
Connecting rod bearing
Connecting rod cap
Crankshaft
Woodruff key
Crankshaft bearing #1, #3
ME-13
(17)
(18)

Crankshaft bearing #5

T1: 44.6 (4.55, 32.9)
T2: 72 (7.3, 52.8)
GENERAL DESCRIPTION
MECHANICAL
7. ENGINE MOUNTING
T2
T2
(2)
(2)
T1
T1
(1)
(1)
T3
T3
EN1005
(1)
Front cushion rubber
(2)
Front engine mounting bracket
ME-14

T1: 35 (3.6, 25.8)
T2: 42 (4.3, 31.0)
T3: 85 (8.7, 63)
GENERAL DESCRIPTION
MECHANICAL
C: CAUTION
part in the vehicle is hot after running.
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 engine in an area where chain
hoists, lifting devices, etc. are available for ready
use.
Be sure not to damage coated surfaces of body
panels with tools or stain seats and windows with
coolant or oil. Place a cover over fenders, as required, for protection.
Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission
jacks, etc.
Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
18231AA010
(Newly adopted
tool)
DESCRIPTION
CAMSHAFT
SPROCKET
WRENCH
REMARKS
Used for removing and installing camshaft
sprocket. (LH side)
Also the CAMSHAFT SPROCKET WRENCH
(499207100) can be used.
NOTE:
For common use with turbo model, this ST is
changed and registered as a newly adoped tool.
Though the previous ST also can be used.
24082AA190
(Newly adopted
tool)
CARTRIDGE
B2M3859
B2M3876
ME-15
GENERAL DESCRIPTION
MECHANICAL
ILLUSTRATION
TOOL NUMBER
22771AA030
DESCRIPTION
SELECT MONITOR KIT
REMARKS
498267800
CYLINDER
HEAD TABLE
Used for replacing valve guides.

Used for removing and installing valve springs.
498277200
STOPPER SET
Used for installing automatic transmission assembly to engine.
498457000
ENGINE STAND
ADAPTER RH
Used with ENGINE STAND (499817000).
B2M3877
B2M3850
B2M2043
B2M3851
ME-16
GENERAL DESCRIPTION
MECHANICAL
ILLUSTRATION
TOOL NUMBER
498457100
DESCRIPTION
ENGINE STAND
ADAPTER LH
REMARKS
498497100
CRANKSHAFT
STOPPER
Used for stopping rotation of flywheel when loosening and tightening crankshaft pulley bolt, etc.
498547000
OIL FILTER
WRENCH
Used for removing and installing oil filter.
PISTON GUIDE
Used for installing piston in cylinder.
B2M3852
B2M3853
B2M3872
498747000
(1600 cc model)
398744300
(2000 cc model)
498747300
(2500 cc model)
B2M3854
ME-17
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 &
INSTALLER
Used for removing and installing connecting rod

bushing.
499057000
TORX PLUS
Used for removing flywheel (Dual mass flywheel).
B2M3855
B2M3856
B2M3857
B2M4159
ME-18
GENERAL DESCRIPTION
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499097700
DESCRIPTION
PISTON PIN
REMOVER
ASSY
REMARKS
Used for removing piston pin.
499207400
CAMSHAFT
SPROCKET
WRENCH

sprocket. (RH side)
499497000
TORX PLUS
Used for removing and installing camshaft cap.
499587100
OIL SEAL
INSTALLER
Used for installing oil pump oil seal.
B2M3858
B2M4158
B2M3873
B2M3875
ME-19
GENERAL DESCRIPTION
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499587200
DESCRIPTION
CRANKSHAFT
OIL SEAL
INSTALLER
REMARKS
Used for installing crankshaft oil seal.
Used with CRANKSHAFT OIL SEAL GUIDE
(499597100).
499587500
OIL SEAL
INSTALLER
Used for installing camshaft oil seal.
499587700
CAMSHAFT OIL
SEAL
INSTALLER
Used for installing cylinder head plug.
499597000
OIL SEAL GUIDE Used for installing camshaft oil seal.

Used with OIL SEAL INSTALLER (499587500).
B2M3861
B2M3874
B2M3860
B2M3862
ME-20
GENERAL DESCRIPTION
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499597100
DESCRIPTION
REMARKS
CRANKSHAFT
OIL SEAL GUIDE Used with CRANKSHAFT OIL SEAL
INSTALLER (499587200).
B2M3863
499718000
VALVE SPRING
REMOVER
Used for removing and installing valve spring.
499767200
VALVE GUIDE
REMOVER
Used for removing valve guides.
499767400
VALVE GUIDE
REAMER
Used for reaming valve guides.
B2M3864
B2M3867
B2M3868
ME-21
GENERAL DESCRIPTION
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499767700
(Intake side)
499767800
(Exhaust side)
DESCRIPTION
VALVE GUIDE
ADJUSTER
REMARKS
Used for installing valve guides.
499817100
ENGINE STAND
Stand used for engine disassembly and assembly.

Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).
499977100
CRANK PULLEY
WRENCH
Used for stopping rotation of crankshaft pulley

when loosening and tightening crankshaft pulley
bolts. (2500 cc model)
499977300
CRANK PULLEY
WRENCH

bolts. (1600 cc and 2000 cc model)
B2M3865
B2M3869
B2M3870
B2M4157
ME-22
GENERAL DESCRIPTION
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499987500
DESCRIPTION
CRANKSHAFT
SOCKET
REMARKS
Used for rotating crankshaft.
B2M3871
2. GENERAL PURPOSE TOOLS

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-23
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.
Fuel.> or <Ref. to FU(w/oOBD)-51, RELEASING
OF FUEL PRESSURE, OPERATION, Fuel.>
4) Remove all the spark plugs. <Ref. to IG-5, REMOVAL, Spark Plug.> or <Ref. to IG(w/oOBD)-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 spark
plug hole.
CAUTION:
When using a screw-in type compression
gauge, the screw (put into cylinder head spark
plug hole) should be less than 18 mm (0.71 in)
long.
8) Crank the engine by means of starter motor, and
then read the maximum value on the gauge when
the pointer is steady.
B2M3133
9) Perform at least two measurements per cylinder,

and make sure that the values are correct.
Compression (350 rpm and fully open throttle):
Standard;
1,275 kPa (13.0 kgf/cm2, 185 psi)
Limit;
1,020 kPa (10.4 kgf/cm2, 148 psi)
Difference between cylinders;
49 kPa (0.5 kgf/cm2, 7 psi), or less
ME-24
IDLE SPEED
MECHANICAL
3. Idle Speed
A: INSPECTION
1) Before checking 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 the hoses are connected properly.
(2) Ensure the malfunction indicator light
(CHECK ENGINE light) does not illuminate.
2) Warm-up the engine.
3) Stop the engine, and then turn the igintion switch
to OFF.
4) When using the SUBARU SELECT MONITOR
<Ref. to ME-15, SPECIAL TOOLS, PREPARATION TOOL, General Description.>
(1) Insert the cartridge to SUBARU SELECT
MONITOR.
(2) Connect the SUBARU SELECT MONITOR
to data link connector.
B2M3148
(3) Turn the igintion switch to ON, and SUBARU SELECT MONITOR switch to ON.
(4) Select the {2. Each System Check} in Main
Menu.
(5) Select the {Engine Control System} in Selection Menu.
(6) Select the {1. Current Data Display & Save}
in Engine Control System Diagnosis.
(7) Select the {1.12 Data Display} in Data Display Menu.
(8) Start the engine, and then read the 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.
(2) Start the engine, and then read the engine
idle speed.
B2M3131
NOTE:
When using the OBD-II general scan tool, carefully read its operation manual.
This ignition system provides simultaneous ignition for #1 and #2 plugs. It must be noted that some
tachometers may register twice that of actual engine speed.
6) Check 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 (MT), or
N or P (AT) position):
700100 rpm
7) Check the idle speed when loaded. (Turn the air
conditioning switch to ON and operate the compressor for at least 1 minute before measurement.)
Idle speed [A/C ON, no load and gears in neutral (MT) or N or P (AT) position]:
850100 rpm
CAUTION:
Never rotate the idle adjusting screw. If the idle
speed is out of specifications, refer to General
On-board Diagnosis Table under Engine Control System. <Ref. to EN-2, Basic Diagnostic
Procedure.> or <Ref. to EN(w/oOBD)-2, Basic
Diagnostic Procedure.>
ME-25
IGNITION TIMING
MECHANICAL
4. Ignition Timing
A: INSPECTION
CAUTION:
2) To check the ignition timing, connect a timing
light to #1 cylinder spark plug cord, and illuminate
the timing mark with timing light.
3) Start the engine at idle speed and check the ignition timing.
Ignition timing [BTDC/rpm]:
510/700 (1600cc MODEL)
1010/700 (2000cc and 2500 cc MODEL)
B2M3130
If the timing is not correct, check the ignition control

system.
Refer to Engine Control System. <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/
oOBD)-2, Basic Diagnostic Procedure.>
ME-26
INTAKE MANIFOLD VACUUM

MECHANICAL
5. Intake Manifold Vacuum

A: INSPECTION
2) Disconnect the brake vacuum hose, and then install the vacuum gauge to hose fitting on manifold.
3) Keep the engine at idle speed, and then read the
vacuum gauge indication.
By observing the gauge needle movement, the internal condition of engine can be diagnosed as described below.
B2M3134
Vacuum pressure (at idling, A/C OFF):

Less than 60.0 kPa (450 mmHg, 17.72 inHg)
Diagnosis of engine condition by measurement of manifold vacuum
Vacuum gauge indication
Possible engine condition
1. Needle is steady but lower than normal position. This tenLeakage around intake manifold gasket or disconnection or
dency becomes more evident as engine temperature rises.
damaged vacuum hose
2. When engine speed is reduced slowly from higher speed,
Back pressure too high, or exhaust system clogged
needle stops temporarily when it is lowering or becomes steady
above normal position.
3. Needle intermittently drops to position lower than normal
Leakage around cylinder
position.
4. Needle drops suddenly and intermittently from normal posiSticky valves
tion.
5. When engine speed is gradually increased, needle begins to Weak or broken valve springs
vibrate rapidly at certain speed, and then vibration increases as
engine speed increases.
6. Needle vibrates above and below normal position in narrow
Defective ignition system or throttle chamber idle adjustment
range.
ME-27
ENGINE OIL PRESSURE

MECHANICAL
6. Engine Oil Pressure
7) Start the engine, and then measure the oil pressure.
A: INSPECTION
S2M0242
G6M0095
2) Remove the generator from bracket. <Ref. to

SC-14, REMOVAL, Generator.>
switch.
4) Remove the oil pressure switch from engine cylinder block. <Ref. to LU-21, REMOVAL, Oil Pressure Switch.>
5) Connect the oil pressure gauge hose to cylinder
block.
Oil pressure:
98 kPa (1.0 kg/cm2, 14 psi) or more at 800 rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000
rpm
CAUTION:
If the oil pressure is out of specification,
check the oil pump, oil filter and lubrication
line. <Ref. to LU-25, INSPECTION, Engine Lubrication System Trouble in General.>
If the oil pressure warning light is turned ON
and oil pressure is in specification, replace the
oil pressure switch. <Ref. to LU-25, INSPECTION, Engine Lubrication System Trouble in
General.>
NOTE:
The specified data is based on an engine oil temperature of 80C (176F).
8) After measuring the oil pressure, install the oil
pressure switch. <Ref. to LU-21, INSTALLATION,
Oil Pressure Switch.>
G6M0095
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
9) Install the generator and V-belt in the reverse order of removal, and then adjust the V-belt deflection. <Ref. to ME-44, INSTALLATION, V-belt.>
ME-28
FUEL PRESSURE
MECHANICAL
7. Fuel Pressure
A: INSPECTION
6) Measure the fuel pressure while disconnecting

the pressure regulator vacuum hose from intake
manifold.
WARNING:
Before removing the fuel pressure gauge, release the fuel pressure.
Fuel pressure:
Standard; 284 314 kPa (2.9 3.2 kg/cm2,
41 46 psi)
NOTE:
If out of specification, check or replace the pressure
regulator and pressure regulator vacuum hose.
2) Open the fuel flap lid, and then remove the fuel
filler cap.
S2M0554
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)
H2M2535
3) Disconnect the fuel delivery hoses from fuel

damper, and then connect the fuel pressure gauge.
S2M0554
NOTE:
The fuel pressure gauge registers 10 to 20 kPa (0.1
to 0.2 kg/cm2, 1 to 3 psi) higher than standard values during high-altitude operations.
S2M0195
4) Connect the connector of fuel pump relay.
EN0344
5) Start the engine.
ME-29
VALVE CLEARANCE
MECHANICAL
8. Valve Clearance
A: INSPECTION
CAUTION:
Inspection and adjustment of the valve clearance should be performed while engine is cold.
8) When inspecting the #2 and #4 cylinders;

(1) Disconnect the spark plug cords from spark
plugs (LH Side) <Ref. to IG-5, LH SIDE, REMOVAL, Spark Plug.> or <Ref. to IG(w/oOBD)5, LH SIDE, REMOVAL, Spark Plug.>.
(2) Disconnect the PCV hose from rocker cover
(LH).
(3) Remove the bolts, and then remove the
rocker cover (LH).
9) Set the #1 cylinder piston to top dead center of
compression stroke by rotating crankshaft pulley
clockwise using ST.
ST 499977300
CRANK PULLEY WRENCH
(1600 cc and 2000 cc model)
ST 499977100
CRANK PULLEY WRENCH
(2500 cc model)
NOTE:
When arrow mark (A) on the camshaft sprocket
(LH) comes exactly to the top, #1 cylinder piston is
brought to the top dead center of compression
stroke.
G6M0095
B2M2027B
B2M2031
7) When inspecting the #1 and #3 cylinders;

plugs RH side. <Ref. to IG-5, RH SIDE, REMOVAL, Spark Plug.> or <Ref. to IG(w/oOBD)5, RH SIDE, REMOVAL, Spark Plug.>
(RH).
rocker cover (RH).
ME-30
VALVE CLEARANCE
MECHANICAL
10) Measure the #1 cylinder valve clearance by using thickness gauge.
13) After inspection, install the related parts in the

reverse order of removal.
CAUTION:
Insert the thickness gauge (A) in as horizontal a direction as possible with respect to the
valve stem end face.
Measure the exhaust valve clearances while
lifting-up the vehicle.
Tightening torque:
Resonator chamber;
33 Nm (3.4 kgf-m, 24 ft-lb)
Valve clearance:
Intake;
0.200.02 mm (0.00790.0008 in)
Exhaust;
0.250.02 mm (0.00980.0008 in)
B6M1237
B2M2028B
11) If necessary, adjust the valve clearance. <Ref.

to ME-32, ADJUSTMENT, Valve Clearance.>
12) Similar to measurement procedures used for
#1 cylinder, measure the #2, #3 and #4 cylinder
valve clearances.
NOTE:
Be sure to set the cylinder pistons to their respective top dead centers on compression stroke
before measuring valve clearances.
To set the #3, #2 and #4 cylinder pistons to their
top dead centers on compression stroke, turn the
crankshaft pulley clockwise 90 at a time starting
with arrow mark on camshaft sprocket (LH) facing
up.
B2M2029B
ME-31
VALVE CLEARANCE
MECHANICAL
B: ADJUSTMENT
CAUTION:
Adjustment of the valve clearance should be
performed while engine is cold.
1) Set the #1 cylinder piston to top dead center of
compression stroke by rotating crankshaft pulley
clockwise using ST.
ST 499977300
CRANK PULLEY WRENCH
ST 499977100
CRANK PULLEY WRENCH
(2500 cc model)
NOTE:
When arrow mark (A) on the camshaft sprocket
(LH) comes exactly to the top, #1 cylinder piston is
brought to the top dead center of compression
stroke.
2) Adjust the #1 cylinder valve clearance.

(1) Loosen the valve rocker nut and screw.
(2) Place suitable thickness gauge.
(3) While noting the valve clearance, tighten the
valve rocker adjust screw.
(4) When 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 horizontal a
direction as possible with respect to the valve
stem end face.
Adjust the exhaust valve clearances while
lifting up the vehicle.
Valve clearance:
Intake;
0.200.02 mm (0.00790.0008 in)
Exhaust;
0.250.02 mm (0.00980.0008 in)
B2M2027B
B2M2030
3) Ensure the valve clearances are within specifications.

4) Turn the crankshaft two complete rotations until
#1 cylinder piston is again set to the top dead center on compression stroke.
5) Ensure the valve clearances are within specifications. If necessary, readjust the valve clearances.
ME-32
VALVE CLEARANCE
MECHANICAL
6) Similar to adjustment procedures used for #1

cylinder, adjust the #2, #3 and #4 cylinder valve
clearances.
NOTE:
Be sure to set the cylinder pistons to their respective top dead centers on compression stroke
before adjusting valve clearances.
To set the #3, #2 and #4 cylinder pistons to their
top dead centers on compression stroke, turn the
crankshaft pulley clockwise 90 at a time starting
with arrow mark on camshaft sprocket (LH) facing
up.
B2M2029B
ME-33
ENGINE ASSEMBLY
MECHANICAL
9. Engine Assembly
10) Remove the air cleaner case stay.

MT MODEL
A: REMOVAL
1) Set the vehicle on lift arms.
2) Open the front hood fully, and then support with
the hood stay.
4) Remove the filler cap.
S2M0900
AT MODEL
G6M0095
6) Remove the air intake duct and air cleaner case.

8) Remove the radiator from vehicle. <Ref. to CO39, REMOVAL, Radiator.>
9) Collect the refrigerant, and then remove the
pressure hoses. (With A/C)
(1) Place and connect the attachment hose to
refrigerant recycle system.
(2) Collect the refrigerant from A/C system.
(3) Disconnect the A/C pressure hoses from
A/C compressor.
B2M4251
11) Disconnect the following connectors and cables.

(1) Front oxygen (A/F) sensor connector (With
OBD)
B2M4243
(2) Front oxygen sensor connector (Without

OBD)
B2M3385
B2M3108
ME-34
ENGINE ASSEMBLY
MECHANICAL
(6) Accelerator cable and cruise control cable
(3) Engine ground cable
S2M0731
B2M3415A
(4) Engine harness connectors
(A) Accelerator cable

(B) Cruise control cable
(7) Pressure switch
EN0360
12) Disconnect the following hoses.

(1) Brake booster vacuum hose
B2M4292
(5) Generator connector, terminal and A/C

compressor connector
B2M3419
(2) Heater inlet outlet hose
B2M3386B
(A) Generator connector and terminal

(B) A/C compressor connector
B2M3390
ME-35
ENGINE ASSEMBLY
MECHANICAL
13) Remove the power steering pump from bracket.

(1) Remove the resonator chamber.
(2) Loosen the lock bolt and slider bolt, and
then remove the front side V-belt.<Ref. to ME44, FRONT SIDE BELT, REMOVAL, V-belt.>
(3) Remove the pipe with bracket.
(6) Place the power steering pump on right side

wheel apron.
EN0208
B2M4126
14) Remove the front and center exhaust pipe.

<Ref. to EX-7, REMOVAL, Front Exhaust Pipe.> or
<Ref. to EX(w/oOBD)-9, REMOVAL, Front Exhaust
Pipe.>
15) Remove the nuts which hold lower side of
transmission to engine.
B2M2047
B2M3151
(5) Remove the power steering tank from

bracket by pulling it upward.
16) Remove the nuts which install front cushion

rubber onto front crossmember.
S2M1927
EN0361
ME-36
ENGINE ASSEMBLY
MECHANICAL
17) 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.
(4) Remove other bolts while rotating the engine using ST.
ST 499977300
CRANK PULLEY WRENCH
ST 499977100
CRANK PULLEY WRENCH
(2500 cc model)
20) Support the engine with a lifting device and

wire ropes.
B2M3391
21) Support the transmission with a garage jack.

CAUTION:
Before moving the engine away from transmission, check to be sure no work has been overlooked. Doing this is very important in order to
facilitate re-installation and because the transmission lowers under its own weight.
S2M0207
18) Remove the pitching stopper.
G2M0298A
(A) Transmission
(B) Garage jack
H3M1839
BO0002
19) Disconnect the fuel delivery hose, return hose

and evaporation hose.
CAUTION:
Disconnect the hose with its end wrapped
with cloth to prevent fuel from splashing.
Catch fuel from the hose into container.
22) Separation of the engine and transmission.

(1) Remove the starter. <Ref. to SC-5, REMOVAL, Starter.>
(2) Remove the bolts which hold upper side of
B3M2044
S2M0500
ME-37
ENGINE ASSEMBLY
MECHANICAL
23) Install the ST to torque converter clutch case.

(AT model)
ST 498277200
STOPPER SET
B: INSTALLATION
1) Install the front cushion rubbers.
Tightening torque:
34 Nm (3.5 kgf-m, 25.3 ft-lb)
2) Install the engine onto transmission.
(1) Position the engine in engine compartment
and align it with transmission.
CAUTION:
Be careful not to damage the adjacent parts or
body panels with crank pulley, oil level gauge,
etc.
H2M1961A
24) Remove the engine from vehicle.

(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
(3) Move the engine horizontally until main
shaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.
CAUTION:
body panels with crank pulley, oil level gauge,
etc.
B2M3391
(2) Apply a small amount of grease to the spline

of main shaft. (MT model)
3) Tighten the bolts which hold upper side of transmission to engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
B2M3391
25) Remove the front cushion rubbers.
B3M2044
4) Remove the lifting device and wire ropes.
B2M3391
5) Remove the garage jack.
ME-38
ENGINE ASSEMBLY
MECHANICAL
6) Install the pitching stopper.
10) Install the power steering pump on bracket.

Tightening torque:
T1: 50 Nm (5.1 kgf-m, 37 ft-lb)
T2: 58 Nm (5.9 kgf-m, 43 ft-lb)
EN0361
(2) Install the power steering pump on bracket,

and then tighten the bolts.
H3M1839A
7) Remove the ST from torque converter clutch

case. (AT model)
Tightening torque:
20.1 Nm (2.05 kgf-m, 14.8 ft-lb)
NOTE:
Be careful not to drop the ST into torque converter
clutch case when removing ST.
ST 498277200
STOPPER SET
8) Install the starter. <Ref. to SC-6, INSTALLATION, Starter.>
9) Install the torque converter clutch onto drive
plate. (AT model)
(1) Tighten the bolts which hold torque converter clutch to drive plate.
(2) Tighten other bolts while rotating the engine
by using ST.
CAUTION:
Be careful not to drop the bolts into torque converter clutch housing.
ST 499977300
CRANK PULLEY WRENCH
ST 499977100
CRANK PULLEY WRENCH
(2500 cc model)
B2M3151A
(3) Tighten the bolts which install power steering pump bracket, and then install the spark plug
cords.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
B2M4126
(4) Connect the power steering switch connector.
S2M0207
(3) Clog the plug onto service hole.
EN0360
ME-39
ENGINE ASSEMBLY
MECHANICAL
(5) Install the front side V-belt, and adjust it.

<Ref. to ME-44, FRONT SIDE BELT, INSTALLATION, V-belt.>
Tightening torque:
33 Nm (3.4 kgf-m, 24.6 ft-lb)
B6M1237
11) Tighten the nuts which hold lower side of transmission to engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
13) Install the front and center exhaust pipe.

<Ref. to EX-8, INSTALLATION, Front Exhaust
Pipe.> and <Ref. to EX(w/oOBD)-10, INSTALLATION, Front Exhaust Pipe.>
14) Connect the following hoses.
(1) Fuel delivery hose, return hose and evaporation hose
(2) Heater inlet and outlet hoses
15) Connect the following connectors.
(1) Engine ground cables
Tightening torque:
14 Nm (1.4 kgf-m, 10.1 ft-lb)
(3) Generator connector and terminal
(4) A/C compressor connectors
(5) Power steering pressure switch
16) Connect the following cables.
(1) Accelerator cable
(2) Cruise control cables (With cruise control)
CAUTION:
After connecting each cable, adjust them.
17) Install the air cleaner case stay.
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
18) Install the A/C pressure hoses.
<Ref. to AC-37, INSTALLATION, Hose and Tube.>
NOTE:
Use new O-rings.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
B3M2047
12) Tighten the nuts which install front cushion rubber onto crossmember.
Tightening torque:
85 Nm (8.7 kgf-m, 63 ft-lb)
CAUTION:
Make sure the front cushion rubber mounting
bolts (A) and locator (B) are securely installed.
B2M3385
B2M3880A
19) Install the radiator to vehicle. <Ref. to CO-42,

INSTALLATION, Radiator.>
20) Install the air intake duct and air cleaner case.
and <Ref. to IN-6, INSTALLATION, Air Cleaner
Case.>
22) Install battery in the vehicle, and then connect
the cables.
ME-40
ENGINE ASSEMBLY
MECHANICAL
23) Fill engine coolant.

<Ref. to CO-26, FILLING OF ENGINE COOLANT,
REPLACEMENT, Engine Coolant.>
24) Check the ATF level and correct if necessary.
(AT model)
<Ref. to AT-9, INSPECTION, Automatic Transmission Fluid.>
25) Charge the A/C system with refrigerant.
<Ref. to AC-22, OPERATION, Refrigerant Charging Procedure.>
26) Remove the front hood stay, and then close the
front hood.
27) Take off the vehicle from lift arms.
C: INSPECTION
1) Make sure the pipes and hoses are installed correctly.
2) Make sure the engine coolant and ATF are at
specified levels.
ME-41
ENGINE MOUNTING
MECHANICAL
10.Engine Mounting
A: REMOVAL
1) Remove the engine assembly. <Ref. to ME-34,
REMOVAL, Engine Assembly.>
2) Remove the engine mounting from engine assembly.
B: INSTALLATION
Tightening torque:
Engine mounting;
34 Nm (3.5 kgf-m, 25.3 ft-lb)
C: INSPECTION
Make sure there are no cracks or other damage.
ME-42
PREPARATION FOR OVERHAUL

MECHANICAL
11.Preparation for Overhaul

A: PROCEDURE
1) After removing the engine from body, secure it in
the ST shown below.
ST1 498457000 ENGINE STAND ADAPTER
RH
LH
ST3 499817100 ENGINE STAND
B2M2582A
2) In this section the procedures described under

each index are all connected and stated in order. It
will be the complete procedure for overhauling of
the engine itself when you go through all steps in
the process.
Therefore, in this section, to conduct the particular
procedure within the flow of a section, you need to
go back and conduct the procedure described previously in order to do that particular procedure.
ME-43
V-BELT
MECHANICAL
12.V-belt
3) Remove the A/C belt.

4) Remove the A/C belt tensioner.
A: REMOVAL
1. FRONT SIDE BELT
NOTE:
Perform the following procedures 1) to 4) with the
engine installed to body.
B2M2585
B: INSTALLATION
1. FRONT SIDE BELT
B2M3401

CAUTION:
1) Install the belt (C), and tighten the slider bolt so
as to obtain the specified belt tension <Ref. to ME45, INSPECTION, V-belt.>
2) Tighten the lock bolt (A)
Tightening torque:
Lock bolt through bolt:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
Slider bolt:
8 Nm (0.8 kgf-m, 5.5 ft-lb)
B2M4291A
2. REAR SIDE BELT

B2M4291A
B2M2584A
ME-44
V-BELT
MECHANICAL
2. REAR SIDE BELT
C: INSPECTION
1) Install the belt, and tighten the slider bolt (B) so

as to obtain the specified belt tension. <Ref. to ME45, INSPECTION, V-belt.>

found.
2) Check the drive belt tension and adjust it if necessary by changing the generator installing position
Tightening torque:
Lock nut (A);
22.6 Nm (2.3 kgf-m, 16.6 ft-lb)
Belt tension
(A)
replaced: 7 9 mm (0.276 0.354 in)
reused: 9 11 mm (0.354 0.433 in)
(B)*
replaced: 7.5 8.5 mm (0.295 0.335 in)
reused: 9.0 10.0 mm (0.354 0.394 in)
B2M2584A
B2M4123A
C/P
GEN
P/S
A/C
I/P
ME-45
Crankshaft pulley
Generator
Idler pulley
CRANKSHAFT PULLEY
MECHANICAL
13.Crankshaft Pulley
(4) Tighten the crankshaft pulley bolts.
A: REMOVAL
1) Remove the V-belt. <Ref. to ME-44, REMOVAL,
V-belt.>
2) Remove the crankshaft pulley bolt. To lock the
crankshaft, use ST.
ST 499977300
ST 499977100
(2500 cc model)
CRANKSHAFT PULLEY WRENCH
Tightening torque:
127 Nm (13.0 kgf-m, 94.0 ft-lb)
B2M2586A
3) Confirm that the tightening angle of crankshaft

pulley bolt is 45 degrees or more. If not, conduct the
following procedures.
CAUTION:
If the tightening angle of crankshaft pulley bolt
is less than 45 degrees, the bolt should be damaged. In this case, the bolt must be replaced.
(1) Replace the crankshaft pulley bolts and
clean them.
B2M2586D
2500 cc MODEL
Crankshaft pulley bolt:

12369AA011
(2) Clean the crankshaft thread using an air
gun.
(3) Tighten the bolts temporarily with tightening
torque of 44 Nm (4.5 kgf-m, 33 ft-lb).
(4) Tighten the crankshaft pulley bolts keeping
them in an angle between 45 degrees and 60
degrees.
H2M2393E
B: INSTALLATION
1) Install the crankshaft pulley.
2) Install the pulley bolt. (1600 cc and 2000 cc model)
To lock the crankshaft, use ST.
ST 499977300
CRANK PULLEY WRENCH
(1) Clean the crankshaft pulley thread using an
air gun.
(2) Apply engine oil to the crankshaft pulley bolt
seat and thread.
CAUTION:
Conduct the tightening procedures by confirming the turning angle of crankshaft pulley bolt
referring to the gauge indicated on belt cover.
4) Install the pulley bolt. (2500 cc model)
ST 499977100
CRANK PULLEY WRENCH
air gun.
seat and thread.
ME-46
CRANKSHAFT PULLEY
MECHANICAL
7) Install the A/C belt.

Tightening torque:
177 Nm (18.0 kgf-m, 130.2 ft-lb)
B2M2584
C: INSPECTION
H2M2393A

following procedures (1) through (4).
clean them.
1) Make sure the V-belt is not worn or otherwise

damaged.
2) Check the tension of the belt. <Ref. to ME-45,
INSPECTION, V-belt.>

12369AA011
gun.
degrees.
CAUTION:
Conduct the tightening procedures by confirming the turning angle of crankshaft pulley bolt
referring to the gauge indicated on belt cover.
6) Install the A/C belt tensioner.
B2M2585
ME-47
BELT COVER
MECHANICAL
14.Belt Cover
A: REMOVAL
V-belt.>
2) Remove the crankshaft pulley. <Ref. to ME-46,
REMOVAL, Crankshaft Pulley.>
B2M2587B
(A) Belt cover (LH)

(B) Front belt cover
B: INSTALLATION
1) Install the front belt cover.
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
2) Install the belt cover (LH).
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
B2M2587B
(A) Belt cover (LH)

(B) Front belt cover
3) Install the crankshaft pulley. <Ref. to ME-46, INSTALLATION, Crankshaft Pulley.>

4) Install the V-belt. <Ref. to ME-44, INSTALLATION, V-belt.>
C: INSPECTION
Make sure the cover is not damaged.
ME-48
TIMING BELT ASSEMBLY

MECHANICAL
15.Timing Belt Assembly

A: REMOVAL
1. TIMING BELT
V-belt.>
3) Remove the belt cover. <Ref. to ME-48, REMOVAL, Belt Cover.>
4) Remove the timing belt guide. (MT vehicle only)
EN0621
S2M0294
(2) Using white paint, put alignment and/or arrow marks on the timing belts in relation to crank
sprocket and cam sprockets.
5) If the alignment mark (a) and/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. Align the
mark (a) of sprocket to cylinder block notch (b)
and ensure the right side cam sprocket mark (c),
cam cap and cylinder head matching surface (d)
and/or left side cam sprocket mark (e) and belt
cover notch (f) are properly adjusted.
ST 499987500
CRANKSHAFT SOCKET
B2M2591
Specified data:
Z1: 46.8 tooth length
Z1
Z2
B2M2590A
B2M4789A
ME-49

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;
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.
Be sure to slowly move the adjuster rod down
applying a pressure of 294 N (30 kgf, 66 lb).
Press-in the push adjuster rod gradually taking more than 3 minutes.
Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 lb).
Press the adjuster rod as far as the end surface of cylinder. Do not press the adjuster rod
into the cylinder. Doing so may damage the cylinder.
Do not release the press pressure until stopper pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to the vertical pressing tool.
(2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kgf, 66 lb) until the adjuster rod is aligned with the stopper pin hole in the
cylinder.
S2M1008
B2M2594
2. BELT IDLER AND AUTOMATIC BELT

TENSION ADJUSTER ASSEMBLY
B2M2596
H2M2382
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2

mm (0.08 in) (nominal) dia. hex bar wrench inserted into the stopper pin hole in the cylinder,
secure the adjuster rod.
H2M2375
H2M2383A
ME-50

MECHANICAL
2) Install the automatic belt tension adjuster assembly.

Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
H2M2384
3) Install the belt idler (No. 1).

Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
2. TIMING BELT
1) Preparation for the installation of automatic belt
tension adjuster assembly. <Ref. to ME-50, AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY
AND BELT IDLER, INSTALLATION, Timing Belt
Assembly.>
2) Installation of timing belt
(1) Turn the camshaft sprocket No. 2 using
ST1, and then turn the camshaft sprocket No. 1
using ST2 so that their alignment marks (A)
come to top positions.
ST1 18231AA010 CAMSHAFT SPROCKET
WRENCH
NOTE:
(499207100) can be used.
ST2 499207400 CAMSHAFT SPROCKET
WRENCH
B2M2602B
B2M2596
(2) While aligning alignment mark on the timing

belt (B) with marks on sprockets (A), position the
timing belt properly.
CAUTION:
Ensure belt's rotating direction is correct.
S2M2312A
3) Install the belt idler No. 2.

Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
ME-51

MECHANICAL
4) Install the belt idler (No. 2).
(2) Check and adjust the clearance between

timing belt and timing belt guide by using thickness gauge.
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
Clearance:
1.00.5 mm (0.0390.020 in)
S2M1008
5) After ensuring that the marks on timing belt and

camshaft sprockets are aligned, remove the stopper pin from belt tension adjuster.
S2M0297
(3) Tighten the remaining bolts.

Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
H2M2387
6) Install the timing belt guide. (MT vehicles only)

(1) Temporarily tighten the remaining bolts.
H2M2415
7) Install the belt cover. <Ref. to ME-48, INSTALLATION, Belt Cover.>

8) Install the crankshaft pulley. <Ref. to ME-46,
S2M0294
ME-52

MECHANICAL
C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks,
and wear. If any fault is found, replace belt.
2) Check the condition of back side of belt; if any
crack is found, replace 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 belt sharply.
Bending radius: h
CAUTION:
N (1,000 kgf, 2,205 lb).
Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster
rod into the cylinder. Doing so may damage the
cylinder.
4) Measure the extension of rod beyond the body.
If it is not within specifications, replace with a new
one.
Rod extension: H
5.70.5 mm (0.2240.020 in)
G2M0115
2. AUTOMATIC BELT TENSION ADJUSTER

1) Visually check oil seals for leaks, and rod ends
for abnormal wear or scratches. If necessary, replace faulty parts.
CAUTION:
Slight traces of oil at rod's oil seal does not indicate a problem.
2) Check that the adjuster rod does not move when
a pressure of 294 N (30 kgf, 66 lb) is applied to it.
This is to check adjuster rod stiffness.
3) If the adjuster rod is not stiff and moves freely
when applying 294 N (30 kgf, 66 lb), check it using
the following procedures:
(1) Slowly press the adjuster rod down to the
end surface of the cylinder. Repeat this motion 2
or 3 times.
(2) With the adjuster rod moved all the way up,
apply a pressure of 294 N (30 kgf, 66 lb) to it.
Check adjuster rod stiffness.
(3) If the adjuster rod is not stiff and moves
down, replace the automatic belt tension adjuster assembly with a new one.
H2M2381A
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 tension pulley for smooth rotation.
Replace if noise or excessive play is noted.
3) Check the tension pulley for grease leakage.
4. BELT IDLER
1) Check the belt idler for smooth rotation. Replace
if noise or excessive play is noted.
2) Check the belt outer contacting surfaces of idler
pulley for abnormal wear and scratches.
3) Check the belt idler for grease leakage.
ME-53
CAMSHAFT SPROCKET
MECHANICAL
16.Camshaft Sprocket
B: INSTALLATION
A: REMOVAL
1) Install the camshaft sprocket No. 1. To lock the

camshaft, use ST.
ST 499207400
CAMSHAFT SPROCKET
WRENCH
1. REMOVAL
V-belt.>
4) Remove the timing belt assembly. <Ref. to ME49, REMOVAL, Timing Belt Assembly.>
5) Remove the camshaft position sensor. <Ref. to
FU-33, REMOVAL, Camshaft Position Sensor.> or
<Ref. to FU(w/oOBD)-32, REMOVAL, Camshaft
Position Sensor.>
6) Remove the camshaft sprocket No. 2. To lock
the camshaft, use ST.
ST 18231AA010 CAMSHAFT SPROCKET
WRENCH
Tightening torque:
78 Nm (8.0 kgf-m, 57.9 ft-lb)
CAUTION:
Do not confuse the right and left side camshaft
sprockets during installation. The camshaft
sprocket No. 2 is identified by a projection used
to monitor camshaft position sensor.
NOTE:
(499207100) can be used.
B2M2599A
2) Install the camshaft sprocket No. 2. To lock camshaft, use ST.

WRENCH
NOTE:
(499207100) can be used.
Tightening torque:
78 Nm (8.0 kgf-m, 57.9 ft-lb)
H2M2377A
7) Remove the camshaft sprocket No. 1. To lock

the camshaft, use ST.
ST 499207400
CAMSHAFT SPROCKET
WRENCH
H2M2377A
B2M2599A
3) Install the camshaft position sensor. <Ref. to

FU-33, INSTALLATION, Camshaft Position Sensor.> or <Ref. to FU(w/oOBD)-32, INSTALLATION,
Camshaft Position Sensor.>
4) Install the timing belt assembly. <Ref. to ME-50,
INSTALLATION, Timing Belt Assembly.>
ME-54
CAMSHAFT SPROCKET
MECHANICAL
C: INSPECTION
1) Check the sprocket teeth for abnormal wear and
scratches.
2) Make sure there is no free play between sprocket and key.
3) Check the camshaft sprocket notch for sensor
for damage and contamination of foreign matter.
ME-55
CRANKSHAFT SPROCKET
MECHANICAL
17.Crankshaft Sprocket
B: INSTALLATION
A: REMOVAL
1) Install the crankshaft sprocket.

V-belt.>
5) Remove the camshaft sprocket. <Ref. to ME-54,
REMOVAL, Camshaft Sprocket.>
6) Remove the crankshaft sprocket.
S2M0414
S2M0414
2) Install the camshaft sprocket. <Ref. to ME-54,

INSTALLATION, Camshaft Sprocket.>
C: INSPECTION
scratches.
3) Check the crankshaft sprocket notch for sensor
for damage and contamination of foreign matter.
ME-56
VALVE ROCKER ASSEMBLY

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

torque.
A: REMOVAL
V-belt.>
6) Disconnect the PCV hose and remove rocker
cover.
7) Removal of valve rocker assembly
(1) Remove the bolts (a) through (h) in alphabetical sequence.
CAUTION:
Leave two or three threads of bolts (g and h) engaged to retain the valve rocker assembly.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
B2M2605A
2) Adjust the valve clearances. <Ref. to ME-32,

ADJUSTMENT, Valve Clearance.>
3) Install the rocker cover and connect PCV hose.
C: DISASSEMBLY
1) Remove the bolts which secure rocker shaft.
2) Extract the rocker shaft. Remove the valve rocker arms, springs and shaft supports from rocker
shaft.
B2M2605F
(2) Remove the valve rocker assembly.
CAUTION:
Arrange all removed parts in order so that they
can be installed in their original positions.
3) Remove the nut and adjuster screw from valve
rocker.
D: ASSEMBLY
1) Install the adjuster screw and nut to valve rocker.
2) Arrange the valve rocker arms, springs and shaft
supports in assembly order and insert valve rocker
shaft.
B2M2606
B: INSTALLATION
1) Installation of valve rocker assembly
(1) Temporarily tighten the bolts (a) through (d)
equally as shown in the figure.
Tightening torque (Shaft supports installing

bolts):
5 Nm (0.5 kgf-m, 3.6 ft-lb)
CAUTION:
Do not allow the valve rocker assembly to
gouge knock pins.
(2) Tighten the bolts (e) through (h) to specified
torque.
CAUTION:
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-57
VALVE ROCKER ASSEMBLY

MECHANICAL
E: INSPECTION
4) If oil clearance exceeds the limit, replace the

rocker shaft support or shaft, whichever shows
greater amount of wear.
1. VALVE ROCKER ARM

1) Measure the inside diameter of valve rocker arm
and outside diameter of valve rocker shaft, and determine the difference between the two (= oil clearance).
Clearance between arm and shaft:
Standard
0.020 0.054 mm (0.0008 0.0021 in)
Limit
0.10 mm (0.0039 in)
Rocker shaft support inside diameter:

22.005 22.026 mm (0.8663 0.8672 in)
Rocker shaft diameter:
21.987 22.000 mm (0.8656 0.8661 in)
5) If cam or valve contact surface of valve rocker
arm is worn or dented excessively, replace the
valve rocker arm.
6) Check that the valve rocker arm roller rotates
smoothly. If not, replace the valve rocker arm.
2. INTAKE AND EXHAUST VALVE ROCKER SHAFT

Visually check the oil relief valve of shaft end for
any of the following abnormalities.
Breaks in check ball body
Foreign particles caught in valve spring
Oil leakage at check ball
CAUTION:
Repair or replace the valve rocker shaft as necessary.
B2M0072
B2M0073
2) If oil clearance exceeds the limit, 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) Measure the inside diameter of rocker shaft support and outside diameter of valve rocker shaft, and
determine the difference between the two (= oil
clearance).
Clearance between support and shaft:
Standard
0.005 0.039 mm (0.0002 0.0015 in)
Limit
0.05 mm (0.0020 in)
ME-58
CAMSHAFT
MECHANICAL
19.Camshaft
(1) Remove the bolts (a) through (b) in alphabetical sequence.
A: REMOVAL
1) Remove the V-belt. <Ref. to ME-44, INSTALLATION, V-belt.>
6) Remove the crankshaft sprocket. <Ref. to ME56, REMOVAL, Crankshaft Sprocket.>
7) Remove the belt cover No. 2 (LH).
8) Remove the belt cover No. 2 (RH).
B2M2612B
(2) Equally loosen the bolts (c) through (j) all the
way in alphabetical sequence.
CAUTION:
Do not damage or lose the seal rubber when removing belt covers.
B2M2612C
(3) Remove the bolts (k) through (p) in alphabetical sequence using ST.
ST 499497000
TORX PLUS
B2M2601
9) Remove the tensioner bracket.
B2M2612D
(4) Remove the camshaft cap.

H2M2380
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-57, REMOVAL, Valve Rocker Assembly.>
13) Remove the camshaft cap.
B2M2613
14) Remove the camshaft.

15) Remove the oil seal.
ME-59
CAMSHAFT
MECHANICAL
16) Remove the plug from rear side of camshaft.
(3) Install the valve rocker assembly.
CAUTION:
Do not remove the oil seal unless necessary.
Do not scratch the journal surface when removing oil seal.
B: INSTALLATION
1) Apply a coat of engine oil to the camshaft journals, and then install the camshaft.
2) Install the camshaft cap.
(1) Apply liquid gasket on the around of camshaft cap.
B2M2615
(4) Tighten the bolts (a) through (h) in alphabetical sequence.
Liquid gasket:
THREE BOND 1280B
P/N K0877YA018
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
B2M2619
NOTE:
Apply a coat of 3 mm (0.12 in) dia (A). liquid gasket
along edge (B) of the camshaft cap (C) mating surface.
B2M2621B
(5) Tighten the TORX bolts (i) through (n) in alphabetical sequence using ST.
ST 499497000
TORX PLUS
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
S2M1199B
(2) Temporarily tighten the bolts (g) through (j)

in alphabetical sequence.
B2M2612E
ME-60
B2M2621C
CAMSHAFT
MECHANICAL
(6) Tighten the bolts (o) through (v) in alphabetical sequence.

Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
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)
9) Install the tensioner bracket.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
B2M2621D
(7) Tighten the bolts (w) through (x) in alphabetical sequence.

Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
H2M2380
10) Install the belt cover No. 2 (RH).

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
11) Install the belt cover No. 2 (LH).
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
B2M2621E
3) Apply a coat of grease to oil seal lips, and then

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
B2M2601
12) Install the crankshaft sprocket. <Ref. to ME-56,

INSTALLATION, Crankshaft Sprocket.>
14) Install the timing belt assembly. <Ref. to ME50, INSTALLATION, Timing Belt Assembly.>
INSTALLATION, Crankshaft Pulley.>
S2M1864A
4) Install the plug using ST.

ST 499587700
CAMSHAFT OIL SEAL INSTALLER
5) Adjust the valve clearance. <Ref. to ME-32, ADJUSTMENT, Valve Clearance.>
ME-61
CAMSHAFT
MECHANICAL
C: INSPECTION
Model
1. CAMSHAFT
Item
Intake
1) Measure the bend, and repair or replace if necessary.
Limit
2500 cc
Exhaust
Limit:
0.025 mm (0.0010 in)
STD
STD
Limit
Unit: mm (in)
39.485 39.585
(1.5545 1.5585)
39.385 (1.5506)
39.257 39.357
(1.5455 1.5495)
39.157 (1.5416)
Cam base circle diameter A:

IN: 34.00 mm (1.3386 in)
EX: 34.00 mm (1.3386 in)
B2M2617
2) Check the journal for damage and wear. Replace if faulty.

3) Measure the outside diameter of camshaft journal and inside diameter of cylinder head journal,
and determine the difference between two (= oil
clearance). If the oil clearance exceeds specifications, replace the camshaft or cylinder head as
necessary.
Clearance at
journal
Standard
Unit: mm (in)
0.055 0.090 (0.0022 0.0035)
Limit
Journal hole I.D.
2. CAMSHAFT SUPPORT
Measure the thrust clearance of camshaft with dial
gauge. If the clearance exceeds the limit, replace
the camshaft support.
Standard:
0.030 0.090 mm (0.0012 0.0035 in)
Limit:
0.10 mm (0.0039 in)
0.10 (0.0039)
Camshaft journal O.D.
B2M1209A
31.928 31.945 (1.2570

1.2577)
32.000 32.018 (1.2598
1.2605)
4) Check the cam face condition; remove the minor

faults by grinding with oil stone. Measure the cam
height H; replace if the limit has been exceeded.
Cam height: H
Model
Item
Intake
STD
Limit
1600 cc
Exhaust
STD
Limit
Intake
STD
Limit
2000 cc
Exhaust
STD
Limit
Unit: mm (in)
39.378 39.478
(1.5503 1.5542)
39.278 (1.5464)
39.565 39.665
(1.5577 1.5616)
39.465 (1.5537)
38.732 38.832
(1.5249 1.528885)
39.632 (1.5209)
39.257 39.357
(1.5455 1.5495)
39.157 (1.5416)
ME-62
B2M2618
CYLINDER HEAD ASSEMBLY

MECHANICAL
20.Cylinder Head Assembly
13) Remove the cylinder head gasket.
A: REMOVAL
CAUTION:
Do not scratch the mating surface of cylinder
head and cylinder block.
14) Similarly, remove the right side cylinder head.

V-belt.>
6) Remove the intake manifold. <Ref. to FU-17,
REMOVAL, Intake Manifold.> or <Ref. to FU(w/
oOBD)-17, REMOVAL, Intake Manifold.>
7) Remove the bolt which installs A/C compressor
bracket on cylinder head.
8) Remove the valve rocker assembly. <Ref. to
ME-57, REMOVAL, Valve Rocker Assembly.>
9) Remove the camshaft. <Ref. to ME-59, REMOVAL, Camshaft.>
10) Remove the cylinder head bolts in alphabetical
sequence shown in the figure.
CAUTION:
Leave the bolts (a) and (c) engaged by three or
four threads to prevent cylinder head from falling.
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 the 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 first; back them off
by 180 again.
(4) Tighten the bolts (a) and (b) to 34 Nm (3.5
kgf-m, 25 ft-lb).
(5) Tighten the bolts (c), (d), (e) and (f) to 15
Nm (1.5 kgf-m, 11 ft-lb).
(6) Tighten all bolts by 80 to 90 in alphabetical
sequence.
CAUTION:
Do not tighten bolts more than 90.
(7) Further tighten all bolts by 80 to 90 in alphabetical sequence shown in figure below.
CAUTION:
Ensure that the total re-tightening angle [in
the former two steps], do not exceed 180.
S2M1589A
11) While tapping the cylinder head with a plastic

hammer, separate it from cylinder block.
12) Remove the bolts (a) and (b) to remove cylinder head.
S2M1589B
S2M1589A
3) Install the camshaft. <Ref. to ME-60, INSTALLATION, Camshaft.>

4) Install the valve rocker assembly. <Ref. to ME57, INSTALLATION, Valve Rocker Assembly.>
5) Install the A/C compressor bracket on cylinder
head.
ME-63

MECHANICAL
6) Install the intake manifold. <Ref. to FU-19, INSTALLATION, Intake Manifold.> or <Ref. to FU(w/
oOBD)-20, INSTALLATION, Intake Manifold.>
C: DISASSEMBLY
1) Place the cylinder head on ST.
ST 498267800
CYLINDER HEAD TABLE
2) Set the ST on valve spring. Compress the valve
spring, and then remove the valve spring retainer
key. Remove each valve and valve spring.
ST 499718000
VALVE SPRING REMOVER
CAUTION:
Mark each valve to prevent confusion.
Use extreme care not to damage the lips of intake valve oil seals and exhaust valve oil seals.
B2M2630A
ME-64

MECHANICAL
D: ASSEMBLY
B2M2629B
(1)
(2)
(3)
(4)
(5)
Valve
Valve guide
Valve spring seat
Oil seal
Valve spring
(6)
(7)
(8)
(9)
(10)
Retainer
Retainer key
Spark plug gasket
Camshaft
Oil seal
1) Installation of valve spring and valve

(1) Place the cylinder head on ST.
ST 498267800
CYLINDER HEAD TABLE
(2) Coat the stem of each valve with engine oil
and insert valve into valve guide.
ST
(11)
(12)
(13)
Plug
Camshaft cap
Valve rocker ASSY
(4) Set the ST on valve spring.

499718000
VALVE SPRING REMOVER
CAUTION:
When inserting the valve into valve guide, use
special care not to damage the oil seal lip.
(3) Install the valve spring and retainer.
CAUTION:
Be sure to install the valve springs with their
close-coiled end facing the seat on the cylinder
head.
ME-65
B2M2630A

MECHANICAL
(5) Compress the valve spring, and then fit the

valve spring retainer key.
2. INTAKE AND EXHAUST VALVE OIL

SEAL
Replace the oil seal with new one, if lip is damaged
or spring out of place, or when the surfaces of intake valve and valve seat are reconditioned or intake valve guide is replaced. Use pliers to pinch
and remove oil seal from valve.
1) Place the cylinder head on ST1.
2) Press-fit oil seal to the specified dimension indicated in the figure using ST2.
B2M2634B
(A) Retainer
(B) Painted face
(6) After installing, tap the valve spring retainers

lightly with wooden hammer for better seating.
E: INSPECTION
1. VALVE SPRING
1) Check the valve springs for damage, free length,
and tension. Replace the valve spring if it is not to
the specifications presented below.
2) To measure the squareness of valve spring,
stand the spring on a surface plate and measure its
deflection at the top using a try square.
Free length
Squareness
Tension/spring
height
CAUTION:
Apply engine oil to oil seal before press-fitting.
When press-fitting oil seal, do not use hammer or strike in.
Differentiate between intake valve oil seal
and exhaust valve oil seal by noting their difference in color.
ST1 498267800 CYLINDER HEAD TABLE
ST2 498857100 VALVE OIL SEAL GUIDE
Color of rubber part:
Intake [Black]
Exhaust [Brown]
Color of spring part:
Intake [Silver]
Exhaust [Silver]
54.30 mm (2.1378 in)

2.5, 2.4 mm (0.094 in)
214 246 N
(21.8 25.1 kgf, 48.1 55.3 lb)/
45.0 mm (1.772 in)
526 582 N
(53.6 59.3 kgf, 118.3 130.8 lb)/
34.7 mm (1.366 in)
B2M2633A
F: ADJUSTMENT
1. CYLINDER HEAD
G2M0154
1) Make sure that no crack or other damage exists.

In addition to visual inspection, inspect important
areas by means of red lead check.
Also make sure that gasket installing surface
shows no trace of gas and water leaks.
2) Place the cylinder head on ST.
ST 498267800
CYLINDER HEAD TABLE
ME-66

MECHANICAL
3) Measure the warping of the cylinder head surface that mates with crankcase using a straight
edge and thickness gauge.
If the warping exceeds 0.05 mm (0.0020 in), regrind the surface with a surface grinder.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder head:
97.5 mm (3.839 in)
CAUTION:
Uneven torque for the cylinder head bolts can
cause warping. When reassembling, pay special attention to the torque so as to tighten
evenly.
2. VALVE SEAT
Inspect the intake and exhaust valve seats, and
then correct the contact surfaces with valve seat
cutter if they are defective or when valve guides are
replaced.
Valve seat width: W
Intake
Standard 1.0 mm (0.039 in)
Limit 1.7 mm (0.067 in)
Exhaust
Limit 2.1 mm (0.083 in)
G2M0149
S2M1817A
(A) Straight edge

(B) Thickness gauge
B2M0074
ME-67

MECHANICAL
3. VALVE GUIDE
1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring
the outside diameter of valve stem and the inside
diameter of valve guide with outside and inside micrometers respectively.
Clearance between the valve guide and valve
stem:
Standard
Intake 0.035 0.062 mm (0.0014 0.0024
in)
Exhaust 0.040 0.067 mm (0.0016 0.0026
in)
Limit
0.15 mm (0.0059 in)
(2) Insert the ST2 into valve guide and press it

down to remove valve guide.
ST2 499767200 VALVE GUIDE REMOVER
G2M0150
(3) Turn the cylinder head upside down and

place ST as shown in the figure.
Intake side:
ST 499767700
VALVE GUIDE ADJUSTER
Exhaust side:
ST 499767800
B2M0387A
B2M0077D
(A) Valve guide
(4) Before installing new oversize valve guide,

make sure that neither scratches nor damages
exist on the inside surface of valve guide holes
in cylinder head.
B2M0076B
2) If the clearance between valve guide and stem

exceeds the limit, replace the valve guide or valve
itself whichever shows greater amount of wear.
See the following procedure for valve guide 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.
ME-68

MECHANICAL
(5) Put new valve guide, coated with sufficient

oil, in the cylinder, and then insert the ST1 into
valve guide. Press in until the valve guide upper
end is flush with the upper surface of ST2.
Intake side:
ST2 499767700 VALVE GUIDE ADJUSTER
Exhaust side:
(7) Ream the inside of valve guide with ST.

Gently rotate the reamer clockwise while pressing it lightly into valve guide, and return it also rotating clockwise. After reaming, clean 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 chips,
use a new reamer or remedy the reamer.
ST 499767400
VALVE GUIDE REAMER
B2M2632A
(6) Check the valve guide protrusion.

Valve guide protrusion: L
Intake
20.0 20.5 mm (0.787 0.807 in)
Exhaust
16.5 17.0 mm (0.650 0.669 in)
B2M0078
(8) Recheck the contact condition between

valve and valve seat after replacing valve guide.
B2M0077C
(A) Valve guide
ME-69

MECHANICAL
4. INTAKE AND EXHAUST VALVE

1) Inspect the flange and stem of valve, and replace if damaged, worn, or deformed, or if H is
less than the specified limit.
H:
Intake
Limit 0.6 mm (0.024 in)
Exhaust
Limit 0.6 mm (0.024 in)
Valve overall length:
Intake
120.6 mm (4.75 in)
Exhaust
121.7 mm (4.79 in)
G2M0153
2) Put a small amount of grinding compound on the

seat surface and lap the valve and seat surface.
<Ref. to ME-67, VALVE SEAT, ADJUSTMENT,
Cylinder Head Assembly.> Install a new intake
valve oil seal after lapping.
ME-70
CYLINDER BLOCK
MECHANICAL
21.Cylinder Block
12) Remove the bolts (a) and (b) to remove cylinder head.
A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely if applicable.
1) Remove the intake manifold. <Ref. to FU-17,
REMOVAL, Intake Manifold.> or <Ref. to FU(w/
oOBD)-17, REMOVAL, Intake Manifold.>
V-belt.>
7) Remove the crankshaft sprocket. <Ref. to ME46, REMOVAL, Crankshaft Pulley.>
8) Remove the generator and A/C compressor with
their brackets.
9) Remove the rocker cover.
B2M2628A

CAUTION:
15) Remove the clutch housing cover (MT vehicles
only).
16) Remove the flywheel (MT vehicles only) or
drive plate (AT vehicles only).
Using the ST, lock the crankshaft.
ST 498497100
CRANKSHAFT STOPPER
MT MODEL
CAUTION:
Leave bolts (a) and (b) engaged by three or four
threads to prevent cylinder head from falling.
S2M1818C
AT MODEL
B2M2628A

B2M3395C
NOTE:
Use the ST to remove flywheel (MT vehicles only)
for 2500 cc model.
ME-71
CYLINDER BLOCK
MECHANICAL
ST1
ST2
498497100
499057000
CRANKSHAFT STOPPER
TORX PLUS
21) Removal of oil pan

(1) Turn the cylinder block with #2 and #4 piston
sides facing 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 then remove
the oil pan.
CAUTION:
Do not use a screwdriver or similar tool in place
of oil pan cutter.
B2M3347A
17) Remove the oil separator cover.

18) Remove the water by-pass pipe for heater.
19) Remove the water pump.
20) Remove the oil pump from cylinder block.
Use a flat-bladed screwdriver as shown in the figure when removing oil pump.
CAUTION:
Be careful not to scratch the mating surface of
cylinder block and oil pump.
S2M1820
22) Remove the oil strainer stay.

23) Remove the oil strainer.
24) Remove the baffle plate.
25) Remove the oil filter using ST.
ST 498547000
OIL FILTER WRENCH
S2M1819
B2M2611A
26) Remove the water pipe.
B2M2638
ME-72
CYLINDER BLOCK
MECHANICAL
S2M1590B
(1)
(2)
Service hole plug

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

hole plugs using hexagon wrench [14 mm (0.55
in)].
(5)
(6)
Service hole cover

O-ring
28) Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, and then remove the piston circlip through service hole of #1
and #2 cylinders.
B2M2620
G2M0165
ME-73
CYLINDER BLOCK
MECHANICAL
29) Draw out the piston pin from #1 and #2 pistons

using ST.
ST 499097700
PISTON PIN REMOVER
CAUTION:
Be careful not to confuse the original combination of piston, piston pin and cylinder.
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, and then remove the
cylinder block connecting bolts.
34) Separate the cylinder blocks (RH) and (LH).
CAUTION:
When separating the cylinder block, do not allow the connecting rod to fall and damage the
cylinder block.
G2M0166
B2M2408A
(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 hammer handle.
(5)
Piston
38) Draw out each piston from cylinder block using

wooden bar or hammer handle.
CAUTION:
Do not confuse the combination of piston and
cylinder.
CAUTION:
Do not confuse the combination of crankshaft
bearings. Press bearing at the end opposite to
locking lip.
ME-74
CYLINDER BLOCK
MECHANICAL
B: INSTALLATION
B2M2407A
(1)
(2)
(3)
Crankshaft bearing
Crankshaft
Cylinder block
(4)
Rear oil seal
CAUTION:
Remove oil in the mating surface of bearing and
cylinder block before installation. Also apply a
coat of engine oil to crankshaft pins.
1) Position the crankshaft on #2 and #4 cylinder
block.
2) Apply fluid packing to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.

T1: 25 (2.5, 18.1)
T2: 47 (4.8, 34.7)
CAUTION:
Do not allow fluid packing to jut into O-ring
grooves, oil passages, bearing grooves, etc.
Fluid packing:
THREE BOND 1215 or equivalent
S2M1826A
ME-75
CYLINDER BLOCK
MECHANICAL
3) Temporarily tighten the 10 mm cylinder block

connecting bolts in alphabetical sequence shown in
the figure.
6) Install the rear oil seal using ST1 and ST2.

B2M0088D
S2M1827A
4) Tighten the 10 mm cylinder block connecting

bolts in alphabetical sequence.
Tightening torque:
47 Nm (4.8 kgf-m, 34.7 ft-lb)
(A) Rear oil seal

(B) Fly wheel attaching bolt
7) Position the top ring gap at (A) or (B) in the figure.

8) Position the second ring gap at 180 on the reverse side for top ring gap.
1600 cc MODEL
B2M0088D
5) Tighten the 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown in the
figure.
Tightening torque:
(A) (G): 25 Nm (2.5 kgf-m, 18.1 ft-lb)
(H): 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
H2M3248
2000 cc MODEL
180
B0SH
B2M4617A
B2M0089F
ME-76
CYLINDER BLOCK
MECHANICAL
2500 cc MODEL
10) Position the lower rail gap at (D) in the figure.

1600 cc MODEL
180
(D)
B5SH
B2M4618A
9) Position the expander gap at (C) in the figure.

1600 cc MODEL
EN1379
2000 cc MODEL
25
B0SH
(C)
EN1378
2000 cc MODEL
B2M4621A
2500 cc MODEL
25
B0SH
B5SH
B2M4619A
2500 cc MODEL
B2M4622A
NOTE:
Align the lower rail stopper (F) to the lateral hole (E)
on the piston.
B5SH
B2M4620A
B2M4601A
ME-77
CYLINDER BLOCK
MECHANICAL
11) Position the upper rail gap at (G) in the figure.

1600 cc MODEL
12) Install circlip.

Install circlips in the piston holes located opposite
service holes in cylinder block, when positioning all
pistons in the corresponding cylinders.
NOTE:
Use new circlips.
(G)
EN1380
2000 cc MODEL
B2M1403A
30
CAUTION:
Piston front mark faces towards the front of the
engine.
1600 cc MODEL
B0SH
B2M4623A
2500 cc MODEL
30
EN1497
B5SH
2000 cc MODEL
B2M4624A
CAUTION:
Ensure ring gaps do not face the same direction.
Ensure ring gaps are not within the piston
skirt area.
B0SH
B2M4625A
ME-78
CYLINDER BLOCK
MECHANICAL
2500 cc MODEL
B5SH
B2M4626A
(A) Front mark
B2M1322J
(1)
(2)
(3)
Piston
Piston pin
Circlip
(4)
(5)
Gasket
Service hole plug
13) Installing piston

(1) Turn the cylinder block so that #1 and #2 cylinders face upward.
(2) Using the 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 pistons and cylinders, and then insert the pistons in their cylinders using ST2.
ST2 498747000 PISTON GUIDE (1600 cc
model)
ST2 398744300 PISTON GUIDE (2000 cc
model)
ST2
ME-79

T: 69 (7.0, 50.6)
498747300
PISTON GUIDE (2500 cc

model)
S2M0306A
CYLINDER BLOCK
MECHANICAL
14) Installing piston pin

(1) Insert the ST3 into service hole to align piston pin hole with connecting rod small end.
(5) Install the service hole plug and gasket.

NOTE:
Use a new gasket.
CAUTION:
Apply a coat of engine oil to the ST3 before insertion.
ST3 499017100 PISTON PIN GUIDE
B2M2620
G2M0189
(2) Apply a coat of engine oil to the piston pin,

and then insert the piston pin into piston and
connecting rod through service hole.
(3) Install the circlip.
NOTE:
Use new circlips.
S2M1828
(4) Apply fluid packing around the service hole

plug.
Fluid packing:
B2M2625
ME-80
CYLINDER BLOCK
MECHANICAL
B2M1323K
(1)
(2)
(3)
(4)
Piston
Piston pin
Circlip
Gasket
(5)
(6)
(7)
Service hole plug

Service hole cover
O-ring
(6) Turn the cylinder block so that #3 and #4 cylinders face upward. Using the same procedures
as used for #1 and #2 cylinders, install the pistons and piston pins.
15) Install the water pipe.

T1: 6.4 (0.65, 4.7)
T2: 69 (7.0, 50.6)
19) Apply fluid packing to the matching surfaces,

then and install the oil pan.
Fluid packing:
S2M1833A
B2M2638
16) Install the baffle plate.

Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
17) Install the oil strainer and O-ring
Tightening torque:
10 Nm (1.0 kgf-m, 7 ft-lb)
18) Install the oil strainer stay.
ME-81
CYLINDER BLOCK
MECHANICAL

and then install the oil separator cover.
ST1
ST2
498497100
499057000
CRANKSHAFT STOPPER
TORX PLUS
Fluid packing:
B2M3347A
22) Install the housing cover.

23) Installation of oil pump
(1) Discard the front oil seal after removal. Replace with a new one using the ST.
ST 499587100
OIL SEAL INSTALLER
S2M1834A
21) Install the flywheel or drive plate.

ST 498497100
CRANKSHAFT STOPPER
Tightening torque:
72 Nm (7.3 kgf-m, 52.8 ft-lb)
S2M0235
(2) Apply fluid packing to the matching surface

of oil pump.
B2M3361A
Fluid packing:
B2M3393A
NOTE:
Use the ST to remove flywheel (MT vehicles only)
for 2500 cc model.
(3) Apply a coat of engine oil to the inside of oil
seal.
ME-82
S2M0739A
(A) O-ring
CYLINDER BLOCK
MECHANICAL
26) Install the oil filter using ST.

ST 498547000
OIL FILTER WRENCH
S2M0118B
(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 the install the O-ring and seal
when installing oil pump.
Align flat surface of oil pump's inner rotor
with crankshaft before installation.
24) Install the water pump and gasket.
Tightening torque:
First; 12 Nm (1.2 kgf-m, 8.7 ft-lb)
Second; 12 Nm (1.2 kgf-m, 8.7 ft-lb)
CAUTION:
Be sure to use a new gasket.
When installing the water pump, tighten the
bolts in two stages in alphabetical sequence as
B2M2611A

bolt threads.
by 180 again.
(4) Tighten the bolts (a) and (b) to 34 Nm (3.5
kgf-m, 25 ft-lb).
(5) Tighten the bolts (c), (d), (e) and (f) to 15
sequence.
CAUTION:
Do not tighten bolts more than 90.
(7) Further tighten all bolts by 80 to 90 in alphabetical sequence.
CAUTION:
Ensure that the total re-tightening angle [in
the former two steps], do not exceed 180.
H2M1568B
25) Install the water by-pass pipe for heater.

B2M2628B
28) Install the oil level gauge guide, and then tighten the attaching bolt (left side only).
29) Install the rocker cover.
30) Install the crankshaft sprocket. <Ref. to ME-56,
INSTALLATION, Crankshaft Sprocket.>
ME-83
CYLINDER BLOCK
MECHANICAL
32) Install the timing belt assembly. <Ref. to ME50, INSTALLATION, Timing Belt Assembly.>
35) Install the generator and A/C compressor
brackets on cylinder head.
37) Install the intake manifold. <Ref. to FU-19, INSTALLATION, Intake Manifold.> or <Ref. to FU(w/
oOBD)-20, INSTALLATION, Intake Manifold.>
ME-84
CYLINDER BLOCK
MECHANICAL
C: DISASSEMBLY
B2M1320I
(1)
(2)
Connecting rod cap

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

2) Remove the connecting rod bearing.
CAUTION:
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.
CAUTION:
Arrange the removed piston rings in good order
to prevent confusion.
5) Remove the circlip.
ME-85
(5)
(6)
Oil ring
Circlip
CYLINDER BLOCK
MECHANICAL
D: ASSEMBLY
B2M1320J
(1)
(2)
(3)
(4)

Connecting rod
Connecting rod cap
Oil ring
(5)
(6)
(7)
Second ring
Top ring
Circlip
1) Install the connecting rod bearings on connecting rods and connecting rod caps.
CAUTION:
Apply oil to the surfaces of the connecting rod
bearings.
2) Install the connecting rod on crankshaft.
CAUTION:
Position each connecting rod with the side
marked facing forward.
3) Install the connecting rod cap with connecting
rod nut.
Ensure the arrow on connecting rod cap faces the
front during installation.
CAUTION:
Each connecting rod has its own mating cap.
Make sure that they are assembled correctly by
checking their matching number.
When tightening the connecting rod nuts, apply oil on the threads.
4) Install the expander, lower rail and upper rail in
this order by hand. Then install the second ring and
top ring with a piston ring expander.

T: 44.6 (4.55, 32.9)
E: INSPECTION
1. CYLINDER BLOCK
1) Visually check for cracks and damage. Especially, inspect the important parts by means of red lead
check.
2) Check the oil passages for clogging.
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:
0.05 mm (0.0020 in)
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 cylinder
block's front upper surface.
CAUTION:
Measurement should be performed at a temperature 20C (68F).
NOTE:
Standard sized pistons are classified into two
grades, A and B. These grades should be used
as a guide line in selecting a standard piston.
ME-86
CYLINDER BLOCK
MECHANICAL
Standard diameter:
1600 cc MODEL
A: 87.905 87.915 mm (3.4608 3.4612
in)
B: 87.895 87.905 mm (3.4604 3.4608
in)
2000 cc MODEL
A: 92.005 92.015 mm (3.6222 3.6226
in)
B: 91.995 92.005 mm (3.6218 3.6222
in)
2500 cc MODEL
A: 99.505 99.515 mm (3.9175 3.9179
in)
B: 99.495 99.505 mm (3.9171 3.9175
in)
2) How to measure the inner diameter of each cylinder

Measure the inner diameter of each cylinder in both
the thrust and piston pin directions at the heights
shown in the figure, using a cylinder bore gauge.
CAUTION:
Measurement should be performed at a temperature 20C (68F).
Taper:
Standard
0.015 mm (0.0006 in)
Limit
0.050 mm (0.0020 in)
Out-of-roundness:
Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)
H2M1732C
(A)
(B)
(C)
(D)
(E)
(F)
Main journal size mark

Cylinder block RH-LH combination mark
#1 cylinder bore size mark
S2M1821A
(A) Piston pin direction

(B) Thrust direction
3) When the piston is to be replaced due to general

or cylinder wear, determine a suitable sized piston
by measuring the piston clearance.
ME-87
CYLINDER BLOCK
MECHANICAL
4) How to measure the outer diameter of each piston

Measure the outer diameter of each piston at the
height shown in the figure. (Thrust direction)
CAUTION:
Measurement should be performed at a temperature of 20C (68F).
Piston grade point H:
40.0 mm (1.575 in)
2500 cc MODEL
37.0 mm (1.457 in)
Piston outer diameter:
1600 cc MODEL
Standard
A: 87.885 87.895 mm
(3.4600 3.4604 in)
B: 87.875 87.885 mm
(3.4596 3.4699 in)
0.25 mm (0.0098 in) oversize
88.125 88.135 mm
(3.4695 3.4699 in)
88.375 88.385 mm
(3.4793 3.4797 in)
2000 cc MODEL
Standard
A: 91.985 91.995 mm
(3.6214 3.6218 in)
B: 91.975 91.985 mm
(3.6211 3.6214 in)
92.225 92.235 mm
(3.6309 3.6313 in)
92.475 92.485 mm
(3.6407 3.6411 in)
2500 cc MODEL
Standard
A: 99.485 99.495 mm
(3.9167 3.9171 in)
B: 99.475 99.485 mm
(3.9163 3.9167 in)
99.725 99.735 mm
(3.9262 3.9266 in)
99.975 99.985 mm
(3.9360 3.9364 in)
B2M1305A
5) Calculate the clearance between cylinder and

piston.
CAUTION:
Cylinder to piston clearance at 20C (68F):
Standard
0.010 0.030 mm (0.0004 0.0012 in)
Limit
0.050 mm (0.0020 in)
6) Boring and honing
(1) If the value of taper, out-of-roundness, or
cylinder-to-piston clearance measured exceeds
the specified limit or if there is any damage on
the cylinder wall, rebore it to use an oversize piston.
CAUTION:
When any of the cylinders needs reboring, all
other cylinders must be bored at the same time,
and use oversize pistons. Do not perform boring on one cylinder only, nor use an oversize
piston for one cylinder only.
(2) If the cylinder inner diameter exceeds the
limit after boring and honing, replace the crankcase.
CAUTION:
Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, pay attention to this when
measuring the cylinder diameter.
Limit of cylinder enlarging (boring):
0.5 mm (0.020 in)
ME-88
CYLINDER BLOCK
MECHANICAL
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-86, CYLINDER AND
PISTON, INSPECTION, Cylinder Block.> If any of
the clearances is not to specification, replace the
piston or bore the cylinder to use an oversize piston.
3) Make the sure that piston pin can be inserted
into piston pin hole with a thumb at 20C (68F).
Replace if defective.
Standard clearance between piston pin and
hole in piston:
Standard
0.004 0.008 mm (0.0002 0.0003 in)
Limit
0.020 mm (0.0008 in)
5) Check the piston pin circlip for distortion, cracks

and wear.
4. PISTON RING
1) If the piston ring is broken, damaged, or worn, or
if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new one of
the same size as the piston.
CAUTION:
Marks are shown on the end of top and second rings. When installing the rings to piston,
face these marks upward.
Oil ring is composed of upper rail, expander
and lower rail. Be careful of the rail direction
when installing oil ring to the pisiton.
B2M1401
B2M4595A
(A) Upper rail

(B) Expander
(C) Lower rail
B2M0084
4) Check the circlip installation groove on piston for

burr (A). If necessary, remove the burr from groove
so that piston pin can lightly move.
B2M0420C
ME-89
CYLINDER BLOCK
MECHANICAL
2) Squarely place the piston ring and oil ring in cylinder, and then measure the piston ring gap with a
thickness gauge.
Top ring
Piston
ring gap
Second
ring
Oil ring
rail
Standard
0.20 0.35
(0.0079 0.0138)
0.35 0.50
(0.0138 0.0197)
0.20 0.50
(0.0079 0.0197)
Unit: mm (in)
Limit
1.0 (0.039)
5. CONNECTING ROD
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.
Limit of bend or twist per 100 mm (3.94 in) in
length:
0.10 mm (0.0039 in)
1.0 (0.039)
1.5 (0.059)
S2M1823
3) Measure the clearance between piston ring and

piston ring groove with a thickness gauge.
CAUTION:
Before measuring the clearance, clean the piston ring groove and piston ring.
Clearance
between piston ring and
piston ring
groove
Top ring
Second
ring
Standard
0.055 0.090
(0.0022
0.0035)
0.030 0.070
(0.0012
0.0028)
Unit: mm (in)
Limit
B2M1184B
(A) Thickness gauge

(B) Connecting rod
0.15 (0.0059)
0.15 (0.0059)
3) Install the connecting rod fitted with bearing to

crankshaft, and then measure the side clearance
(thrust clearance). Replace the connecting rod if
the side clearance exceeds the specified limit.
Connecting rod side clearance:
Standard
0.070 0.330 mm (0.0028 0.0130 in)
Limit
0.4 mm (0.016 in)
B2M1402
EN0335
ME-90
CYLINDER BLOCK
MECHANICAL
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 specification, replace the
defective bearing with a new one of standard size
or undersize as necessary. (See the table below.)
Connecting rod oil clearance:

2500 cc MODEL
Standard
0.012 0.037 mm (0.0005 0.0015 in)
Limit
0.050 mm (0.0020 in)
Unit: mm (in)

1600 cc MODEL
Standard
0.010 0.038 mm (0.0004 0.0015 in)
Limit
0.05 mm (0.0020 in)
Bearing
Standard
0.03
(0.0012)
undersize
0.05
(0.0020)
undersize
0.25
(0.0098)
undersize
Unit: mm (in)
Bearing
Standard
0.03
(0.0012)
undersize
0.05
(0.0020)
undersize
0.25
(0.0098)
undersize
Bearing size
(Thickness at center)
1.492 1.501
(0.0587 0.0591)
47.954 48.000
(4.8879 1.8898)
1.510 1.513
(0.0594 0.0596)
47.954 47.970
(1.8879 1.8886)
1.520 1.523
(0.0598 0.0600)
47.934 47.950
(1.8872 1.8878)
1.620 1.623
(0.0638 0.0639)
47.734 47.750
(1.8793 1.8799)
Outer diameter of
crank pin
Bearing size
1.490 1.502
(0.0587 0.0591)
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
(2.0446 2.0453)
1.614 1.622
(0.0635 0.0639)
51.734 51.750
(2.0368 2.0374)
Outer diameter of
crank pin
6) Inspect the bushing at connecting rod small end,

and replace if worn or damaged. Also measure the
piston pin clearance at connecting rod small end.
Clearance between piston pin and bushing:
Standard
0 0.022 mm (0 0.0009 in)
Limit
0.030 mm (0.0012 in)

2000 cc MODEL
Standard
0.010 0.038 mm (0.0004 0.0015 in)
Limit
0.05 mm (0.0020 in)
Unit: mm (in)
Bearing
Standard
0.03
(0.0012)
undersize
0.05
(0.0020)
undersize
0.25
(0.0098)
undersize
Bearing size
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
B2M0085
EN0337
ME-91
CYLINDER BLOCK
MECHANICAL
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.
ST 499037100
CONNECTING ROD BUSHING REMOVER AND INSTALLER
G2M0177
(3) Make two 3 mm (0.12 in) holes in bushing.

Ream the inside of bushing.
(4) After the completion of reaming, clean the
bushing to remove chips.
ME-92
CYLINDER BLOCK
MECHANICAL
6. CRANKSHAFT AND CRANKSHAFT

BEARING
1) Clean the crankshaft completely and check for
cracks by means of red lead check etc., and replace if defective.
2) Measure the crankshaft bend, and correct or replace if it exceeds the limit.
CAUTION:
If a suitable V-block is not available, install the
#1 and #5 crankshaft bearing on cylinder block,
position the crankshaft on these bearings and
measure the crankshaft bend using a dial
gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
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 then
replace or recondition the crankshaft as necessary.
When grinding the crank journal or crank pin, finish
them to specified dimensions according to the undersize bearing to be used.
Crank pin and crank journal:
Out-of-roundness
0.020 mm (0.0008 in) or less
Taper limit
0.07 mm (0.0028 in)
Grinding limit
0.250 mm (0.0098 in)
G2M0179
EN0339
Standard
0.03
(0.0012)
undersize
0.05
(0.0020)
undersize
0.25
(0.0098)
undersize
Journal
O.D.
Bearing
size
(Thickness
at center)
Journal
O.D.
Bearing
size
(Thickness
at center)
Journal
O.D.
Bearing
size
(Thickness
at center)
Journal
O.D.
Bearing
size
(Thickness
at center)
Unit: mm (in)
Crank journal diameter
Crank pin diameter
#1, #3
#2, #4, #5
1600 cc
2000 cc
2500 cc
59.992 60.008
59.992 60.008
47.984 48.000
51.984 52.000
51.984 52.000
(2.3619 2.3625) (2.3619 2.3625) (1.8891 1.8898) (2.0466 2.0472) (2.0466 2.0472)
1.998 2.011
2.000 2.013
1.492 1.510
1.492 1.501
1.490 1.502
(0.0787 0.0792) (0.0787 0.0793) (0.0587 0.0594) (0.0587 0.0591) (0.0587 0.0591)
59.962 59.978
59.962 59.978
47.954 47.970
51.954 51.970
51.954 51.970
(2.3607 2.3613) (2.3607 2.3613) (1.8879 1.8886) (2.0454 2.0461) (2.0454 2.0461)
2.017 2.020
2.019 2.022
1.510 1.513
1.510 1.513
1.504 1.512
(0.0794 0.0795) (0.0795 0.0796) (0.0594 0.0596) (0.0594 0.0596) (0.0592 0.0595)
59.942 59.958
59.942 59.958
47.934 47.950
51.934 51.950
51.934 51.950
(2.3599 2.3605) (2.3599 2.3605) (1.8872 1.8878) (2.0446 2.0453) (2.0446 2.0453)
2.027 2.030
2.029 2.032
1.520 1.523
1.520 1.523
1.514 1.522
(0.0798 0.0799) (0.0799 0.0800) (0.0598 0.0600) (0.0598 0.0600) (0.0596 0.0599)
59.742 59.758
59.742 59.758
47.734 47.750
51.734 51.750
51.734 51.750
(2.3520 2.3527) (2.3520 2.3527) (1.8793 1.8799) (2.0368 2.0374) (2.0368 2.0374)
2.127 2.130
2.129 2.132
1.620 1.623
1.620 1.623
1.614 1.622
(0.0837 0.0839) (0.0838 0.0839) (0.0638 0.0639) (0.0638 0.0639) (0.0635 0.0639)
O.D. : Outer Diameter
ME-93
CYLINDER BLOCK
MECHANICAL
4) Measure the thrust clearance of crankshaft at

center bearing. If the clearance exceeds the limit,
replace bearing.
Crankshaft thrust clearance:
Standard
0.030 0.115 mm (0.0012 0.0045 in)
Limit
0.25 mm (0.0098 in)
EN0341
5) Inspect the 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 then
Unit: mm (in)
Crankshaft oil clearance
0.010 0.030 (0.0004
Standard
0.0012)
Limit
0.040 (0.0016)
ME-94
ENGINE TROUBLE IN GENERAL

MECHANICAL
22.Engine Trouble in General

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

not occur.
PROBLEM PARTS, ETC.

Starter
POSSIBLE CAUSE
Defective battery-to-starter harness

Defective starter switch
Defective inhibitor switch or neutral switch
Defective starter
Battery
Poor terminal connection
Run-down battery
Defective charging system
Friction
Seizure of crankshaft and connecting rod bearing
Seized camshaft
Seized or stuck piston and cylinder
Starter
Defective starter
Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/
Fuel line
Defective fuel pump and relay
Lack of or insufficient fuel
Belt
Defective
Defective timing
Compression
Incorrect valve clearance
Loosened spark plugs or defective gasket
Loosened cylinder head bolts or defective gasket
Improper valve seating
Defective valve stem
Worn or broken valve spring
Worn or stuck piston rings, cylinder and piston
Incorrect valve timing
Improper engine oil (low viscosity)
ME-95
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

MECHANICAL
TROUBLE
3) Initial combustion occur.
4) Engine stalls after initial

combustion.
PROBLEM PARTS, ETC.

POSSIBLE CAUSE
Intake system
Defective intake manifold gasket
Defective throttle body gasket
Fuel line
Clogged fuel line
Belt
Defective
Defective timing
Compression
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
Defective
Defective timing
Compression
ME-96
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
TROUBLE
2. Rough idle and engine
stall
PROBLEM PARTS, ETC.

POSSIBLE CAUSE
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
Overheating
Others
Malfunction of evaporative emission control system
Stuck or damaged throttle valve
Accelerator cable out of adjustment
ME-97
RANK
A
A
A
A
B
B
C
B
C
C
C
B
C
B
B
B
B
C
B
B
A
B
B
C
C
A
B
C

MECHANICAL
TROUBLE
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
Overheating
Over cooling
Others
Intake system
Defective PCV valve
Fuel line
Clogged fuel line
Belt
Defective timing
Compression
Cooling system
Overheating
Others
ME-98
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
TROUBLE
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
Others
Cooling system
Overheating
Others
Intake system
Defective PCV valve
Belt
Defective timing
Compression
Lubrication system
Cooling system
Over cooling
Others
Intake system
Belt
Defective timing
Compression
Cooling system
Overheating
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-99
RANK
A
A
A
B
A
B
B
A
C
C
B
B
C
B
B
C
C
B
C
C
C
A
C
C
C
A
B
B
C
B
A
A
B
C
A
A
B
B
B
B
B
B

MECHANICAL
TROUBLE
PROBLEM PARTS, ETC.
POSSIBLE CAUSE
10. Excessive fuel consump- Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/
tion
Intake system
Belt
Defective timing
Compression
Lubrication system
Cooling system
Over cooling
Others
ME-100
RANK
A
A
B
B
C
C
B
C
C
B
B
C
C
B
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

medium (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 crankshaft main bearing
Oil pressure is low.
Worn connecting rod bearing (big end)
Loose flywheel mounting bolts
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 case/adjacent part
NOTE*:
When disconnecting fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code is
stored in ECM memory.
Therefore, carry out the CLEAR MEMORY MODE <Ref. to EN-49, OPERATION, Clear Memory Mode.> or <Ref. to EN(w/
oOBD)-30, OPERATION, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN-42, OPERATION, Inspection Mode.> or
<Ref. to EN(w/oOBD)-28, OPERATION, Inspection Mode.> after connecting fuel injector connector.
ME-101
ENGINE NOISE
MECHANICAL
ME-102
EXHAUST
EX
1.
2.
3.
4.
5.
Page
Front Exhaust Pipe......................................................................................7
Center Exhaust Pipe .................................................................................10
Rear Exhaust Pipe ....................................................................................11
Muffler .......................................................................................................12
GENERAL DESCRIPTION
EXHAUST
A: COMPONENT
1. 1600 CC
(16)
(15)
(13)
(14)
T7
(16)
(11)
(10)
(12)
(9)
(16)
T1
T4
(27)
T6
T2
(26)
T2
(17)
(22)
(28)
(18)
T4
T2
(23)
(25)
(24)
T2
(8)
(3)
(31)
T3
(1)
(30)
(2)
(3)
T6
(19)
T1
(7)
T5
T2
(31)
(29)
(21)
(4)
(20)
T5
(6)
(5)
T5
EN1372
EX-2
GENERAL DESCRIPTION
EXHAUST
(1)
(2)
Upper front exhaust pipe cover

CTR
Lower front exhaust pipe cover
CTR
(3)
(4)
(5)
(6)
(7)
Clamp
Upper front exhaust pipe cover LH
Lower front exhaust pipe cover LH
Front exhaust pipe
RH
(8)

RH
(9)
(10)
(11)
(12)
Gasket
Spring
Chamber
Rear exhaust pipe
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
Gasket
Self-locking nut
Muffler
Cushion rubber
Lower clamp
Upper center exhaust pipe cover
Lower center exhaust pipe cover
Protector
Gasket
Front oxygen (A/F) sensor
Front catalytic converter
Center exhaust pipe
Lower front catalytic converter
cover
(26)
Upper front catalytic converter

cover
EX-3
(27)
(28)
(29)
(30)
(31)
Rear oxygen sensor

Upper rear catalytic converter
cover
Lower rear catalytic converter
cover
Rear catalytic converter
Gasket

T1: 8 (0.8, 5.8)
T2: 13 (1.3, 9.4)
T3: 18 (1.8, 13.0)
T4: 21 (2.1, 15.2)
T5: 30 (3.1, 22.4)
T6: 35 (3.6, 26.0)
T7: 48 (4.9, 35.4)
GENERAL DESCRIPTION
EXHAUST
2. 2000 CC AND 2500 CC
(16)
(15)
(13)
(14)
T2
T7
(16)
(11)
(10)
(17)
(9)
(16)
(12)
T1
T4
(28)
T6
T2
(27)
T2
(18)
(23)
(29)
(19)
T4
T2
(24)
(26)
(25)
T2
(8)
(3)
(32)
T3
(1)
(31)
(2)
(3)
T6
(20)
T1
(7)
T5
T2
(32)
(30)
(22)
(4)
(21)
T5
(6)
(5)
T5
EN1373
EX-4
GENERAL DESCRIPTION
EXHAUST
(1)

CTR
(2)

CTR
(3)
(4)
(5)
(6)
(7)
Clamp
Upper front exhaust pipe cover LH
Lower front exhaust pipe cover LH
Front exhaust pipe
RH
(8)

RH
Gasket
Spring
Chamber
Rear exhaust pipe cover
Gasket
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
Self-locking nut
Muffler
Cushion rubber
Rear exhaust pipe
Lower clamp
Protector
Gasket
Center exhaust pipe
cover
(27)

cover
(28)
Rear oxygen sensor
EX-5
(29)
(30)
(31)
(32)

cover
cover
Gasket

T1: 8 (0.8, 5.8)
T2: 13 (1.3, 9.4)
T3: 18 (1.8, 13.0)
T4: 21 (2.1, 15.2)
T5: 30 (3.1, 22.4)
T6: 35 (3.6, 26.0)
T7: 48 (4.9, 35.4)
GENERAL DESCRIPTION
EXHAUST
B: CAUTION
points.
cable from battery.
EX-6
FRONT EXHAUST PIPE

EXHAUST
2. Front Exhaust Pipe
5) Separate the front and center exhaust pipe assembly from rear exhaust pipe.
A: REMOVAL
WARNING:
G6M0095
B2M3109
2) Disconnect the front oxygen (A/F) sensor connector.

CAUTION:
Be careful not to pull down the front and center
exhaust pipe assembly.
B2M4243
3) Disconnect the rear oxygen sensor connector.
B2M3200
8) Remove the bolt which installs front and center

exhaust pipe assembly to hanger bracket.
B2M4244
B2M3111
EX-7
FRONT EXHAUST PIPE

EXHAUST
9) Remove the front and center exhaust pipe assembly from 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.
4) Temporarily tighten the bolt which installs front

and center exhaust pipe assembly to hanger bracket.
B2M3111

Tightening torque:
30 Nm (3.1 kgf-m, 22.4 ft-lb)
S2M0923
11) Remove the front oxygen (A/F) sensor and the

rear oxygen sensor. <Ref. to FU-47, REMOVAL,
Front Oxygen (A/F) Sensor.> and <Ref. to FU-49,
REMOVAL, Rear Oxygen Sensor.> .
B: INSTALLATION
1) Install the front oxygen (A/F) sensor and the rear
oxygen sensor. <Ref. to FU-47, INSTALLATION,
Front Oxygen (A/F) Sensor.> and <Ref. to FU-49,
INSTALLATION, Rear Oxygen Sensor.> .
2) Install the front exhaust pipe to center exhaust
pipe.
NOTE:
Replace the gaskets with new ones.
B2M3200

exhaust pipe assembly to rear exhaust pipe.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
Tightening torque:
30 Nm (3.1 kgf-m, 22.4 ft-lb)
B2M3109
S2M0923
3) Install the front and center exhaust pipe assembly to vehicle.
EX-8
FRONT EXHAUST PIPE

EXHAUST
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
C: INSPECTION
B2M3111

10) Connect the rear oxygen sensor connector.
B2M4244
11) Connect the front oxygen (A/F) sensor connector.
B2M4243
G6M0095
EX-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 the procedure
for removing the front exhaust pipe. <Ref. to EX-7,
REMOVAL, Front Exhaust Pipe.>
B: INSTALLATION
Install the center exhaust pipe and front exhaust
pipe as one unit. Refer to the procedure for installing the front exhaust pipe. <Ref. to EX-8, INSTALLATION, Front Exhaust Pipe.>
C: INSPECTION
EX-10
REAR EXHAUST PIPE

EXHAUST
4. Rear Exhaust Pipe
2) Install the rear exhaust pipe bracket to cushion

rubber.
A: REMOVAL
1) Separate the rear exhaust pipe from center exhaust pipe.
CAUTION:
S2M0560
NOTE:
3) Install the rear exhaust pipe to muffler.
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
B2M3109
2) Separate the rear exhaust pipe from muffler.

CAUTION:
Be careful not to pull down the rear exhaust
pipe.
G2M0382
4) Install the rear exhaust pipe to center exhaust

pipe.
G2M0382
3) Apply a coat of SUBARU CRC to mating area of

the cushion rubbers in advance.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)

4) Remove the rear exhaust pipe bracket from the
cushion rubber.
B2M3109
C: INSPECTION
3) Make sure the cushion rubber is not worn or
cracked.
S2M0560
B: INSTALLATION
EX-11
MUFFLER
EXHAUST
5. Muffler
B: INSTALLATION
A: REMOVAL

NOTE:
1) Separate the muffler from rear exhaust pipe.

CAUTION:
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
G2M0382

G2M0382
C: INSPECTION
cracked.
G2M0385
3) Remove the front, right and left cushion rubber,

and detach the muffler assembly.
EX-12
COOLING
CO
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Page
Radiator Main Fan System........................................................................10
Radiator Sub Fan System .........................................................................18
Engine Coolant..........................................................................................26
Water Pump ..............................................................................................28
Thermostat ................................................................................................37
Radiator.....................................................................................................39
Radiator Cap .............................................................................................47
Radiator Main Fan and Fan Motor ............................................................48
Radiator Sub Fan and Fan Motor..............................................................50
Reservoir Tank..........................................................................................52
Coolant Filler Tank ....................................................................................53
Engine Cooling System Trouble in General ..............................................54
GENERAL DESCRIPTION
COOLING
A: SPECIFICATIONS
Model
Cooling system
2 (US qt, Imp qt)
Total engine coolant capacity
Type
Discharge performance I
Discharge performance II
Water pump
Discharge performance III
Thermostat
Radiator fan
Discharge
Pump speedtotal engine
coolant head
Engine coolant temperature
Discharge
coolant head
Discharge
coolant head
Impeller diameter
Number of impeller vanes
Pump pulley diameter
Clearance between Standard
impeller and case
Limit
Thrust runout of impeller end
Type
Starts to open
Fully opened
Valve lift
Valve bore
Main fan
Motor
Sub fan
Fan diameter Blade
Type
Core dimensions
Radiator
Pressure range in which cap valve is open
Fins
Reservoir
tank
Non-turbo
Turbo
Electric fan + Forced engine coolant circulation system
1.6 L AT: Approx. 7.3
(7.71, 6.42)
1.6 L MT: Approx. 7.4
AT: Approx. 7.6
(7.82, 6.51)
(8.03, 6.69)
2.0 and 2.5 L AT: Approx. 6.9
MT: Approx. 7.7
(8.14, 6.78)
(7.29, 6.07)
2.0 and 2.5 L MT: Approx. 7
(7.4, 6.2)
Centrifugal impeller type
20 2 (5.3 US gal, 4.4 Imp gal)/min.
760 rpm 0.3 mAq (1.0 ftAq)
85C (185F)
100 2 (26.4 US gal, 22.0 Imp gal)/min.
3,000 rpm 5.0 mAq (16.4 ftAq)
85C (185F)
200 2 (52.8 US gal, 44.0 Imp gal)/min.
6,000 rpm 23.0 mAq (75.5 ftAq)
85C (185F)
76 mm (2.99 in)
8
60 mm (2.36 in)
0.5 0.7 mm (0.020 0.028 in)
1.0 mm (0.039 in)
0.5 mm (0.020 in)
Wax pellet type
76 80C (169 176F)
91C (196F)
9.0 mm (0.354 in) or more
35 mm (1.38 in)
70 W
120 W
70 W
120 W
320 mm (11.81 in) 5 (main fan)
320 mm (11.81 in) 7 (sub fan)
Down flow, pressure type
AT: 691.5 340 16
mm
691.5 340 16 mm
(27.22 13.39 0.63 in)
(27.22 13.39 0.63 in)
MT: 691.5 340 27
mm
(27.22 13.39 1.06 in)
Above: 10815 kPa
(1.10.15 kg/cm2, 162 psi)
Below: 1.0 to 4.9 kPa
(0.01 to 0.05 kg/cm2, 0.1 to 0.7 psi)
Corrugated fin type
0.5 2 (0.5 US qt, 0.4 Imp qt)
Capacity
CO-2
GENERAL DESCRIPTION
COOLING
B: COMPONENT
1. WATER PUMP
NON-TURBO MODEL
H2M2354A
(1)
(2)
(3)
(4)
Water pump ASSY

Gasket
Heater by-pass hose
Thermostat
(5)
(6)
Gasket
Thermostat cover

T1: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
T2: 6.4 (0.65, 4.7)
CO-3
GENERAL DESCRIPTION
COOLING
TURBO MODEL
H2M1785B
(1)
(2)
(3)
(4)
(5)
Thermostat cover
Gasket
Thermostat
Water pump ASSY
Gasket
(6)
(7)
(8)
Heater by-pass hose

Coolant filler tank by-pass hose
Water by-pass pipe

T1: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
T2: 6.4 (0.65, 4.7)
CO-4
GENERAL DESCRIPTION
COOLING
2. RADIATOR AND RADIATOR FAN

NON-TURBO MODEL
(8)
(6)
(5)
T5
(12)
(10)
(7)
T3
T5
(5)
T5
(4)
(15)
T1
(3)
(9)
(11)
(13)
(24)
T4
T1
(16)
T2
(17)
(2)
T4
(16)
(14)
(18)
(21)
(16)
T2
(16)
(1)
(16)
(23)
(19)
(20)
(16)
(5)
(22)
EN0068
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
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
Radiator main fan shroud
(14)
(15)
(16)
Radiator main fan

Radiator main fan motor
ATF hose clamp (AT vehicles
only)
(22)
(23)
(24)
(17)
ATF inlet hose A (AT vehicles

only)
(18)
ATF outlet hose A (AT vehicles

only)
(19)
(20)
ATF pipe (AT vehicles only)

ATF inlet hose B (AT vehicles
only)

T1: 4.4 (0.45, 3.3)
T2: 12 (1.2, 8.7)
T3: 18 (1.8, 13.0)
T4: 3.4 (0.35, 2.5)
T5: 4.9 (0.50, 3.6)
(21)
ATF outlet hose B (AT vehicles

only)
CO-5
Radiator outlet hose

Radiator lower bracket
Radiator drain plug
GENERAL DESCRIPTION
COOLING
TURBO MODEL
(21)
(20)
(19)
(5)
(5)
(6)
(5)
T4
T4
(11)
(7)
(10)
(8)
(5)
T2
T4
(13)
(16)
(4)
T1
(3)
(9)
(2)
(12)
(14)
(18)
T3
T1
(5)
T3
(15)
(17)
(1)
(5)
(22)
EN0069
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
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
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Over flow pipe

Radiator sub fan shroud
Radiator sub fan
Radiator sub fan motor
Radiator main fan shroud
Radiator main fan
Radiator main fan motor
Radiator outlet hose
Radiator drain plug
CO-6
(19) Engine coolant filler tank

(20) Engine coolant filler tank cap
(21) Engine coolant hose
(22) Radiator lower bracket
T1: 4.4 (0.45, 3.3)
T2: 18 (1.8, 13.0)
T3: 3.4 (0.35, 2.5)
T4: 4.9 (0.50, 3.6)
GENERAL DESCRIPTION
COOLING
C: CAUTION
points.
cable from battery.
CO-7
GENERAL DESCRIPTION
COOLING
D: PREPARATION TOOL
1. NON-TURBO MODEL
ILLUSTRATION
TOOL NUMBER
499977100
DESCRIPTION
CRANK PULLEY
WRENCH
REMARKS
Used for stopping crankshaft pulley when
loosening and tightening crankshaft pulley
bolts. (2500 cc model)
CRANK PULLEY
WRENCH

bolts. (1600 cc and 2000 cc model)
CAMSHAFT
SPROCKET
WRENCH

sprocket.
Also the CAMSHAFT SPROCKET
WRENCH (499207100) can be used.
NOTE:
For common use with turbo model, this ST is
changed and registered as a newly adopted
tool. Though the previous ST also can be
used.
B2M3870
499977300
B2M4157
18231AA010
(Newly adopted
tool)
B2M3859
CO-8
GENERAL DESCRIPTION
COOLING
2. TURBO MODEL
ILLUSTRATION
TOOL NUMBER
499977300
DESCRIPTION
CRANK PULLEY
WRENCH
REMARKS
bolts.
18231AA010
(Newly adopted
tool)
CAMSHAFT
SPROCKET
WRENCH

sprocket. (Intake)
499207400
CAMSHAFT
SPROCKET
WRENCH

sprocket. (Exhaust)
B2M4157
B2M3859
B2M4158
CO-9
RADIATOR MAIN FAN SYSTEM

COOLING
2. Radiator Main Fan System

A: SCHEMATIC
1. NON-TURBO MODEL
BATTERY
SBF-1
B72
IGNITION
SWITCH
SBF-4
No.17
No.18
AIR CONDITIONING
RELAY HOLDER
AIR CONDITIONING
RELAY HOLDER
26
28
27
25
18
20
19
17
F27 20A
MAIN
F66 FAN
RELAY
F27 20A
SUB
F29 FAN
RELAY
SUB FAN
MOTOR
MAIN FAN
MOTOR
F45
2
1
1
2
2
1
B62
F17
F16
1 LHD :2
RHD :7
2 LHD :12
3
12
RHD :17
B134 ECM
F16
LHD:
RHD:
F45
F45
F17
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
2 1
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
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
F27
1
F29
F66
5 6 9 13 14 17 21 22 25
7
10
15
18
23
26
8 11 12 16 19 20 24 27 28
29
30
EN1413
CO-10

COOLING
2. TURBO MODEL
BATTERY
SBF-1
B72
IGNITION
SWITCH
No.18
SBF-4
17
28
LHD : 2
RHD : 7
*2
LHD : 12
RHD : 17
* 12
*
F29
F28
1
3
2
1
3
2
F16
B72
1 2
3 4
(BLUE)
F27
SUB FAN
MOTOR
F28
F17
F29
4
3
MAIN FAN MAIN FAN

RELAY1
RELAY2
30A
SUB FAN
RELAY1
2
1
SUB FAN
RELAY2
30A
25
27
28
26
24
22
21
23
F45
8
6
5
7
B62
17
19
20
18
B137 ECM
No.17
*1
MAIN FAN
MOTOR
F30
5 6 9 13 14 17 21 22 25
7
10
15
18
23
26
8 11 12 16 19 20 24 27 28
F66
29
30
F30
F66
F27
AIR CONDITIONING RELAY HOLDER
B137
F45
F16
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
(LHD)
F17
3 2 1
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
(RHD)
EN0260
CO-11

COOLING
B: INSPECTION
1. NON-TURBO MODEL
DETECTING CONDITION:
Engine coolant temperature is above 95C (203F).
Vehicle speed is below 19 km/h (12 MPH).
TROUBLE SYMPTOM:
Radiator main fan does not rotate under the above conditions.
Step
Check
Yes
CHECK POWER SUPPLY TO MAIN FAN MO- Is the voltage more than 10 V? Go to step 2.
TOR.
CAUTION:
Be careful not to overheat the engine during
repair.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from main fan
motor.
3)Start the engine, and warm it up until engine
coolant temperature increases over 95C
(203F).
4)Stop the engine and turn ignition switch to
ON.
5)Measure the voltage between main fan
motor connector and chassis ground.
Connector & terminal
(F17) No. 2 (+) Chassis ground ():
CHECK GROUND CIRCUIT OF MAIN FAN
MOTOR.
2)Measure the resistance between main fan
(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, and ground () terminal to terminal No. 1 of main fan motor connector.
CHECK POWER SUPPLY TO MAIN FAN RELAY.
2)Remove the main fan relay from A/C relay
holder.
3)Measure the voltage between main fan relay
terminal and chassis ground.
CHECK POWER SUPPLY TO MAIN FAN RELAY.
1)Turn the ignition switch to ON.
2)Measure the voltage between main fan relay
No
Go to step 5.
Is the resistance less than 5

?
Go to step 3.
Repair the open

circuit in harness
between main fan
motor connector
and chassis
ground.
Is there poor contact in main

fan motor connector?
Repair the poor

contact in main fan
motor connector.
Repair the poor
contact in main fan
motor connector.
Go to step 4.
Does the main fan rotate?
Replace the main

fan motor with a
new one.
Is the voltage more than 10 V? Go to step 6.
Go to step 7.
Go to step 9.
CO-12

COOLING
10
11
12
13
14
Step
Check
CHECK 20 A FUSE.
Is the fuse blown-out?
1)Remove the 20 A fuse from A/C relay holder.
2)Check the condition of fuse.
Is the voltage more than 10 V?
CHECK POWER SUPPLY TO A/C RELAY
HOLDER 20 A FUSE TERMINAL.
Measure the voltage of harness between A/C
relay holder 20 A fuse terminal and chassis
ground.
CHECK FUSE.
2)Remove the fuse No. 18 from joint box.
CHECK MAIN FAN RELAY.
2)Remove the main fan relay.
3)Measure the resistance of main fan relay.
Terminal
No. 26 No. 25:
1)Connect the battery to terminals No. 27 and
No. 28 of main fan relay.
2)Measure the resistance of main fan relay.
Terminal
No. 26 No. 25:
CHECK HARNESS BETWEEN MAIN FAN
RELAY TERMINAL AND MAIN FAN MOTOR
CONNECTOR.
Measure the resistance of harness between
main fan motor connector and main fan relay
terminal.
(F17) No. 2 (F66) No. 25:
RELAY AND ECM.
2)Disconnect the connector from ECM.
3)Measure the resistance of harness between
main fan relay connector and ECM connector.
(F66) No. 27 (B134) No. 3:
CHECK POOR CONTACT.
Check poor contact in connector between main
fan and ECM.
Yes
Replace the fuse.
No
Go to step 8.
Repair the open

circuit in harness
between 20 A fuse
and main fan relay
terminal.
Repair the open

circuit in harness
between main fuse
box connector and
20 A fuse terminal.
Replace the fuse.
Repair the open

circuit in harness
between main fan
relay and ignition
switch.
Replace the main
fan relay.
Is the resistance more than 1

M?
Go to step 11.

?
Go to step 12.
Replace the main

fan relay.

?
Go to step 13.
Repair the open

circuit in harness
between main fan
motor connector
and main fan relay
terminal.

?
Go to step 14.
Repair the open

circuit in harness
between main fan
relay and ECM.
Is there poor contact in conRepair the poor

Contact with your
nector between main fan motor contact connector. Subaru distributor
and ECM?
service.
NOTE:
Inspection by your Subaru distributor is required,
because probable cause is deterioration of multiple
parts.
CO-13

COOLING
2. TURBO MODEL
A/C compressor is rotated.
TROUBLE SYMPTOM:
Radiator main fan does not rotate under the above conditions.
Radiator main fan does not rotate at high speed when the following conditions are both met:
(1) Engine coolant temperature is above 90C (194F)
(2) A/C is ON
Step
CHECK OPERATION OF RADIATOR.
1)Run the engine at idle. (Vehicle stationary)
2)Turn the A/C switch to OFF.
3)Warm the engine coolant temperature over
96C (205F).
1)Turn the A/C switch ON at condition of step
1.
CHECK POWER SUPPLY TO MAIN FAN MOTOR.
CAUTION:
repair.
motor.
(205F).
ON.
MOTOR.
CHECK POOR CONTACT.
Check
Does the main radiator fan
rotate?
Yes
Go to step 2.
No
Go to step 3.
Does the main radiator fan

Radiator main fan Go to step 17.
rotate faster when A/C comsystem is okay.
pressor is operated?
Go to step 7.

?
Go to step 5.
Repair the open

circuit in harness
between main fan
motor connector
and chassis
ground.

Repair the poor

contact in main fan
motor connector.
Repair the poor
contact in main fan
motor connector.
Go to step 6.
CO-14
Replace the main

fan motor with a
new one.

COOLING
10
11
12
13
14
15
Step
CHECK POWER SUPPLY TO MAIN FAN
RELAY1.
2)Remove the main fan relay1 from A/C relay
holder.
relay1 terminal and chassis ground.
RELAY1.
CHECK 30 A FUSE.
ground.
CHECK FUSE.
2)Remove the main fan relay1.
3)Measure the resistance of main fan relay1.
Terminal
No. 26 No. 25:
No. 28 of main fan relay1.
Terminal
No. 26 No. 25:
CONNECTOR.
terminal.
(F17) No. 3 (F66) No. 25:
RELAY AND ECM.
(F66) No. 28 (B137) No. 17:
Check
Yes
No
Go to step 9.
Go to step 11.
Go to step 10.
Replace the fuse.
Is the voltage more than 10 V? Repair the open

circuit in harness
between 30 A fuse
and main fan relay
terminal.
Repair the open

circuit in harness
between main fuse
box connector and
30 A fuse terminal.
Replace the fuse.

M?
Go to step 13.
Repair the open

circuit in harness
between main fan
relay and ignition
switch.
Replace the main
fan relay.

?
Go to step 14.
Replace the main

fan relay.

?
Go to step 15.
Repair the open

circuit in harness
between main fan
motor connector
and main fan relay
terminal.

?
Go to step 16.
Repair the open

circuit in harness
between main fan
relay and ECM.
CO-15

COOLING
16
17
18
19
20
21
22
23
24
Step
CHECK POOR CONTACT.
fan and ECM.
CAUTION:
repair.
motor.
(205F).
4)Turn the A/C switch ON.
5)Measure the voltage while A/C compressor
is rotating.
CHECK POOR CONTACT.
RELAY2.
2)Remove the main fan relay2 from A/C relay
holder.
RELAY2.
CHECK 30 A FUSE.
ground.
CHECK FUSE.
Check
Yes
No
Contact with your
and ECM?
service.
Go to step 20.

Repair the poor

contact in main fan
motor connector.
Repair the poor
contact in main fan
motor connector.
Go to step 19.
Replace the main

fan motor with a
new one.
Go to step 22.
Go to step 24.
Go to step 23.
Replace the fuse.

circuit in harness
between 30 A fuse
and main fan relay
terminal.
Repair the open

circuit in harness
between main fuse
box connector and
30 A fuse terminal.
Repair the open

circuit in harness
between main fan
relay and ignition
switch.
CO-16
Replace the fuse.

COOLING
25
26
27
28
29
Step
Terminal
No. 23 No. 24:
No. 22 of main fan relay1.
Terminal
No. 23 No. 24:
CONNECTOR.
terminal.
(F17) No. 2 (F66) No. 24:
RELAY AND ECM.
(F30) No. 21 (B134) No. 28:
CHECK POOR CONTACT.
fan and ECM.
Check
M?
Yes
Go to step 26.
No
Replace the main
fan relay.

?
Go to step 27.
Replace the main

fan relay.

?
Go to step 28.
Repair the open

circuit in harness
between main fan
motor connector
and main fan relay
terminal.

?
Go to step 29.
Repair the open

circuit in harness
between main fan
relay and ECM.

Contact with your
and ECM?
service.
NOTE:
parts.
CO-17
RADIATOR SUB FAN SYSTEM

COOLING
3. Radiator Sub Fan System

A: SCHEMATIC
1. NON-TURBO MODEL
BATTERY
SBF-1
B72
IGNITION
SWITCH
SBF-4
No.17
No.18
AIR CONDITIONING
RELAY HOLDER
AIR CONDITIONING
RELAY HOLDER
26
28
27
25
18
20
19
17
F27 20A
MAIN
F66 FAN
RELAY
F27 20A
SUB
F29 FAN
RELAY
SUB FAN
MOTOR
MAIN FAN
MOTOR
F45
2
1
1
2
2
1
B62
F17
F16
1 LHD :2
RHD :7
2 LHD :12
3
12
RHD :17
B134 ECM
F16
LHD:
RHD:
F45
F45
F17
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
2 1
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
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
F27
1
F29
F66
5 6 9 13 14 17 21 22 25
7
10
15
18
23
26
8 11 12 16 19 20 24 27 28
29
30
EN1413
CO-18

COOLING
2. TURBO MODEL
BATTERY
SBF-1
B72
IGNITION
SWITCH
No.18
SBF-4
17
28
LHD : 2
RHD : 7
*2
LHD : 12
RHD : 17
* 12
*
F29
F28
1
3
2
1
3
2
F16
B72
1 2
3 4
(BLUE)
F27
SUB FAN
MOTOR
F28
F17
F29
4
3
MAIN FAN MAIN FAN

RELAY1
RELAY2
30A
SUB FAN
RELAY1
2
1
SUB FAN
RELAY2
30A
25
27
28
26
24
22
21
23
F45
8
6
5
7
B62
17
19
20
18
B137 ECM
No.17
*1
MAIN FAN
MOTOR
F30
5 6 9 13 14 17 21 22 25
7
10
15
18
23
26
8 11 12 16 19 20 24 27 28
F66
29
30
F30
F66
F27
B137
F45
F16
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
(LHD)
F17
3 2 1
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
(RHD)
EN0260
CO-19

COOLING
B: INSPECTION
1. NON-TURBO MODEL
NOTE:
System for A/C equipped vehicles only.
Condition (1):
Engine coolant temperature is below 95C (203F).
A/C switch is turned ON.
Condition (2):
A/C switch is turned OFF.
TROUBLE SYMPTOM:
Radiator sub fan does not rotate under conditions (1) and (2) above.
Step
Check
Yes
CHECK POWER SUPPLY TO SUB FAN MO- Is the voltage more than 10 V? Go to step 2.
TOR.
CAUTION:
repair.
2)Disconnect the connector from sub fan motor
and main fan motor.
(212F).
ON.
5)Measure the voltage between sub fan motor
connector and chassis ground.
CHECK GROUND CIRCUIT OF SUB FAN
MOTOR.
2)Measure the resistance between sub fan
CHECK POOR CONTACT.
Check poor contact in sub fan motor connector.
CHECK SUB FAN MOTOR.
Connect the battery positive (+) terminal to terminal No. 2, and ground () terminal to terminal No. 1 of sub fan motor connector.
CHECK POWER SUPPLY TO SUB FAN RELAY.
2)Remove the sub fan relay from A/C relay
holder.
3)Measure the voltage between sub fan relay

?
Go to step 3.
No
Go to step 5.
Repair the open

circuit in harness
between sub fan
motor connector
and chassis
ground.
Is there poor contact in sub fan Repair the poor

motor connector?
contact in sub fan
motor connector.
Does the sub fan rotate?
Repair the poor
contact in sub fan
motor connector.
Replace the sub

fan motor with a
new one.
Go to step 7.
CO-20
Go to step 4.

COOLING
10
11
12
13
14
Step
CHECK POWER SUPPLY TO SUB FAN RELAY.
2)Measure the voltage between sub fan relay
CHECK 20 A FUSE.
ground.
CHECK FUSE.
CHECK SUB FAN RELAY.
2)Measure the resistance of sub fan relay.
Terminal
No. 17 No. 18:
No. 19 of sub fan relay.
Terminal
No. 17 No. 18:
CHECK HARNESS BETWEEN SUB FAN RELAY TERMINAL AND SUB FAN MOTOR
CONNECTOR.
sub fan motor connector and sub fan relay terminal.
(F16) No. 2 (F29) No. 17:
CHECK HARNESS BETWEEN SUB FAN RELAY AND ECM.
sub fan relay connector and ECM connector.
(F29) No. 19 (B134) No. 12:
CHECK POOR CONTACT.
Check poor contact in connector between sub
fan and ECM.
Check
Yes
No
Go to step 9.
Go to step 8.
Replace the fuse.

circuit in harness
between 20 A fuse
and sub fan relay
terminal.
Repair the open

circuit in harness
between main fuse
box connector and
20 A fuse terminal.
Replace the fuse.

M?
Go to step 11.
Repair the open

circuit in harness
between sub fan
relay and ignition
switch.
Replace the sub
fan relay.

?
Go to step 12.
Replace the sub

fan relay.

?
Go to step 13.
Repair the open

circuit in harness
between sub fan
motor and sub fan
relay connector.

?
Go to step 14.
Repair the open

circuit in harness
between sub fan
relay and ECM.

Contact with your
nector between sub fan motor contact connector. Subaru distributor
and ECM?
service.
NOTE:
parts.
CO-21

COOLING
2. TURBO MODEL
A/C compressor is rotated.
TROUBLE SYMPTOM:
Radiator sub fan does not rotate under the above conditions.
Radiator sub fan does not rotate at high speed when the following conditions are both met:
(1) Engine coolant temperature is above 90C (194F)
(2) A/C is ON
Step
1)Run the engine at idle. (Vehicle stationary)
3)Warm the engine coolant temperature over
96C (205F).
1)Turn the A/C switch ON at condition of step
1.
CHECK POWER SUPPLY TO SUB FAN MOTOR.
CAUTION:
repair.
2)Disconnect the connector from sub fan
motor.
(205F).
ON.
MOTOR.
CHECK POOR CONTACT.
Check
Does the radiator sub fan
rotate?
Yes
Go to step 2.
No
Go to step 3.
Does the radiator sub fan

Radiator main fan Go to step 17.
rotate faster when A/C comsystem is okay.
pressor is operated?
Go to step 7.

?
Go to step 5.

motor connector?
contact in sub fan
motor connector.
Repair the poor
contact in sub fan
motor connector.
CO-22
Repair the open

circuit in harness
between sub fan
motor connector
and chassis
ground.
Go to step 6.
Replace the sub

fan motor with a
new one.

COOLING
10
11
12
13
14
15
Step
CHECK POWER SUPPLY TO SUB FAN
RELAY1.
2)Remove the sub fan relay1 from A/C relay
holder.
3)Measure the voltage between sub fan relay1
RELAY1.
CHECK 30 A FUSE.
ground.
CHECK FUSE.
3)Measure the resistance of sub fan relay1.
Terminal
No. 7 No. 8:
No. 5 of sub fan relay1.
Terminal
No. 7 No. 8:
CONNECTOR.
sub fan motor connector and sub fan relay terminal.
(F16) No. 3 (F28) No. 8:
(F28) No. 6 (B137) No. 17:
Check
Yes
No
Go to step 9.
Go to step 11.
Go to step 10.
Replace the fuse.

circuit in harness
between 30 A fuse
and sub fan relay
terminal.
Repair the open

circuit in harness
between sub fuse
box connector and
30 A fuse terminal.
Replace the fuse.

M?
Go to step 13.
Repair the open

circuit in harness
between sub fan
relay and ignition
switch.
Replace the sub
fan relay.

?
Go to step 14.
Replace the sub

fan relay.

?
Go to step 15.
Repair the open

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

?
Go to step 16.
Repair the open

circuit in harness
between sub fan
relay and ECM.
CO-23

COOLING
16
17
18
19
20
21
22
23
24
Step
CHECK POOR CONTACT.
fan and ECM.
CAUTION:
repair.
motor.
(205F).
5)Measure the voltage while A/C compressor
is rotating.
CHECK POOR CONTACT.
RELAY2.
2)Remove the sub fan relay2 from A/C relay
holder.
RELAY2.
CHECK 30 A FUSE.
ground.
CHECK FUSE.
Check
Yes
No
Contact with your
and ECM?
service.
Go to step 20.

motor connector?
contact in sub fan
motor connector.
Repair the poor
contact in sub fan
motor connector.
Replace the sub

fan motor with a
new one.
Go to step 22.
Go to step 24.
Go to step 23.
Replace the fuse.
Go to step 19.

circuit in harness
between 30 A fuse
and sub fan relay
terminal.
Repair the open

circuit in harness
between sub fuse
box connector and
30 A fuse terminal.
Repair the open

circuit in harness
between sub fan
relay and ignition
switch.
CO-24
Replace the fuse.

COOLING
25
26
27
28
29
Step
2)Remove the sub fan relay2.
Terminal
No. 18 No. 17:
No. 20 of sub fan relay2.
Terminal
No. 18 No. 17:
CONNECTOR.
sub fan motor connector and sub fan relay2
terminal.
(F16) No. 2 (F29) No. 17:
(F29) No. 19 (B137) No. 28:
CHECK POOR CONTACT.
fan and ECM.
Check
M?
Yes
Go to step 26.
No
Replace the sub
fan relay.

?
Go to step 27.
Replace the sub

fan relay.

?
Go to step 28.
Repair the open

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

?
Go to step 29.
Repair the open

circuit in harness
between sub fan
relay and ECM.

Contact with your
and ECM?
service.
NOTE:
parts.
CO-25
ENGINE COOLANT
COOLING
4. Engine Coolant
2. FILLING OF ENGINE COOLANT
A: REPLACEMENT
1) Fill engine coolant into the radiator up to filler

neck position.
1. DRAINING OF ENGINE COOLANT

3) Remove the drain cock to drain engine coolant
into container.
NOTE:
Remove the radiator cap so that engine coolant will
drain faster.
EN0073
Coolant capacity (fill up to FULL level):

1.6 L AT model
Approx. 7.3 2(7.71 US qt, 6.42 Imp qt)
1.6 L MT model
Non-turbo 2.0 L and 2.5 L AT model
Non-turbo 2.0 L and 2.5 L MT model
Approx. 7 2 (7.4 US qt, 6.2 Imp qt)
Turbo AT model
Turbo MT model
CAUTION:
The SUBARU Genuine Coolant containing antifreeze and anti-rust agents is especially made
for SUBARU engine, which has an aluminum
crankcase. Always use SUBARU Genuine Coolant, since other coolant may cause corrosion.
2) Fill engine coolant into the reservoir tank up to
upper level.
S2M0552A
3) Warm-up the engine completely for more than 5

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 upper level
of reservoir tank, add engine coolant to upper level.
6) Attach the radiator cap and reservoir tank cap
properly.
CO-26
ENGINE COOLANT
COOLING
B: INSPECTION
1. RELATIONSHIP OF SUBARU COOLANT
CONCENTRATION AND FREEZING TEMPERATURE
The concentration and safe operating temperature
of the SUBARU coolant is shown in the diagram.
Measuring the temperature and specific gravity of
the coolant will provide this information.
[Example]
If the coolant temperature is 25C (77F) and its
specific gravity is 1.054, the concentration is 35%
(point A), the safe operating temperature is 14C
(7F) (point B), and the freezing temperature is
20C (4F) (point C).
2. PROCEDURE TO ADJUST THE CONCENTRATION OF THE COOLANT

To adjust the concentration of the coolant according to temperature, find the proper fluid concentration in the above diagram and replace the
necessary amount of coolant with an undiluted solution of SUBARU genuine coolant (concentration
50%).
The amount of coolant that should be replaced can
be determined using the diagram.
[Example]
Assume that the coolant concentration must be increased from 25% to 40%. Find point A, where the
25% line of coolant concentration intersects with
the 40% curve of the necessary coolant concentration, and read the scale on the vertical axis of the
graph at height A. The quantity of coolant to be
drained is 2.12 (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 2.12 (2.2 US qt, 1.8 Imp qt) of the
undiluted solution of SUBARU coolant.
If a coolant concentration of 50% is needed, drain
all the coolant and refill with the undiluted solution
only.
B2M3128A
B2M3129A
CO-27
WATER PUMP
COOLING
5. Water Pump
7) Disconnect the radiator outlet hose and heater

hose from water pump.
A: REMOVAL
1. NON-TURBO MODEL
EN0112

9) Remove the air intake duct.
G6M0095

5) Drain the engine coolant completely.
<Ref. to CO-26, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
6) Disconnect the connectors from radiator main
fan motor (A) and sub fan motor (B).
EN0063
2500 cc MODEL
(A)
EN0077
(B)
B6M1224
10) Disconnect the over flow hose.
EN0078
B2M2925
CO-28
WATER PUMP
COOLING
11) Remove the reservoir tank.
17) Remove the camshaft sprocket (LH) by using

ST.
WRENCH
NOTE:
(499207100) can be used.
B2M2926
12) Remove the radiator main fan and sub fan assemblies. <Ref. to CO-48, REMOVAL, Radiator
Main Fan and Fan Motor.> and <Ref. to CO-50,
REMOVAL, Radiator Sub Fan and Fan Motor.>
13) Remove the V-belts.
<Ref. to ME-49, TIMING BELT, REMOVAL, Timing
Belt Assembly.>
15) Remove the automatic belt tension adjuster.
B2M2039A
B2M2040

H2M2375
H2M2380
S2M0024
20) Disconnect the heater hose from water pump.

B2M3894
CO-29
WATER PUMP
COOLING
2. TURBO MODEL
WARNING:
The radiator is pressurized. Wait until the engine cools down before working on the radiator.
7) Remove the bolt which installs water by-pass

pipe of oil cooler onto oil pump.
S2M0027
8) Disconnect the radiator outlet hose (A) and heater hose (B) from water pump.
9) Disconnect the water by-pass hose (C) and oil
cooler hose (D).
G6M0095

5) Drain the engine coolant completely. <Ref. to
CO-26, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
6) Disconnect the connectors of radiator main fan
motor (A) and sub fan motor (B).
S2M1159A

(A)
EN0077
(B)
S2M0931
EN0078
13) Remove the radiator main fan and sub fan assemblies. <Ref. to CO-48, REMOVAL, Radiator
Main Fan and Fan Motor.> and <Ref. to CO-50,
REMOVAL, Radiator Sub Fan and Fan Motor.>
14) Remove the V-belts. <Ref. to ME(TURBO)-44,
REMOVAL, V-belt.>
15) Remove the timing belt. <Ref. to ME(TURBO)48, REMOVAL, Timing Belt Assembly.>
16) Remove the automatic belt tension adjuster
(A).
17) Remove the belt idler (B).
CO-30
WATER PUMP
COOLING
18) Remove the belt idler No. 2 (C).
S2M1160A
S2M1163

FU(TURBO)-31, REMOVAL, Camshaft Position
Sensor.>
20) Remove the camshaft sprockets (LH) by using
ST.
WRENCH (Intake)
ST 499207400
CAMSHAFT SPROCKET
WRENCH (Exhaust)
23) Disconnect the heater hose from water pump.

S2M1829
B: INSTALLATION
ST
1. NON-TURBO MODEL
1) Install water pump onto cylinder head (LH).
EN1320
NOTE:
When installing the water pump, tighten bolts in
two stages in alphabetical sequence as shown in
the figure.
Tightening torque:
First:
12 Nm (1.2 kgf-m, 8.7 ft-lb)
Second:
12 Nm (1.2 kgf-m, 8.7 ft-lb)
S2M1162
S2M0760A
CO-31
WATER PUMP
COOLING
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
B2M2040
S2M0024
6) Install the automatic belt tension adjuster which

tension rod is holded with pin. <Ref. to ME-50, AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, Timing
Belt Assembly.>
7) Install the timing belt. <Ref. to ME-51, TIMING
BELT, INSTALLATION, Timing Belt Assembly.>
8) Install the V-belts. <Ref. to ME-44, INSTALLATION, V-belt.>
9) Install the radiator main fan and sub fan motor
assemblies. <Ref. to CO-49, INSTALLATION, Radiator Main Fan and Fan Motor.> and <Ref. to CO50, INSTALLATION, Radiator Sub Fan and Fan
Motor.>
10) Install the reservoir tank.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
H2M2380
4) Install the camshaft sprockets (LH) by using ST.

WRENCH
NOTE:
(499207100) can be used.
Tightening torque:
78 Nm (8.0 kgf-m, 57.9 ft-lb)
B2M2926
11) Connect the over flow hose.
B2M2039A
B2M2925
CO-32
WATER PUMP
COOLING
12) Install air intake duct.

15) Connect the connectors to radiator main fan

(A)
EN0077
EN0063
2500 cc MODEL
(B)
EN0078
B6M1224

14) Connect the radiator outlet hose and heater
hose to water pump.

G6M0095
EN0112
19) Fill engine coolant. <Ref. to CO-26, FILLING

OF ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
CO-33
WATER PUMP
COOLING
2. TURBO MODEL
1) Install the water pump onto cylinder head (LH).
NOTE:
When installing the water pump, tighten bolts in
two stages in alphabetical sequence as shown in
the figure.
4) Install the camshaft sprockets (LH) by using ST.

WRENCH (Intake)
ST 499207400
CAMSHAFT SPROCKET
WRENCH (Exhaust)
Tightening torque:
98 Nm (10.0 kgf-m, 72.4 ft-lb)
Tightening torque:
First:
12 Nm (1.2 kgf-m, 8.7 ft-lb)
Second:
12 Nm (1.2 kgf-m, 8.7 ft-lb)
ST
EN1320
H2M1846C

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)

FU(TURBO)-31, INSTALLATION, Camshaft Position Sensor.>
6) Install the belt idler No. 2 (C).
7) Install the belt idler (B).
8) Install the automatic belt tension adjuster (A)
which has a tension rod held by a pin. <Ref. to
ME(TURBO)-50, AUTOMATIC BELT TENSION
ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, Timing Belt Assembly.>
Tightening torque:
39.4 Nm (4.0 kgf-m, 28.9 ft-lb)
S2M1162

Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
S2M1160A
9) Install the timing belt. <Ref. to ME(TURBO)-51,

TIMING BELT, INSTALLATION, Timing Belt Assembly.>
10) Install the V-belts. <Ref. to ME(TURBO)-45,
INSTALLATION, V-belt.>
11) Install the radiator main fan and sub fan motor
assemblies. <Ref. to CO-49, INSTALLATION, Radiator Main Fan and Fan Motor.> and <Ref. to CO50, INSTALLATION, Radiator Sub Fan and Fan
Motor.>
S2M1163
CO-34
WATER PUMP
COOLING

(A)
S2M0931
EN0077

15) Connect the radiator outlet hose (A) and heater
hose (B) to water pump.
16) Connect the water by-pass hose (C) and oil
cooler hose (D).
(B)
EN0078

S2M1159A
17) Install the bolt which installs water by-pass pipe

onto oil pump.
G6M0095
S2M0027

Coolant.>
CO-35
WATER PUMP
COOLING
C: INSPECTION
1) Check the water pump bearing for smooth rotation.
2) Check the water pump pulley for abnormalities.
3) Using a dial gauge, measure the impeller runout
in thrust direction while rotating the pulley.
Thrust runout limit:
0.5 mm (0.020 in)
G2M0211
4) Check the clearance between impeller and

pump case.
Clearance between impeller and pump case:
Standard
0.5 0.7 mm (0.020 0.028 in)
Limit
1.0 mm (0.039 in)
G2M0212
5) After water pump installation, check the pulley

shaft for engine coolant leaks. If leaks are noted,
replace the water pump assembly.
CO-36
THERMOSTAT
COOLING
6. Thermostat
6) Remove the thermostat cover and gasket, and

pull out the thermostat.
A: REMOVAL
G2M0214
B: INSTALLATION
1) Install the thermostat in the water pump, and
then install the thermostat cover together with a
gasket.
EN0073
4) Disconnect the radiator outlet hose from thermostat cover.

Non-turbo MODEL
NOTE:
When reinstalling the thermostat, use a new gasket.
The thermostat must be installed with the jiggle
pin (A) facing to front side.
At this time, set the jiggle pin of thermostat for
front side.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
EN0112
5) Disconnect the radiator outlet hose.

Turbo MODEL
EN0100
2) Fill engine coolant. <Ref. to CO-26, FILLING OF

ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
EN0107
CO-37
THERMOSTAT
COOLING
C: INSPECTION
Replace the thermostat if the valve does not close
completely at an ambient temperature or if the following test shows unsatisfactory results.
Immerse the thermostat and a thermometer in water. Raise water temperature gradually, and measure the temperature and valve lift when the valve
begins to open and when the valve is fully opened.
During the test, agitate the water for even temperature distribution. The measurement should be to
the specification.
Starts to open:
76 80C (169 176F)
Fully opens:
91C (196F)
H2M2357A
(A) Thermometer
(B) Thermostat
CO-38
RADIATOR
COOLING
7. Radiator
A: REMOVAL
1. NON-TURBO MODEL
EN0112
6) Disconnect the ATF cooler hoses from radiator.

(AT vehicles only)
G6M0095

EN0102
(A)

EN0077
(B)
EN0063
2500 cc MODEL
EN0078
B6M1224
CO-39
RADIATOR
COOLING
13) Detach the power steering hose from the clip

on the radiator.
B2M2925
B2M2932
14) While slightly lifting the radiator, slide it to left.

15) Lift the radiator up and away from vehicle.
B2M2926
11) Disconnect the radiator inlet hose from engine.
B2M2930
12) Remove the radiator upper brackets.
B2M2931
CO-40
B2M2933
RADIATOR
COOLING
2. TURBO MODEL
WARNING:
7) Disconnect the oil cooler hoses from oil cooler

pipes. (if equipped)
S2M1743
G6M0095

EN0107

(A)
EN0077
EN0108
(B)

EN0078
S2M0931
CO-41
RADIATOR
COOLING
B: INSTALLATION
13) Remove the V-belt covers.
1. NON-TURBO MODEL
1) Attach the radiator mounting cushions to holes
on the vehicle.
EN0048
14) Disconnect the radiator inlet hose (A) and water tank hose (B) from radiator.
B2M2934
2) Install the radiator while fitting radiator pins to

cushions.
(A)
NOTE:
Fit pins on the lower side of radiator into cushions
on body side.
EN0109
B2M2933
(B)
3) Install the radiator brackets and tighten bolts.

Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
EN0110
B2M2931
EN0035
16) While slightly lifting the radiator, slide it to left.

17) Lift the radiator up and away from vehicle.
CO-42
RADIATOR
COOLING
4) Attach the power steering hose to radiator.
2500 cc MODEL
B2M2932
5) Connect the radiator inlet hose.
B6M1224

9) Connect the ATF cooler hoses. (AT vehicles
only)
B2M2930
EN0102
Tightening torque:
4.9 Nm (0.50 kgf-m, 3.6 ft-lb)

(A)
B2M2926
EN0077
7) Install the air intake duct.

(B)
EN0078
EN0063
CO-43
RADIATOR
COOLING
2) Install the radiator brackets, and then tighten the

bolts.
11) Connect the radiator outlet hose.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
EN0112

EN0035
3) Connect the radiator inlet hose (A) and water

tank hose (B).
(A)
G6M0095

Coolant.>
16) Check the ATF level. <Ref. to AT-9, INSPECTION, Automatic Transmission Fluid.>
EN0109
2. TURBO MODEL
1) Attach the radiator mounting cushions to holes
on the vehicle.
(B)
EN0110

Tightening torque:
4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
B2M2934
S2M0934
CO-44
RADIATOR
COOLING

7) Connect the connectors to radiator main fan motor (A) and sub fan motor (B).
12) Install the V-belt covers.
(A)
EN0048

EN0077
(B)
EN0108
EN0078
8) Connect the oil cooler hoses. (if equipped)
G6M0095
S2M1743
9) Connect the radiator outlet hose.

Coolant.>
EN0107

CO-45
RADIATOR
COOLING
C: INSPECTION
1) Remove the radiator cap, top off radiator, and
then attach the tester to radiator in place of cap.
Non-turbo MODEL
B2M3127
Turbo MODEL
EN0116
2) Apply a pressure of 157 kPa (1.6 kg/cm2, 23 psi)

to the radiator to check if:
(1) Engine coolant leaks at/around radiator.
(2) Engine coolant leaks at/around hoses or
connections.
CAUTION:
Engine should be off.
Wipe engine coolant from check points in advance.
Be careful to prevent engine coolant from
spurting out when removing the tester.
Be careful also not to deform the filler neck of
radiator when installing or removing tester.
CO-46
RADIATOR CAP
COOLING
8. Radiator Cap
A: INSPECTION
1) Attach the radiator cap to tester.
G2M0223
2) Increase the pressure until tester gauge pointer

stops. Radiator cap is functioning properly if it holds
the service limit pressure for 5 to 6 seconds.
Standard pressure:
93 123 kPa (0.95 1.25 kg/cm2, 14 18
psi)
Service limit pressure:
83 kPa (0.85 kg/cm2, 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-47
RADIATOR MAIN FAN AND FAN MOTOR

COOLING
9. Radiator Main Fan and Fan

Motor
Turbo MODEL (includes Non-turbo 2500 cc

MODEL)
A: REMOVAL
EN0108

G6M0095

4) Disconnect the connector of main fan motor (A).
(A)
B2M2925
8) Remove the over flow pipe. (Turbo model)

EN0077

Non-turbo MODEL (except 2500 cc MODEL)
B2M2926
10) Remove the radiator main fan motor assembly.
EN0063
B2M2927
CO-48
RADIATOR MAIN FAN AND FAN MOTOR

COOLING
B: INSTALLATION
2) Remove the nut which holds fan itself onto fan

motor and shroud assembly.

NOTE:
When the main fan motor assembly cannot be installed as is, loosen the sub fan motor assembly
securing bolts to install it.
Tightening torque:
4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
EN0120
3) Remove the bolts which install fan motor onto

shroud.
B2M2927
Tightening torque:
4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
EN0121
D: ASSEMBLY
Assemble in the reverse order of disassembly.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
B2M2926
C: DISASSEMBLY
1) Remove the clip which holds motor connector
onto shroud.
EN0121
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
S2M0937
EN0120
CO-49
RADIATOR SUB FAN AND FAN MOTOR

COOLING
10.Radiator Sub Fan and Fan

Motor
Turbo MODEL (includes Non-turbo 2500 cc

MODEL)
A: REMOVAL
EN0108
G6M0095

4) Disconnect the connector of sub fan motor (B).
7) Remove the bolts which hold sub fan shroud to

radiator.
8) Remove the over flow pipe. (Turbo model)
9) Remove the radiator sub fan shroud through the
under side of vehicle.
(B)
B2M2937
EN0078

Non-turbo MODEL (except 2500 cc MODEL)
B: INSTALLATION
Tightening torque:
4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
EN0063
B2M2937
CO-50
RADIATOR SUB FAN AND FAN MOTOR

COOLING
C: DISASSEMBLY
D: ASSEMBLY
1) Remove the clip which holds motor harness onto

shroud.

Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
S2M0937
2) Remove the nut which holds fan itself onto fan

motor and shroud assembly.
EN0121
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
EN0123
3) Remove the bolts which install fan motor onto

shroud.
EN0121
CO-51
EN0123
RESERVOIR TANK
COOLING
11.Reservoir Tank
A: REMOVAL
1) Disconnect the over flow hose from radiator filler
neck position.
2) Remove the bolts which install reservoir tank
onto radiator main fan shroud.
B2M2926
B: INSTALLATION
Tightening torque:
4.9Nm (0.50 kgf-m, 3.6 ft-lb)
B2M2926
C: INSPECTION
Make sure the engine coolant level is between full
and low.
CO-52
COOLANT FILLER TANK

COOLING
12.Coolant Filler Tank
B: INSTALLATION
A: REMOVAL
WARNING:
1) Drain the coolant about 3.0 2 (3.2 US qt, 2.6
lmp qt). <Ref. to CO-26, DRAINING OF ENGINE
COOLANT, REPLACEMENT, Engine Coolant.>
2) Remove the air cleaner upper cover and air intake boot. <Ref. to IN(TURBO)-7, REMOVAL, Air
Cleaner.>
4) Disconnect the engine coolant hoses from coolant filler tank.
Tightening torque:
T1: 19 Nm (1.9 kgf-m, 13.7 ft-lb)
T2: 21 Nm (2.1 kgf-m, 15.2 ft-lb)
T1
T2
EN0125
EN0127
5) Remove the bolts and nut which install coolant

filler tank.
6) Disconnect the engine coolant hose which connects under side of coolant filler tank.
7) Remove the coolant filler tank.
2) Fill engine coolant. <Ref. to CO-26, FILLING OF

ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
EN0126
CO-53
ENGINE COOLING SYSTEM TROUBLE IN GENERAL

COOLING
13.Engine Cooling System Trouble in General

A: INSPECTION
Trouble
Over-heating
Over-cooling
Engine coolant
leaks.
Noise
Possible cause
Corrective action
Replenish the engine coolant, inspect for leakage, and
a. Insufficient engine coolant
repair.
b. Loose timing belt
Repair or replace the 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 EN-2, Basic Diagnostic Procedure.> or <Ref. to
g. Improper ignition timing
EN(w/oOBD)-2, Basic Diagnostic Procedure.> or <Ref.
to EN(TURBO)-2, PROCEDURE, Basic Diagnostic Procedure.>
h. Clogged or leaking radiator
Clean or repair, or replace.
i. Improper engine oil in engine coolant
Replace the engine coolant.
Inspect and repair the fuel injection system.
<Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to
j. Air/fuel mixture ratio too lean
EN(w/oOBD)-2, Basic Diagnostic Procedure.> or <Ref.
to EN(TURBO)-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
Adjust.
o. Improper transmission oil
Replace.
p. Defective thermostat
Replace.
Inspect the radiator fan relay, engine coolant temperaq. Malfunction of electric fan
ture sensor or radiator motor and replace there.
a. Atmospheric temperature extremely low
Partly cover the radiator front area.
b. Defective thermostat
Replace.
a. Loosened or damaged connecting units on hoses Repair or replace.
b. Leakage from water pump
Replace.
c. Leakage from water pipe
Repair or replace.
d. Leakage around cylinder head gasket
Retighten the cylinder head bolts or replace gasket.
e. Damaged or cracked cylinder head and crankcase Repair or replace.
f. Damaged or cracked thermostat case
Repair or replace.
g. Leakage from radiator
Repair or replace.
a. Defective drive belt
Replace.
b. Defective radiator fan
Replace.
c. Defective water pump bearing
Replace the water pump.
d. Defective water pump mechanical seal
Replace the water pump.
CO-54
LUBRICATION
LU
1.
2.
3.
4.
5.
6.
7.
8.
9.
Page
Oil Pressure System ...................................................................................7
Engine Oil..................................................................................................10
Oil Pump ...................................................................................................12
Oil Pan and Strainer..................................................................................16
Oil Pressure Switch...................................................................................21
Engine Oil Cooler ......................................................................................22
Engine Oil Filter.........................................................................................24
Engine Lubrication System Trouble in General.........................................25
GENERAL DESCRIPTION
LUBRICATION
A: SPECIFICATIONS
Lubrication method
Pump type
Inner rotor
Outer rotor
Number of teeth
Outer rotor diameter thickness
Tip clearance between inner and outer rotor
Oil pump
Side clearance between inner rotor and pump

case
Case clearance between outer rotor and pump
case
600 rpm
Discharge
5,000 rpm
Discharge
Capacity at
80C (176F)
STANDARD
LIMIT
STANDARD
LIMIT
STANDARD
LIMIT
- pressure
- quantity
- pressure
- quantity
Type
157 kPa (1.6 kg/cm2, 23 psi)

80 70 mm (3.15 2.76 in)
M 20 1.5
By-pass valve opening pressure

Outer diameter width
Oil filter to engine thread size
69 kPa (0.7kg/cm2, 10 psi)

Immersed contact point type
12 V 3.4 W or less
Relief valve (on rocker shaft) operation pressure

Type
Working voltage wattage
14.7 kPa (0.15 kg/cm2, 2.1 psi)
Warning light activation pressure

Proof pressure
Oil capacity (at replacement)
294 kPa (3.0 kg/cm2, 43 psi)

32.6 2 (8.6 US gal, 7.2 Imp gal)/min.
1,000 cm2 (155 sq in)
Filtration area
Oil pressure
switch
98 kPa (1.0 kg/cm2, 14 psi)

3.2 2 (3.4 US qt, 2.8 Imp qt)/min.
490 kPa (5.0 kg/cm2, 71 psi)

Full-flow filter type
Relief valve operation pressure
Oil filter
Forced lubrication
Trochoid type
9
10
78 7 mm (3.07 0.28 in)
0.04 0.14 mm (0.0016 0.0055 in)
0.18 mm (0.0071 in)
0.02 0.07 mm (0.0008 0.0028 in)
0.12 mm (0.0047 in)
0.10 0.175 mm (0.0039 0.0069 in)
0.20 mm (0.0079 in)
Non-Turbo model
Turbo model
LU-2
More than 981 kPa (10 kg/cm2, 142 psi)

4.0 2 (4.2 US qt, 3.5 Imp qt)
4.5 2 (4.8 US qt, 4.0 Imp qt)
GENERAL DESCRIPTION
LUBRICATION
B: COMPONENT
1. NON-TURBO MODEL
EN1491
(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
Oil filler cap
O-ring
Baffle plate
O-ring
Oil strainer
O-ring
Oil pan
Oil level gauge
Drain plug
Metal gasket
LU-3
(27)
Gasket

T1: 5 (0.5, 3.6)
T2: 5 (0.5, 3.6)
T3: 6.4 (0.65, 4.7)
T4: 10 (1.0, 7.2)
T5: 44 (4.5, 32.5)
T6: 6.4 (0.65, 4.7)
T7: 25 (2.5, 18.1)
T8: 44 (4.5, 32.5)
GENERAL DESCRIPTION
LUBRICATION
2. TURBO MODEL
(16)
T8
(17)
T7
(15)
(18)
T3
(14)
(19)
T3
(20)
(29)
(9)
T6
T2
T3
(8)
(21)
(13)
(6)
(7)
(12)
(23)
(22)
(24)
(26)
T7
(5)
(4)
(3)
(1)
(11)
T4
T10
(2)
T1
T1
T5
(10)
T9
(28)
(25)
(27)
EN1492
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Plug
Gasket
Relief valve spring
Relief valve
Oil seal
Oil pump case
Inner rotor
Outer rotor
Oil pump cover
Oil filter
Connector
Water by-pass pipe
Oil cooler
O-ring
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
Oil pump ASSY

Oil pressure switch
Oil filler duct
O-ring
Cylinder head cover
Baffle plate
O-ring
Oil strainer
Gasket
Oil pan
Oil level gauge
Metal gasket
Drain plug
LU-4
(29)
O-ring

T1: 5 (0.5, 3.6)
T2: 5 (0.5, 3.6)
T3: 6.4 (0.65, 4.7)
T4: 10 (1.0, 7.0)
T5: 44 (4.5, 32.5)
T6: 69 (7.0, 50.9)
T7: 6.4 (0.65, 4.7)
T8: 25 (2.5, 18.1)
T9: 44 (4.5, 32.5)
T10: 54 (5.5, 40)
GENERAL DESCRIPTION
LUBRICATION
C: CAUTION
points.
cable from battery.
LU-5
GENERAL DESCRIPTION
LUBRICATION
D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
499977100
DESCRIPTION
CRANK PULLEY
WRENCH
REMARKS
bolt. (2500 cc model)
499977300
CRANK PULLEY
WRENCH

bolt. (1600 cc and 2000 cc model)
498547000
OIL FILTER
WRENCH
499587100
OIL SEAL
INSTALLER
B2M3870
B2M4157
B2M3872
B2M3875
LU-6
OIL PRESSURE SYSTEM

LUBRICATION
2. Oil Pressure System

A: SCHEMATIC
1. NON-TURBO MODEL
BATTERY
No.13
SBF-4
4
SBF-1
1
IGNITION
B72 SWITCH
RHD
LHD
MT
AT
B36
B36
i1
22
23
B38
i1
i3
MT
AT
RHD
A7
LHD
A:
i10
B:
i11
B2
OIL PRESSURE
WARNING LIGHT
COMBINATION
METER
i2
LHD : 23
RHD : 14
B37
B21
E2
E11
E
OIL PRESSURE
SWITCH
A:
B72
1 2
3 4
1 2 3 4 5 6 7 8 9 10
LHD:
i11
B21
i2
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
3 4
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
B:
i10
B36
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
RHD:
i1
1 2 3
4 5 6
7 8 9 10 11 12 13 14
RHD:
i3
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
1 2
(LHD)
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
(RHD)
EN1381
LU-7
OIL PRESSURE SYSTEM

LUBRICATION
2. TURBO MODEL
BATTERY
No.13
SBF-4
4
SBF-1
1
IGNITION
B72 SWITCH
RHD
LHD
MT
AT
B36
B36
i1
22
23
B38
i1
i3
MT
AT
RHD
A7
LHD
A:
i10
B:
i11
B2
OIL PRESSURE
WARNING LIGHT
COMBINATION
METER
23
LHD
RHD
i2
14
B209
SMJ
i2
B76
B37
F61
B21
14
14
I1
B37
E2
E2
E11
E11
OIL PRESSURE
SWITCH
A:
B72
1 2
3 4
OIL PRESSURE
SWITCH
B:
i10
1 2 3 4 5 6 7 8 9 10
i2
i11
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
(LHD)
LHD:
B36
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
RHD:
F61
i3
B21
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
1 2
RHD:
i1
1 2 3
4 5 6
7 8 9 10 11 12 13 14
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
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 32
(RHD)
B209
A1 K2 A3
B1 L2
C1 M2 C3
D1 N2
E1
K4 A5
L4 B5
M4 C5
N4 D5
E5
F1
F5
Q4 G5
G1 Q2
H1 R2 H3 R4 H5
I1 S2
S4 I5
J1 T2 J3 T4 J5
EN1382
LU-8
OIL PRESSURE SYSTEM

LUBRICATION
B: INSPECTION
1
Step
Check
Yes
Does the warning lights go on? Go to step 2.
CHECK COMBINATION METER.
1)Turn the ignition switch to ON. (engine OFF)
2)Check other warning lights.
CHECK HARNESS CONNECTOR BETWEEN Is the voltage more than 10 V?

COMBINATION METER AND OIL PRESSURE SWITCH.
2)Disconnect the connector from oil pressure
switch.
3)Turn the ignition switch ON.
4)Measure the voltage of harness between the
combination meter connector and chassis
ground.
(E11) No. 1 (+) Chassis ground (-):
?
2)Remove the combination meter.
3)Measure the resistance of combination
meter.
Terminal
No. A7 No. B2:
LU-9
Replace the oil

pressure switch.
Replace the harness connector

between combination meter and oil
pressure switch.
No
Repair or replace
the combination
meter. <Ref. to
IDI-5, INSPECTION, Combination Meter
System.>
Go to step 3.
Repair or replace
the combination
meter and the oil
pressure switch
warning light bulb.
ENGINE OIL
LUBRICATION
3. Engine Oil
B: REPLACEMENT
A: INSPECTION
1) Drain the engine oil by loosening the engine oil

drain plug.
Non-Turbo MODEL

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 F line.
5) After turning off the engine, wait a few minutes
for the oil to drain back into the oil pan before
checking the level.
6) Just after driving or while the engine is warm, engine oil level may show in the range between the
F line and notch mark. This is caused by thermal
expansion of the engine oil.
7) To prevent overfilling the engine oil, do not add
oil above the F line when the engine is cold.
(A)
(B)
EN0009
Turbo MODEL
(A)
(B)
EN0010
(A) Gasket
(B) Drain plug
B2M3883A
2) Open the engine oil filler cap for quick draining of

the engine oil.
B2M3883A
3) Replace the drain plug gasket.
LU-10
ENGINE OIL
LUBRICATION
4) Tighten the engine oil drain plug after draining

engine oil.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
Non-Turbo MODEL
Engine oil capacity: (Turbo model)

Upper level
4.5 2 (4.8 US qt, 4.0 Imp qt)
Lower level
3.5 2 (3.7 US qt, 3.1 Imp qt)
(A)
(B)
B2M3885A
EN0009
The proper viscosity helps vehicle get good cold

and hot starting by reducing viscous friction and
thus increasing cranking speed.
Turbo MODEL
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.
(A)
(B)
EN0010
(A) Gasket
(B) Drain plug
5) Fill engine oil through the filler pipe up to upper

point on level gauge. Make sure that the vehicle is
placed level when checking oil level. Use the engine oil of proper quality and viscosity, selected in
accordance with the table in figure.
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.)
NOTE:
If the vehicle is used in desert areas with very high
temperatures or for other heavy duty applications,
the following viscosity oils may be used: API classification: SL or SJ or SH
SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W50.
6) Close the engine oil filler cap.
7) Start the engine and warm it up for a time.
8) After the engine stops, recheck the oil level. If
necessary, add engine oil up to the upper level on
level gauge.
Engine oil capacity: (Non-Turbo model)

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)
B2M3883A
LU-11
OIL PUMP
LUBRICATION
4. Oil Pump
7) Remove the crankshaft position sensor.
A: REMOVAL
B2M1252
G6M0095

4) Remove the bolts which install water pipe of oil
cooler to oil pump. (Turbo model)
8) Remove the V-belts. <Ref. to ME-44, REMOVAL, V-belt.> or <Ref. to ME(TURBO)-44, REMOVAL, V-belt.>
9) Remove the rear side V-belt tensioner.
S2M0113
S2M0027
5) Remove the water pipe and hoses between oil

cooler and water pump. (Turbo model)
10) Remove the crankshaft pulley by using ST.

1600 cc and 2000 cc model:
ST 499977300
CRANKSHAFT PULLEY
WRENCH
2500 cc model:
ST 499977100
CRANKSHAFT PULLEY
WRENCH
S2M0112
6) Remove the radiator. <Ref. to CO-39, REMOVAL, Radiator.>
S2M0114
11) Remove the water pump. <Ref. to CO-28, REMOVAL, Water Pump.>
LU-12
OIL PUMP
LUBRICATION
12) Remove the timing belt guide. (MT vehicles

only)
B: INSTALLATION
Do the following:
1) Apply fluid packing to the matching surfaces of
oil pump.
Fluid packing:
S2M0115
S2M0739B
2) Replace the O-ring (A) with a new one.

3) Apply a coat of engine oil to the inside of oil seal.
S2M0116
14) Remove the bolts which install oil pump onto

cylinder block.
S2M0118B
4) Be careful not to scratch the oil seal when installing oil pump on cylinder block.
5) Position the oil pump, aligning the notched area
with crankshaft, and push the oil pump straight.
S2M0117
15) Remove the oil pump by using flat bladed

screwdriver.
CAUTION:
Be careful not to scratch the mating surfaces of
CAUTION:
Make sure the oil seal lip is not folded.
6) Install the oil pump.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
S2M0740B
S2M1819
LU-13
OIL PUMP
LUBRICATION
C: DISASSEMBLY
D: ASSEMBLY
Remove the screws which secure oil pump cover

and 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 by using ST.

ST 499587100
OIL SEAL INSTALLER
NOTE:
Use a new oil seal.
CAUTION:
Before removing the relief valve, loosen the
plug when removing oil pump from cylinder
block.
S2M0235A
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.
5) Install the oil pump cover.
Tightening torque:
T1: 5 Nm (0.5 kgf-m, 3.6 ft-lb)
T2: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
S2M0735A
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
Oil seal
Pump case
Inner rotor
Outer rotor
Pump cover
Relief valve
Relief valve spring
Plug
Gasket
S2M0735B
LU-14
OIL PUMP
LUBRICATION
E: INSPECTION
3. SIDE CLEARANCE
1. TIP CLEARANCE
Measure the clearance between the oil pump inner

rotor and pump cover. If clearance exceeds the limit, replace the rotor or pump body.
Measure the tip clearance of rotors. If clearance exceeds the limit, replace the rotors as a matched set.
Tip clearance:
Standard
0.04 0.14 mm (0.0016 0.0055 in)
Limit
0.18 mm (0.0071 in)
Side clearance:
Standard
0.02 0.07 mm (0.0008 0.0028 in)
Limit
0.12 mm (0.0047 in)
S2M0738
S2M0736
4. OIL RELIEF VALVE
2. CASE CLEARANCE
Measure the clearance between the outer rotor and
cylinder block rotor housing. If clearance exceeds
the limit, replace the rotor.
Case clearance:
Standard
0.10 0.175 mm (0.0039 0.0069 in)
Limit
0.20 mm (0.0079 in)
Check the valve for fitting condition and damage,

and the relief valve spring for damage and deterioration. Replace the parts if defective.
Relief valve spring:
Free length
71.8 mm (2.827 in)
Installed length
54.7 mm (2.154 in)
Load when installed
77.08 N (7.86 kgf, 17.33 lb)
5. OIL PUMP CASE

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.
S2M0737
LU-15
OIL PAN AND STRAINER

LUBRICATION
5. Oil Pan and Strainer
A: REMOVAL
2) Remove the front wheels.
H3M1839

Non-Turbo MODEL
G6M0095
4) Remove the air intake duct and air cleaner case.

(Non-Turbo model)
5) Disconnect the connector from mass air flow
sensor. (Turbo model)
B2M2931
Turbo MODEL
EN0031
6) Remove the air intake boot and air cleaner upper

cover. (Turbo model)
EN0035

wire ropes.
EN0032
7) Remove the intercooler (Turbo model) <Ref. to

IN(TURBO)-10, REMOVAL, Intercooler.>
G2M0297

CAUTION:
At this time, raise up the wire ropes.
LU-16

LUBRICATION
13) Drain the engine oil.

Set a container under the vehicle, and remove the
drain plug from oil pan.
Non-Turbo MODEL
17) Insert the oil pan cutter blade between the cylinder block-to-oil pan clearance.
CAUTION:
of oil pan cutter.
Non-Turbo MODEL
(A)
(B)
EN0009
Turbo MODEL
EN0040
Turbo MODEL
(A)
(B)
EN0010
(A) Gasket
(B) Drain plug
EN0041
14) Remove the front and center exhaust pipes.

(Non-Turbo model) <Ref. to EX-7, REMOVAL,
Front Exhaust Pipe.> or <Ref. to EX(w/oOBD)-9,
REMOVAL, Front Exhaust Pipe.>
S2M0238
S2M1831
16) Remove the bolts which install oil pan on cylinder block while raising up engine.
S2M0309
LU-17

LUBRICATION
B: INSTALLATION
CAUTION:
Before installing the oil pan, clean sealant from
oil pan and engine block.
4) Tighten the bolts which install the oil pan onto

engine block.
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
Non-Turbo MODEL
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
EN0040
Turbo MODEL
S2M0309
2) Install the oil strainer onto baffle plate.

NOTE:
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
EN0041
5) Lower the engine onto front crossmember.

6) Tighten the nuts which install front cushion rubber onto front crossmember.
Tightening torque:
69 Nm (7.0 kgf-m, 50.9 ft-lb)
S2M0238
3) Apply fluid packing to the mating surfaces and

install oil pan.
Fluid packing:
S2M1831
S2M1833A
LU-18

LUBRICATION
7) Install the front and center exhaust pipes. (NonTurbo model)

Pipe.> or <Ref. to EX(w/oOBD)-10, INSTALLATION, Front Exhaust Pipe.>
12) Install the radiator upper brackets.

Non-Turbo MODEL
NOTE:
B2M2931
Turbo MODEL
B2M3200

CAUTION:
At this time, lower the lifting device and release
steel cables.
10) Remove the lifting device and steel cables.
EN0035
13) Install the air intake duct and air cleaner case.
(Non-Turbo model)
<Ref. to IN-6, INSTALLATION, Air Cleaner Case.>
and <Ref. to IN-7, INSTALLATION, Air Intake
Duct.>
14) Install the intercooler. (Turbo model) <Ref. to
IN(TURBO)-11, INSTALLATION, Intercooler.>
15) Install the air intake boot and air cleaner upper
cover. (Turbo model)
G2M0297

Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
EN0032
H3M1839A
LU-19

LUBRICATION
16) Connect the connector to mass air flow sensor.

(Turbo model)
EN0031
17) Install the front wheels.

G6M0095
19) Fill engine oil. <Ref. to LU-10, INSPECTION,

Engine Oil.>
C: INSPECTION
By visual check make sure the oil pan, oil strainer,
oil strainer stay and baffle plate are not damaged.
LU-20
OIL PRESSURE SWITCH

LUBRICATION
6. Oil Pressure Switch
B: INSTALLATION
A: REMOVAL
1) Apply fluid packing to the oil pressure switch

threads.
1) Remove the generator from bracket. <Ref. to

SC-14, REMOVAL, Generator.>
2) Disconnect the terminal from oil pressure switch.
Fluid packing:
S2M0124B
G2M0091
2) Install the oil pressure switch onto engine block.
3) Remove the oil pressure switch.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
S2M0119
S2M0119
3) Connect the terminal of oil pressure switch.
G2M0091
4) Install the generator on bracket. <Ref. to SC-14,

INSTALLATION, Generator.>
C: INSPECTION
Make sure oil does not leak or seep from where the
oil pressure switch is installed.
LU-21
ENGINE OIL COOLER

LUBRICATION
7. Engine Oil Cooler
7) Remove the connector and remove oil cooler.
A: REMOVAL
3) Drain the engine oil.
Set a container under the vehicle, and remove the
drain plug from oil pan.
(A)
(B)
EN0010
(A) Gasket
(B) Drain plug
4) Drain the engine coolant.

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

LUBRICATION
B: INSTALLATION
C: INSPECTION
1) Check that the coolant passages are not

clogged using air blow method.
2) Check the mating surfaces of cylinder block, Oring groove and oil filter for damage.
Tightening torque:
T: 54 Nm (5.5 kgf-m, 40 ft-lb)
NOTE:
Always use a new O-ring.
G2M0784
LU-23
ENGINE OIL FILTER

LUBRICATION
8. Engine Oil Filter

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

LUBRICATION
9. Engine Lubrication System Trouble in General

A: INSPECTION
Before performing diagnostics, make sure that the engine oil level is correct and no oil leakage exists.
Trouble
1) Oil pressure switch
failure
1. Warning light remains

on.
2) Low oil pressure
3) No oil pressure
2. Warning light does

not go on.
3. Warning light flickers

momentarily.
Possible cause
Cracked diaphragm or oil leakage within switch
Broken spring or seized contacts
Clogged oil filter
Malfunction of oil by-pass valve of oil filter
Malfunction of oil relief valve of oil pump
Clogged oil passage
Excessive tip clearance and side clearance of oil
pump rotor and gear
Clogged oil strainer or broken pipe
Insufficient engine oil
Broken pipe of oil strainer
Stuck oil pump rotor
1) Burn-out bulb
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-25
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).
ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL

LUBRICATION
LU-26
SP
1.
2.
3.
Page
Accelerator Pedal........................................................................................4
Accelerator Control Cable ...........................................................................9
GENERAL DESCRIPTION
A: SPECIFICATION
Accelerator pedal
Free play
Stroke
At pedal pad
At pedal pad
1 4 mm (0.04 0.16 in)

52 57 mm (2.05 2.24 in)
B: COMPONENT
1. LHD MODEL
B2M4176A
(1)
(2)
(3)
(4)
(5)
(6)
Accelerator bracket
Stopper
Bushing
Clip
Accelerator spring
Accelerator pedal spring
(7)
(8)
(9)
(10)
(11)
(12)
Accelerator pedal lever

Spring pin
Accelerator pedal
Accelerator stopper
Accelerator plate
Clip
SP-2
(13)
Kick-down switch (AT model)

T: 18 (1.8, 13.0)
GENERAL DESCRIPTION
2. RHD MODEL
EN1493
(1)
(2)
(3)
(4)
(5)
Accelerator bracket
Stopper
Accelerator pedal
(6)
(7)
(8)
(9)
(10)
Spring pin
Accelerator spring
Bushing
Clip
Accelerator stopper
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.
points.
cable from battery.
SP-3
(11)
Kick-down switch (AT model).

T: 18 (1.8, 13.0)
ACCELERATOR PEDAL
2. Accelerator Pedal
RHD SOHC MODEL
A: REMOVAL
(C)
(B)

2) Remove the lock nut from accelerator cable
bracket.
3) Separate the accelerator cable from bracket.
4) Remove the accelerator cable end from throttle
cam.
5) Disconnect the accelerator cable from throttle
body.
CAUTION:
Be careful not to kink the accelerator cable.
SOHC MODEL
(E)
(E)
(D)
(E)
(A)
(E)
EN0921
LHD DOHC turbo MODEL

(D)
(E)
(A)
(E)
(A)
(B)
(C)
(E)
(D)
(B) (C)
EN0918
(E)
RHD DOHC turbo MODEL
DOHC turbo MODEL
(B)
(A)
EN0922
(E)
(C)
(C)
(D)
(D)
(B)
(A)
(E)
EN0923
EN0919
(A)
(B)
(C)
(D)
(A)
(B)
(C)
(D)
(E)
Lock nut
Accelerator cable
Throttle cam
6) Remove the clip inside engine compartment.

LHD SOHC MODEL
(A)
(D)
7) Remove the instrument panel lower cover from

instrument panel, and connector.
8) Disconnect the connector from kick-down
switch. (AT model)
9) Remove the brake and clutch pedal bracket.
(LHD MT model) <Ref. to BR-65, REMOVAL,
Brake Pedal.>
(C)
(E)
Toe board
Accelerator cable
To accelerator pedal
Brake booster
Clip
(E)
(B)
EN0920
SP-4
ACCELERATOR PEDAL
10) Remove the accelerator pedal connecting bolt

from accelerator pedal bracket.
LHD MODEL
13) Disconnect the accelerator cable bushing from

accelerator pedal lever.
B4M1741B
EN0924
(A) Slot type screwdriver
RHD MODEL
14) Disconnect the accelerator cable stopper (A)

from bracket.
EN0925
11) Disconnect the grommet from toe board.
B4M1742B
NOTE:
From the inside compartment, push the grommet
(A) into hole.
15) Separate the accelerator cable and bracket.
B: INSTALLATION
CAUTION:
If the cable clamp is damaged, replace it with
a new one.
Never fail to cover the outer cable end with
boot.
Always use new clevis pins.
B4M1740C
12) Pull out the cable from toe board hole.
SP-5
ACCELERATOR PEDAL
C: DISASSEMBLY
RHD MODEL
1) Remove the clip, and then remove the accelerator pedal from bracket.
2) Pull out the spring pin, and then remove the accelerator pedal from accelerator pedal lever.
LHD MODEL
EN1494
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
(J)
EN0926
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
(J)
Accelerator bracket
Stopper
Bushing
Clip
Accelerator spring
Spring pin
Accelerator pedal
Accelerator bracket
Stopper
Bushing
Clip
Accelerator spring
Spring pin
Accelerator pedal
D: ASSEMBLY
CAUTION:
Clean and apply grease to the portions indicated in the figure.
Grease:
Nigtight LYW No.2 or equivalent
SP-6
ACCELERATOR PEDAL
E: INSPECTION
F: ADJUSTMENT
1. ACCELERATOR PEDAL
Lightly move the pedal pad in lateral direction to ensure that pedal deflection is in specified range.
CAUTION:
If excessive deflection is noted, replace the
bushing and clip with new ones.
1) Check the pedal stroke and free play by operating accelerator pedal by hand.
If it is not within specified value, adjust it by turning
the nut connecting the accelerator cable to throttle
body.
Free play at pedal pad: L
1 4 mm (0.04 0.16 in)
Deflection of accelerator pedal:

Service limit
5.0 mm (0.197 in) or less
Stroke at pedal pad: A

52 57 mm (2.05 2.24 in)
G4M0333
2. KICK-DOWN SWITCH
If the kick-down switch does not operate properly
(or if it does not stop at the specified position), replace with a new one.
Specified position: A
2+1.5/0 mm (0.079 +0.059/0 in)
B4M1739A
(A) Accelerator pedal

(B) Accelerator pedal bracket
Accelerator cable lock nut tightening torque:

12 Nm (1.2 kgf-m, 9 ft-lb)
B4M0155A
SP-7
ACCELERATOR PEDAL
2) Check to ensure the kick-down switch operates

at the specified value in relation to the stroke of the
accelerator pedal.
If it is not within specified value, adjust it by adjusting the position of kick-down switch.
CAUTION:
Be careful not to rotate the kick-down switch.
Kick-down switch stroke: A
481 mm (1.890.04 in)
Kick-down switch tightening torque:
12 Nm (1.2 kgf-m, 9 ft-lb)
B4M1758C
(A) Kick down switch
SP-8
ACCELERATOR CONTROL CABLE

3. Accelerator Control Cable

A: REMOVAL
1) Remove the accelerator pedal. <Ref. to SP-4,
REMOVAL, Accelerator Pedal.>
2) Separate the accelerator cable and accelerator
pedal.
B: INSTALLATION
CAUTION:
a new one.
boot.
Do not apply grease to the throttle cable on
engine side.
2) Adjustment after pedal installation. <Ref. to SP5, INSTALLATION, Accelerator Pedal.>
C: INSPECTION
1) Make sure the inner cable is not twisted or
frayed.
2) Make sure the outer cable is not cracked.
SP-9
ACCELERATOR CONTROL CABLE

SP-10
IGNITION
IG
1.
2.
3.
4.
Page
Spark Plug...................................................................................................5
Ignition Coil and Ignitor Assembly...............................................................8
Spark Plug Cord........................................................................................10
GENERAL DESCRIPTION
IGNITION
A: SPECIFICATIONS
Item
Ignition coil
and ignitor
assembly
Designation
CM12100C
1600 cc
Model
2000 cc and
2500 cc
1600 cc
Manufacturer
2000 cc and
2500 cc
1600 cc
Primary coil resistance 2000 cc and
2500 cc
1600 cc
Secondary coil resis2000 cc and
tance
2500 cc
Insulation resistance between primary
terminal and case
FH0137
HITACHI
DIAMOND
0.7 10%
0.73 10%
13.0 k20%
12.8 k15%
More than 100 M
CHAMPION: RC8YC4
NGK: BKR6E-11 (Alternate)
CHAMPION: RC10YC4
14, P = 1.25
1.0 1.1 (0.039 0.043)
1600 cc
Type and manufacturer
Spark plug
Thread size
Spark gap
2000 cc and
2500 cc
mm
mm (in)
IG-2
GENERAL DESCRIPTION
IGNITION
B: COMPONENT
1. 1600 CC MODEL
T1
(3)
(2)
(2)
(1)
T2
(4)
(4)
T2
EN1039
S6M0329B
(1)
(2)
(3)
Spark plug
Spark plug cord (#1, #3)
Ignition coil and ignitor ASSY
(4)
IG-3

T1: 6.4 (0.65, 4.7)
T2: 21 (2.1, 15.2)
GENERAL DESCRIPTION
IGNITION
2. 2000 CC AND 2500 CC MODEL
S6M0329B
(1)
(2)
(3)
Spark plug
(4)
C: CAUTION

T1: 21 (2.1, 15.2)
T2: 6.4 (0.65, 4.7)

points.
cable from battery.
IG-4
SPARK PLUG
IGNITION
2. Spark Plug
2. LH SIDE
A: REMOVAL
CAUTION:
All spark plugs installed on an engine, must be
of the same heat range.
1600 cc
2000 cc
and
2500 cc
Spark plug
CHAMPION: RC8YC4
CHAMPION: RC10YC4
G6M0095
1. RH SIDE
2) Disconnect the washer motor connector.
B6M0562
G6M0095

suitable cap.
4) Remove the two bolts which hold washer tank,
then take the tank away from the working area.
2) Remove the resonator chamber. <Ref. to IN-8,

REMOVAL, Resonator Chamber.>
3) Remove the spark plug cords by pulling boot, not
the cord itself.
B2M2023
B2M4127
5) Remove the spark plugs cord by pulling boot, not

the cord itself.
4) Remove the spark plugs with spark plug sockets.
B2M4287
B2M4286
IG-5
SPARK PLUG
IGNITION
C: INSPECTION
Check the electrodes and inner and outer porcelain

of plugs, noting the type of deposits and the degree
of electrode erosion.
B2M4288
B: INSTALLATION
S6M0420A
1. RH SIDE
(A)
(B)
(C)
(D)
(E)

Tightening torque (Spark plug):
21 Nm (2.1 kgf-m, 15.2 ft-lb)
CAUTION:
The above torque should be only applied to
new spark plugs without oil on their threads.
In case their threads are lubricated, the torque
should be reduced by approx. 1/3 of the specified torque in order to avoid over-stressing.
Electrode gap
Carbon accumulation or wear
Cracks
Damage
Damaged gasket
1) Normal:
Brown to grayish-tan deposits and slight electrode
wear indicates correct spark plug heat range.
2. LH SIDE
21 Nm (2.1 kgf-m, 15.2 ft-lb)
CAUTION:
G6M0087
2) Carbon fouled:
Dry fluffy carbon deposits on insulator and electrode are mostly caused by slow speed driving in
city, weak ignition, too rich fuel mixture, dirty air
cleaner, etc.
It is advisable to replace with plugs having hotter
heat range.
G6M0088
IG-6
SPARK PLUG
IGNITION
E: ADJUSTMENT
3) Oil fouled:
Wet black deposits show excessive oil entrance
into combustion chamber through worn rings and
pistons or excessive clearance between valve
guides and stems. If the same condition remains
after repair, use a hotter plug.
Correct it if the spark plug gap is measured with a

gap gauge, and it is necessary.
Spark plug gap: L
1.0 1.1 mm (0.039 0.043 in)
S6M0412B
G6M0089
4) Overheating:
White or light gray insulator with black or gray
brown spots and bluish burnt electrodes indicates
engine overheating. Moreover, the appearance results from incorrect ignition timing, loose spark
plugs, wrong selection of fuel, hotter range plug,
etc. It is advisable to replace with plugs having
colder heat range.
NOTE:
Replace with a new spark plug if this area (A) is
worn to ball shape.
G6M0090
D: CLEANING
Clean the spark plugs in a sand blast type cleaner.
Avoid excessive blasting. Clean and remove the
carbon or oxide deposits, but do not wear away
porcelain.
If deposits are too stubborn, replace the spark
plugs.
IG-7
IGNITION COIL AND IGNITOR ASSEMBLY

IGNITION
3. Ignition Coil and Ignitor Assembly

1600 cc MODEL
A: REMOVAL
EN1044

G6M0095
2) Disconnect the spark plug cords from ignition

coil and ignitor assembly.
1600 cc MODEL
B6M0930
B: INSTALLATION
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
EN1040
CAUTION:
Be sure to connect wires to their proper positions. Failure to do so will damage unit.
1600 cc MODEL
S6M0373

ignitor assembly.
EN1044
IG-8

IGNITION
Specified resistance: (2000 cc and 2500 cc)

[Primary side]
Between terminal No. 1 and No. 2
0.73 10%
0.73 10%
B6M0930
C: INSPECTION
Using the accurate tester, inspect the following

items, and replace if defective.
1) Primary resistance
2) Secondary coil resistance
EN1041
CAUTION:
If the resistance is extremely low, this indicates
the presence of a short-circuit.
[Secondary side]
Between (A) and (B)
12.8 k15%
Between (C) and (D)
12.8 k15%
Specified resistance:(1600 cc)

[Primary side]
0.7 10%
0.7 10%
(C)
(A)
(D)
(B)
EN1043
3) Insulation between primary terminal and case:

100 M or more.
EN1041
[Secondary side]
Between (A) and (B)
13.0 k20%
Between (C) and (D)
13.0 k20%
(C)
(D)
(A)
(B)
EN1042
IG-9
SPARK PLUG CORD

IGNITION
4. Spark Plug Cord

A: INSPECTION
Check for:
1) Damage to cords, deformation, burning or rust
formation of terminals
2) Resistance values of cords
Resistance value:
#1 cord: 5.6 10.6 k
#2 cord: 7.3 13.7 k
#3 cord: 5.9 11.1 k
#4 cord: 7.3 13.7 k
S6M0337
IG-10
SC
1.
2.
3.
4.
Page
Starter .........................................................................................................5
Generator ..................................................................................................14
Battery.......................................................................................................20
GENERAL DESCRIPTION
A: SPECIFICATIONS
Starter
Item
Type
Vehicle type
Model
Manufacturer
Voltage and output
Direction of rotation
Number of pinion teeth
Voltage
No-load characCurrent
teristics
Rotating speed
Voltage
Load character- Current
istics
Torque
Rotating speed
Voltage
Lock characterCurrent
istics
Torque
Type
Generator
Model
Manufacturer
Voltage and output
Polarity on ground side
Rotating direction
Armature connection
Output current
Regulated voltage
Designation
Reduction type
MT vehicles
M000T83981
AT vehicles
M001T86381
Mitsubishi Electric
12 V 1.0 kW
12 V 1.4 kW
Counterclockwise (when observed from pinion)
8
9
11 V
90 A or less
2,800 rpm or more
2,400 rpm or more
7.5 V
7.7 V
300 A
400 A
8.6 N (0.88 kgf, 1.93 lb) or more
16.0 N (1.63 kgf, 3.60 lb) or more
920 rpm or more
740 rpm or more
4V
3.5 V
650 A or less
940 A or less
14.7 N (1.50 kgf, 3.30 lb) or more
28.9 N (2.95 kgf, 6.50 lb) or more
Rotating-field three-phase type, Voltage regulator built-in type, with load
response control system
A2TB2891
Mitsubishi Electric
12 V 90 A
Negative
Clockwise (when observed from pulley side)
3-phase Y-type
1,500 rpm 36 A or more
14.1 14.8 V [20C (68F)]
SC-2
GENERAL DESCRIPTION
B: COMPONENT
1. STARTER
H6M0492C
(1)
(2)
(3)
(4)
(5)
(6)
Sleeve bearing
Front bracket
Lever set
Magnet switch ASSY
Stopper set
Over running clutch
(7)
(8)
(9)
(10)
(11)
(12)
Internal gear ASSY

Shaft ASSY
Gear ASSY
Ball
Packing
Yoke
SC-3
(13)
(14)
(15)
(16)
(17)
Armature
Brush holder
Brush
Sleeve bearing
Rear bracket
GENERAL DESCRIPTION
2. GENERATOR
H6M0493C
(1)
(2)
(3)
(4)
Pulley
Front cover
Ball bearing
Bearing retainer
(5)
(6)
(7)
(8)
Rotor
Bearing
Stator coil
IC regulator with brush
C: CAUTION
(9)
(10)
(11)
(12)
Brush
Rectifier
Rear cover
Terminal

points.
cable from battery.
SC-4
STARTER
2. Starter
AT vehicles
A: REMOVAL
EN0370
5) Disconnect the connector and terminal from

starter.
G6M0095
2) Remove the air cleaner case. (Non-Turbo Model)
S6M0002A
(A) Terminal
(B) Connector
B6M1221
3) Remove the intercooler. (Turbo Model) <Ref. to

4) Remove the air cleaner case stay. (Non-Turbo
Model)
MT vehicles
6) Remove the starter from transmission.
EN1007
EN0369
SC-5
STARTER
B: INSTALLATION
2) Remove the bolts which hold switch assembly,

and then remove the switch assembly, plunger and
plunger spring from starter as a unit.

Tightening torque:
50 Nm (5.1 kgf-m, 37 ft-lb)
CAUTION:
Be careful because the pinion gap adjustment
washer may sometimes be used on the mounting surface of switch assembly.
EN1007
C: DISASSEMBLY
B2M4455A
1. STARTER ASSEMBLY
(A) Switch ASSY
(B) Plunger
1) Loosen the nut which holds terminal M of switch

assembly, and then disconnect the connector.
3) Remove both through-bolts and brush holder

screws, and then detach the rear bracket and brush
holder.
CAUTION:
Before removal, confirm the attachment locations of brush holder and rear bracket.
B2M4454A
(A) Terminal M
(B) Terminal B
(C) Terminal S
H6M0494B
(A) Brush holder

(B) Rear bracket
SC-6
STARTER
4) Remove the armature and yoke. The ball used

as a bearing will then be removed from the end of
armature.
CAUTION:
Be sure to mark an alignment mark on the yoke
and front bracket before removing yoke.
6) Remove the shaft assembly and overrunning

clutch as a unit.
CAUTION:
Before removal, confirm the following:
Lever direction
Internal gear assembly position
B2M4458B
H6M0495D
(A)
(B)
(C)
(D)
Armature
Ball
Yoke
Front bracket
(A)
(B)
(C)
(D)
5) Remove the packing A, three planetary gears,

packing B and plate.
CAUTION:
Before removal, confirm the inserting location
of packing A.
B2M4793A
(A)
(B)
(C)
(D)
Packing A
Planetary gear
Plate
Packing B
SC-7
Lever
Shaft ASSY
Overrunning clutch
Internal gear ASSY
STARTER
7) 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 14 mm (0.55 in) socket wrench).
(2) Remove the ring, stopper and clutch from
shaft.
2. BRUSH HOLDER
Slightly open the metal fitting holding the insulating
plate to brush holder. Remove the insulating plate.
NOTE:
The brush and spring can be easily removed from
the brush holder at this time.
H6M0497B
(A) Brush holder

(B) Insulating plate
(C) Metal fitting
B2M4769A
(A)
(B)
(C)
(D)
Socket wrench
Ring
Shaft
Stopper
SC-8
STARTER
D: ASSEMBLY
Assemble in the reverse order of disassembly. Do
the following:
1) Carefully assemble all parts in the order of assembly and occasionally inspect nothing has been
overlooked.
2) When installing the shaft assembly to front
bracket, be careful of the following.
Lever direction
3) When installing the yoke to the front bracket,

match bolt hole.
B2M4773A
(A) Bolt hole
4) When installing the rear bracket, match brush

holder and yoke's groove.
B2M4770
Internal gear position
B2M4774
B2M4771
Packing position
5) When installing the switch assembly, catch

plunger protrusion to lever edge.
6) Apply grease to the following parts during assembly.
Front and rear bracket sleeve bearing
Armature shaft gear
Outer periphery of plunger
Mating surface of plunger and lever
Gear shaft splines
Mating surface of lever and clutch
Ball at the armature shaft end
Internal and planetary gears
7) After assembling parts correctly, make sure the
starter operates properly.
B2M4772
SC-9
STARTER
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 run-out, and then replace if
it exceeds the limit.
4) Armature short-circuit test

Check the armature for short-circuit by placing it on
growler tester. Hold a hacksaw blade against the
armature core while slowly rotating armature. A
short-circuited armature will cause the blade to vibrate and to be attracted to core. If the hacksaw
blade is attracted or vibrates, the armature, which
is short-circuited, must be replaced or repaired.
Commutator run-out:
Standard
0.05 mm (0.0020 in)
Service limit
Less than 0.10 mm (0.0039 in)
S6M0402A
(A) Iron sheet

(B) Grower tester
B2M4460A
(A) Dial gauge

(B) V-block
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.
3) Depth of segment mold

Check the depth of segment mold.
Depth of segment mold:
0.5 mm (0.020 in)
G6M0041
2. YOKE
Make sure the pole is set in position.
3. OVERRUNNING CLUTCH
S6M0401A
(A) Depth of mold

(B) Segment
(C) Mold
Inspect the teeth of pinion for wear and damage.

Replace if it is damaged. Rotate the pinion in direction of rotation (counterclockwise). It should rotate
smoothly. But in opposite direction, it should be
locked.
CAUTION:
Do not clean the overrunning clutch with oil to
prevent grease from flowing out.
SC-10
STARTER
4. BRUSH AND BRUSH HOLDER
5. SWITCH ASSEMBLY
1) Brush length
Measure the brush length, and then replace if it exceeds the service limit.
Replace if abnormal wear or cracks are noticed.
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.
Brush length:
Standard
12.3 mm (0.484 in)
Service limit
7.0 mm (0.276 in)
Terminal / Specified resistance:

S M / Less than 1
S Ground / Less than 1
M B / More than 1 M
S6M0403
H6M0496B
6. SWITCH ASSEMBLY OPERATION
(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
21.6 N (2.2 kgf, 4.9 lb) (when new)
Service limit
5.9 N (0.6 kgf, 1.3 lb)
1) Connect the terminal S of switch assembly to

positive terminal of battery with a lead wire, 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, and
then connect the positive terminal of battery and
terminal M using a lead wire 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.
S6M0393A
(A) Terminal S
(B) Terminal M
SC-11
STARTER
7. PINION GAP
8. PERFORMANCE TEST
1) Measure the pinion gap while the pinion is pulled

out as shown in the figure.
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.
Pinion gap:
0.5 2.0 mm (0.020 0.079 in)
S6M0394A
(A) Pinion
(B) Gap
(C) Stopper
If the motor is running with the pinion forced endwise on shaft, disconnect the connector from terminal M of switch assembly, and then connect
terminal M to ground terminal () of battery with a
lead wire. Next, gently push the pinion back with
your fingertips, and then measure the pinion gap.
2) If the pinion gap is outside specified range, remove or add number of adjustment washers used
on the mounting surface of switch assembly until
correct pinion gap is obtained.
S6M0395A
(A) Variable resistance

(B) Magnetic switch
(C) Starter body
1) No-load test
With switch on, adjust the variable resistance to obtain 11 V, take the ammeter reading, and then measure the starter speed. Compare these values with
the specifications.
No-load test (Standard):
Voltage / Current
11 V / 90 A max.
Rotating speed
MT vehicles
2,800 rpm or more
AT vehicles
2,400 rpm or more
SC-12
STARTER
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.
Load test (Standard):
Voltage / Load
MT vehicles
7.5 V/8.6 N (0.88 kgf, 1.93 lb)
AT vehicles
7.7 V/16.0 N (1.63 kgf, 3.60 lb)
Current / Speed
MT vehicles
300 A/920 rpm or more
AT vehicles
400 A/740 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 vehicles
4 V/650 A or less
AT vehicles
3.5 V/940 A or less
Torque
MT vehicles
14.7 N (1.50 kgf, 3.30 lb) or more
AT vehicles
28.9 N (2.95 kgf, 6.50 lb) or more
SC-13
GENERATOR
3. Generator
Turbo Model
A: REMOVAL
EN0048
G6M0095
2) Disconnect the connector and terminal from

generator.
Non-Turbo Model
4) Remove the front side V-belt.

<Ref. to ME-44, FRONT SIDE BELT, REMOVAL,
V-belt.> or <Ref. to ME(TURBO)-44, FRONT SIDE
BELT, REMOVAL, V-belt.>
5) Remove the bolts which install generator onto
bracket.
B2M3105
S6M0352
B: INSTALLATION
Turbo Model

CAUTION:
Check and adjust the V-belt tension. <Ref. to
ME-45, INSPECTION, V-belt.> or <Ref. to
ME(TURBO)-45, INSPECTION, V-belt.>
EN0046

Non-Turbo Model
S6M0352
B2M3106
SC-14
GENERATOR
C: DISASSEMBLY
1) Heat the portion (A) of rear cover to 50C
(122F) with heater drier.
H6M0498B
(A)
(B)
(C)
(D)
B6M0476B
2) Remove the four through bolts. Then insert the

tip of a flat-head screwdriver into the gap between
stator core and front bracket. Pry them apart to disassemble.
Front bracket
Pulley
Nut
Rotor
4) Unsolder connection between rectifier and stator

coil to remove the stator coil.
CAUTION:
Finish the work rapidly (less than 3 seconds)
because the rectifier cannot withstand heat
very well.
G6M0065A
(A) Screwdriver
3) Hold the rotor with a vise and remove pulley nut.

G6M0068
5) Remove the screws which secure IC regulator to

rear cover, and then unsolder connection between
IC regulator and rectifier to remove the IC regulator.
G6M0066
CAUTION:
When holding the rotor with vise, insert aluminum plates or wood pieces on the contact surfaces of vise to prevent rotor from damage.
G6M0069
SC-15
GENERATOR
6) Remove the brushes by unsoldering at pigtails.
2) Heat the bearing box in rear bracket [50 to 60C

(122 to 140F)], and then press the rear bearing
into rear bracket.
CAUTION:
Grease should not be applied to rear bearing.
Remove the oil completely if it is found on bearing box.
3) After reassembly, turn the pulley by hand to
check that rotor turns smoothly.
E: INSPECTION
G6M0070
7) Remove the nut and insulating bushing at terminal B, and then remove the rectifier.
1. DIODE
CAUTION:
Never use a mega tester (measuring use for
high voltage) or any other similar measure for
this test; otherwise, the diodes may be damaged.
1) Checking positive diode
Check for continuity between the diode lead and
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.
S6M0405A
(A) Ractifier
(B) Rear cover
(C) Nut
D: ASSEMBLY
To assemble, reverse order of disassembly.
1) Pulling up brush
Before assembling, press the brush down into
brush holder with your finger, and then secure in
that position by passing a [2 mm (0.08 in) dia.
length 4 to 5 cm (1.6 to 2.0 in)] wire (A) through the
hole shown in the figure.
CAUTION:
Be sure to remove the wire after reassembly.
S6M0411A
SC-16
S6M0406A
(A) Diode lead

(B) Heat sink (Positive side)
GENERATOR
2) Checking negative diode

Check for continuity between the negative side
heat sink and diode lead. The negative diode is in
good condition if resistance is 1 or less only in the
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.
S6M0407A
G6M0076
5) Ball bearing (rear side)

(1) Check the rear ball bearing. Replace if it is
noisy or if the rotor does not turn smoothly.
(2) The rear bearing can be removed by using
common bearing puller.
(A) Diode lead

(B) Heat sink (Negative side)
2. ROTOR
1) Slip ring surface
Inspect the slip rings for contamination or any
roughness of 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 rotor assembly.
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 specification, replace
the rotor assembly.
G6M0077
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.
Specified resistance:
Approx. 2.7 3.2
G6M0078A
(A) Stator
G6M0075
SC-17
GENERATOR
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 20.81 oz).
G6M0079
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.
G6M0143
5. BEARING (FRONT SIDE)

1) Check the front ball bearing. If the resistance is
felt while rotating, or if abnormal noise is heard, replace the ball bearing.
2) Replacing front bearing
(1) Remove the front bearing retainer.
(2) Closely install a fit tool on the bearing inner
race. Press the bearing down out of front bracket with a hand press or vise. A socket wrench
can serve as the tool.
Brush length:
Standard
18.5 mm (0.728 in)
Service limit
5.0 mm (0.197 in)
H6M0499B
S6M0409A
(A) Front bracket

(B) Socket wrench
(3) Set a new bearing and closely install a fit

tool on the bearing outer race. Press the bearing
down into place with a hand press or vise. A
socket wrench can serve as the tool.
SC-18
GENERATOR
(4) Install the front bearing retainer.
S6M0410A
(A) Bearing
(B) Socket wrench
(C) Front bracket
SC-19
BATTERY
4. Battery
C: INSPECTION
A: REMOVAL
WARNING:
Electrolyte has toxicity; be careful handling
the fluid.
Avoid contact with skin, eyes or clothing. Especially at contact with eyes, blush with water
for 15 minutes and get prompt medical attention.
Batteries produce explosive gasses. Keep
sparks, flame, cigarettes away.
Ventilate when charging or using in enclosed
space.
For safety, in case an explosion does occur,
wear eye protection or shield your eyes when
working near any battery. Never lean over a battery.
Do not let the battery fluid contact eyes, skin,
fabrics, or paint-work because battery fluid is
corrosive acid.
To lessen the risk of sparks, remove rings,
metal watch-bands, and other metal jewelry.
Never allow metal tools to contact the positive
battery terminal and anything connected to it
while you are at the same time in contact with
any other metallic portion of the vehicle because a short circuit will be caused.
1) Disconnect the positive (+) cable after disconnecting the ground () cable of battery.
2) Remove the flange nuts from battery rods, and
then take off the battery holder.
B6M1506
3) Remove the battery.
B: INSTALLATION
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
NOTE:
Clean the battery cable terminals, and then apply
grease to retard formation of corrosion.
Connect the positive (+) cable of battery and then
the ground () cable of battery.
1. EXTERNAL PARTS:
Check for the existence of dirt or cracks on battery
case, top cover, vent plugs, and terminal posts. If
necessary, clean with water and wipe with a dry
cloth.
Apply a thin coat of grease on the terminal posts to
prevent corrosion.
2. ELECTROLYTE LEVEL:
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.
SC-20
BATTERY
3. SPECIFIC GRAVITY OF ELECTROLYTE:

1) Measure the 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:
S20 = St + 0.0007 (t 20)
S20: Specific gravity corrected at electrolyte
temperature of 20C
St : Measured specific gravity
t : Measured temperature (C)
Determine whether or not battery must be
charged, according to corrected specific
gravity.
Standard specific gravity: 1.220 1.290 [at
20C (68F)]
1. JUDGMENT OF BATTERY IN CHARGED

CONDITION
1) Specific gravity of electrolyte is held at a specific
value in a range from 1.250 to 1.290 for more than
one hour.
2) Voltage per battery cell is held at a specific value
in a range from 2.5 to 2.8 volts for more than one
hour.
2. CHECK HYDROMETER FOR STATE OF

CHARGE
Hydrometer
indicator
Green dot
Dark dot
State of charge
Required action
Above 65%
Below 65%
Load test
Charge battery
Replace battery*
Clear dot
Low electrolyte
(If cranking complaint)
*: Check electrical system before replacement.
3. NORMAL CHARGING
Charge the battery at current value specified by
manufacturer or at approx. 1/10 of battery's ampere-hour rating.
4. QUICK CHARGING
G6M0103
2) Measuring the specific gravity of the electrolyte

in battery will disclose the state of charge of battery. The relation between specific gravity and state
of charge is as shown in the figure.
D: MEASUREMENT
WARNING:
Do not bring an open flame close to the battery at this time.
CAUTION:
Prior to charging, corroded terminals should
be cleaned with a brush and common baking
soda solution.
Be careful since the battery electrolyte overflows while charging the battery.
Observe the instructions when handling battery charger.
Before charging the battery on vehicle, disconnect battery ground terminal. Failure to follow this rule may damage alternator's diodes or
other electrical units.
Quick charging is a method in which the battery is

charged in a short period of time with a relatively
large current by using a quick charger.
Since a large current flow raises electrolyte temperature, the battery is subject to damage if large current is used for prolonged time. For this reason, the
quick charging must be carried out within a current
range that will not increase the electrolyte temperature above 40C (104F).
It should be also remembered that the quick charging is a temporary means to bring battery voltage
up to a fair value and, as a rule, a battery should be
charged slowly with a low current.
CAUTION:
Observe the items in 1. NORMAL CHARGING.
Never use more than 10 amperes when
charging the battery because that will shorten
battery life.
SC-21
BATTERY
SC-22
EN
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Page
Basic Diagnostic Procedure ........................................................................2
Check List for Interview...............................................................................4
Electrical Components Location................................................................10
Engine Control Module (ECM) I/O Signal .................................................24
Engine Condition Data ..............................................................................27
Transmission Control Module (TCM) I/O Signal .......................................28
Data Link Connector .................................................................................31
OBD-II General Scan Tool ........................................................................32
Subaru Select Monitor...............................................................................34
Read Diagnostic Trouble Code (DTC) ......................................................41
Inspection Mode........................................................................................42
Drive Cycle................................................................................................47
Clear Memory Mode..................................................................................49
Compulsory Valve Operation Check Mode ...............................................50
Engine Malfunction Indicator Lamp (MIL) .................................................52
Diagnostics for Engine Starting Failure.....................................................62
List of Diagnostic Trouble Code (DTC) .....................................................83
Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....................90
General Diagnostic Table........................................................................292
BASIC DIAGNOSTIC PROCEDURE

1. Basic Diagnostic Procedure

A: PROCEDURE
1. ENGINE
Step
Check
CHECK ENGINE START FAILURE.
Does the engine start?
1)Ask the customer when and how the trouble
occurred using the interview check list. <Ref.
to EN-4, CHECK, Check List for Interview.>
2)Start the engine.
CHECK ILLUMINATION OF CHECK ENGINE Does the CHECK ENGINE

MALFUNCTION INDICATOR LAMP (MIL).
malfunction indicator lamp illuminate?
CHECK INDICATION OF DIAGNOSTIC

Does the Subaru Select MoniTROUBLE CODE (DTC) ON DISPLAY.
tor or OBD-II general scan tool
indicate DTC?
2)Connect the Subaru Select Monitor or OBDII general scan tool to data link connector.
3)Turn the ignition switch to ON and Subaru
Select Monitor or OBD-II general scan tool
switch to ON.
4)Read the DTC on the Subaru Select Monitor
or OBD-II general scan tool.
PERFORM THE DIAGNOSIS.

1)Perform the clear memory mode. <Ref. to
EN-49, Clear Memory Mode.>
2)Perform the inspection mode. <Ref. to EN42, Inspection Mode.>
Does the Subaru Select Monitor or OBD-II general scan tool

indicate DTC?
EN-2
Yes
Go to step 2.
No
Inspection using
Diagnostics for
Engine Start Failure. <Ref. to EN62, Diagnostics for
Engine Starting
Failure.>
Go to step 3.
Inspection using
General Diagnostics Table. <Ref.
to EN-292,
INSPECTION,
General Diagnostic Table.>
Record the DTC. Repair the related
Repair the trouble parts.
cause. <Ref. to
NOTE:
EN-83, List of
If a DTC is not
Diagnostic Trou- shown on display
ble Code (DTC).> although the MIL ilGo to step 4.
luminates,
perform diagnostics of
MIL (CHECK ENGINE malfunction
indicator lamp) circuit or combination
meter. <Ref. to
EN-52,
Engine
Malfunction Indicator Lamp (MIL).>
Inspect using
Complete the
Diagnostics Pro- diagnosis.
cedure with Diagnostic Trouble
Code (DTC).
<Ref. to EN-90,
Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>

2. AUTOMATIC TRANSMISSION
When the diagnostic trouble code (DTC) about automatic transmission is shown on display, carry out
the following basic check. After that, carry out the
replacement or repair work.
1) ATF level check <Ref. to AT-9, Automatic Transmission Fluid.>
2) Differential gear oil level check <Ref. to AT-11,
Differential Gear Oil.>
3) ATF leak check <Ref. to AT-9, Automatic Transmission Fluid.>
4) Differential gear oil leak check <Ref. to AT-11,
Differential Gear Oil.>
5) Stall test <Ref. to AT-13, Stall Test.>
6) Line pressure test <Ref. to AT-16, Line Pressure
Test.>
7) Transfer clutch pressure test <Ref. to AT-18,
Transfer Clutch Pressure Test.>
8) Time lag test <Ref. to AT-15, Time Lag Test.>
9) Road test <Ref. to AT-12, Road Test.>
10) Shift characteristics <Ref. to AT-18, Transfer
Clutch Pressure Test.>
EN-3
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.
Customer's name
Date of sale
Date of repair
Vin No.
Weather
Engine No.
Fuel brand
Odometer reading
Fine
Cloudy
Rainy
Snowy
Various/Others:
C (F)
Outdoor temperature
Place
Engine temperature
Engine speed
Vehicle speed
Driving conditions
Headlight
Blower
A/C compressor
Cooling fan
Front wiper
Rear wiper
km
miles
Hot
Warm
Cool
Cold
Highway
Suburbs
Inner city
Uphill
Downhill
Rough road
Others:
Cold
Warming-up
After warming-up
Any temperature
Others:
rpm
MPH
Not affected
At starting
While idling
At racing
While accelerating
While cruising
While decelerating
While turning (RH/LH)
ON/ OFF
ON/ OFF
ON/ OFF
ON/ OFF
ON/ OFF
ON/ OFF
Rear defogger
Radio
CD/Cassette
Car phone
CB
EN-4
ON/ OFF
ON/ OFF
ON/ OFF
ON/ OFF
ON/ OFF

2. CHECK LIST NO. 2

Check the following items about the vehicle's state when MIL turns on.
NOTE:
a) Other warning lights or indicators turn on. Yes/ No
Low fuel warning light
Charge indicator light
AT diagnostics indicator light
ABS warning light
Engine oil pressure warning light
b) Fuel level
Lack of gasoline: Yes/ No
Indicator position of fuel gauge:
c) Intentional connecting or disconnecting of harness connectors or spark plug cords: Yes/ No
What:
d) Intentional connecting or disconnecting of hoses: Yes/ No
What:
e) Installing of parts other than genuine parts: Yes/ No
What:
Where:
f) Occurrence of noise: Yes/ No
From where:
What kind:
g) Occurrence of smell: Yes/ No
From where:
What kind:
h) Intrusion of water into engine compartment or passenger compartment: Yes/ No
i) Troubles occurred
Engine does not start.
Engine stalls during idling.
Engine stalls while driving.
Engine speed decreases.
Engine speed does not decrease.
Rough idling
Poor acceleration
Back fire
After fire
No shift
Excessive shift shock
EN-5
GENERAL DESCRIPTION
8) Use the ECM mounting stud bolt at the body

head grounding points when measuring voltage
and resistance inside the passenger compartment.
A: CAUTION
1) Airbag system wiring harness is routed near the
engine control module (ECM), main relay and fuel
pump relay.
CAUTION:
All airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuit.
Be careful not to damage the airbag system
wiring harness when servicing the engine control module (ECM), transmission control module (TCM), main relay and fuel pump relay.
2) Never connect the battery in reverse polarity.
The ECM will be destroyed instantly.
The fuel injector and other part will be damaged
in just a few minutes more.
3) Do not disconnect the battery cables while the
engine is running.
A large counter electromotive force will be generated in the alternator, and this voltage may damage
electronic parts such as ECM, etc.
4) Before disconnecting the connectors of each
sensor and the ECM, be sure to turn the ignition
switch to OFF.
5) Poor contact has been identified as a primary
cause of this problem. To measure the voltage and/
or resistance of individual sensors or all electrical
control modules at the harness side connector, use
a tapered pin with a diameter of less than 0.64 mm
(0.025 in). Do not insert the pin more than 5 mm
(0.20 in) into the part.
6) Before removing the ECM from located position,
disconnect two cables on battery.
Otherwise, the ECM may be damaged.
EN1393
(A) Stud bolt
9) Use the engine grounding terminal or engine

proper as the grounding point to the body, when
measuring voltage and resistance in the engine
compartment.
B2M2779
10) Use the TCM mounting stud bolts at the body

head grounding point, when measuring voltage and
resistance inside the passenger compartment.
CAUTION:
the wrong spec. ECM to avoid any damage on
the fuel injection system.
7) The connectors to each sensor in the engine
compartment and the harness connectors on the
engine side and body side are all designed to be
waterproof. However, it is still necessary to take
care not to allow water to get into the connectors
when washing the vehicle, or when servicing the
vehicle on a rainy day.
EN1394
(A) Stud bolt
11) Every MFI-related part is a precision part. Do

not drop them.
EN-6
GENERAL DESCRIPTION
12) Observe the following cautions when installing

a radio in MFI equipped models.
CAUTION:
The antenna must be kept as far apart as possible from the control unit.
(The ECM is located under the steering column,
inside of the instrument panel lower trim panel.)
The antenna feeder must be placed as far
apart as possible from the ECM and MFI harness.
Carefully adjust the antenna for correct
matching.
When mounting a large power type radio, pay
special attention to the three items above mentioned.
Incorrect installation of the radio may affect
the operation of the ECM.
13) Before disconnecting the fuel hose, disconnect
the fuel pump connector and crank the engine for
more than 5 seconds to release pressure in the fuel
system. If the engine starts during this operation,
run it until it stops.
14) Problems in the electronic-controlled automatic
transmission may be caused by failure of the engine, the electronic control system, the transmission proper, or by a combination of these. These
three causes must be distinguished clearly when
performing diagnostics.
15) Diagnostics should be conducted by rotating
with simple, easy operations and proceeding to
complicated, difficult operations. The most important thing in diagnostics is to understand the customer's complaint, and distinguish between the
three causes.
16) In AT vehicles, do not continue the stall for
more than 5 seconds at a time (from closed throttle,
fully open throttle to stall engine speed).
17) On ABS vehicle, when performing driving test
in jacked-up or lifted-up position, sometimes the
warning light may be lit, but this is not a malfunction
of the system. The reason for this is the speed difference between the front and rear wheels. After diagnosis of engine control system, perform the ABS
memory clearance procedure of self-diagnosis system.
B: INSPECTION
Before performing diagnostics, check the following
items which might affect engine problems:
1. BATTERY
1) Measure the battery voltage and specific gravity
of electrolyte.
Standard voltage: 12 V
Specific gravity: Above 1.260
2) Check the condition of the main and other fuses,
and harnesses and connectors. Also check for
proper grounding.
2. ENGINE GROUNDING
Make sure the engine grounding cable is properly
connected to the engine.
EN-7
B2M2779
GENERAL DESCRIPTION
C: NOTE
2. ENGINE AND EMISSION CONTROL SYSTEM
1. DESCRIPTION
The on-board diagnostics (OBD) system detects
and indicates a fault in various inputs and outputs
of the complex electronic control. CHECK ENGINE
malfunction indicator lamp (MIL) in the combination
meter indicates occurrence of a fault or trouble.
Further, against such a failure or sensors as may
disable the drive, the fail-safe function is provided
to ensure the minimal driveability.
The OBD system incorporated with the vehicles
within this engine family complies with Section
1968.1, California Code of Regulations (OBD-II
regulation). The OBD system monitors the components and the system malfunction listed in Engine
Section which affects on emissions.
When the system decides that a malfunction occurs, MIL illuminates. At the same time of the MIL illumination or blinking, a diagnostic trouble code
(DTC) and a freeze frame engine conditions are
stored into on-board computer.
The OBD system stores freeze frame engine
condition data (engine load, engine coolant temperature, fuel trim, engine speed and vehicle
speed, etc.) into on-board computer when it detects
a malfunction first.
If the OBD system detects the various malfunctions including the fault of fuel trim or misfire, the
OBD system first stores freeze frame engine conditions about the fuel trim or misfire.
When the malfunction does not occur again for
three consecutive driving cycles, MIL is turned off,
but DTC remains at on-board computer.
The OBD-II system is capable of communication
with a general scan tool (OBD-II general scan tool)
formed by ISO 9141 CARB.
The OBD-II diagnostics procedure is different
from the usual diagnostics procedure. When troubleshooting OBD-II vehicles, connect Subaru Select Monitor or the OBD-II general scan tool to the
vehicle.
The Multipoint Fuel Injection (MFI) system is a

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

ELECTRONIC-HYDRAULIC CONTROL SYSTEM
The electronic-hydraulic control system consists of
various sensors and switches, a transmission control module (TCM) and the hydraulic controller including solenoid valves. The system controls the
transmission proper including shift control, lock-up
control, overrunning clutch control, line pressure
control and shift timing control. It also controls the
AWD transfer clutch. In other words, the system
detects various operating conditions from various
input signals and sends output signals to shift solenoids 1, 2 and low clutch timing solenoid and 2-4
brake timing solenoid, line pressure duty solenoid,
lock-up duty solenoid, transfer duty solenoid and 24 brake duty solenoid (a total of eight solenoids).
EN-8
GENERAL DESCRIPTION
D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
24082AA190
(New adopted tool)
DESCRIPTION
CARTRIDGE
REMARKS
Troubleshooting for electrical
systems.
22771AA030
SELECT MONITOR KIT

systems.
German: 22771AA070
(Without printer)
French: 22771AA080
(Without printer)
Spanish: 22771AA090
(Without printer)
B2M3876
B2M3877
EN-9
ELECTRICAL COMPONENTS LOCATION

4. Electrical Components Location

A: LOCATION
1. ENGINE
Module
LHD model
(1)
(3) (2)
(4)
EN1423
RHD model
(3) (2)
(4)
(1)
EN1424
(1)
(2)
Engine control module (ECM)

CHECK ENGINE malfunction indicator lamp (MIL)
(3)
(4)
Test mode connector

Data link connector
EN-10

(2)
EN0718
B3M1575A
(3)
EN0716
EN-11
(4)
EN1425

Sensor
(1)
(3)
(4)
(2)
(5)
(7)
(6)
EN0719
(1)
(2)

(3)
Engine coolant temperature sensor
(4)
EN-12
(5)
(6)
(7)
Knock sensor

B2M3713A
B2M3714A
S2M1248B
B2M2240A
B2M2241A
B2M2242A
B2M0213J
EN-13

B2M4231A
(1)
(2)

Rear oxygen sensor
(3)
(4)

S2M0264A
S2M0265A
OBD0524G
OBD0525G
EN-14

LHD model
(1)
(2)
EN1019
RHD model
(1)
(2)
EN1020
(1)
Fuel level sensor
(2)
Fuel sub level sensor (2500 cc

model only)
EN1036
EN1037
EN-15

Solenoid Valve, Emission Control System Parts and Ignition System Parts
(3)
(1)
(4)
(2)
EN0736
(1)
(2)

(3)
(4)

Ignition coil & ignitor ASSY
EN-16

B2M3715A
H2M3259A
H2M3258B
B2M3720A
EN-17

(1)
(6)
(5)
(3)
(4)
(2)
(7)
EN0741
(1)
(6)
(5)
(2)
(7)
(3)
(4)
EN0742
(1)
(2)
(3)
Inhibitor switch
Fuel pump
Main relay
(4)
(5)
(6)
Fuel pump relay

Radiator main fan relay
Radiator sub fan relay
EN-18
(7)
Starter

B2M2246A
LHD model
EN1505
RHD model
(3)
(3)
(4)
(4)
EN1504
EN1506
(6)
(5)
EN0746
B2M2247E
EN-19

2. TRANSMISSION
Module
(2)
(1)
EN0751
(1)
(2)
EN0752
(1)
Transmission control module

(TCM) (for AT vehicles)
(2)
AT diagnostic indicator light (for

AT vehicles)
EN-20

B3M1592D
(2)
EN0754
EN-21
B3M1652B

Sensor
B2M2258A
B2M2259A
B2M2260A
B2M2261A
OBD0653B
(1) Rear vehicle speed sensor (for AT vehicles)

(2) Front vehicle speed sensor (for MT vehicles)
(3) Front vehicle speed sensor (for AT vehicles)
(4) Torque converter turbine speed sensor
(5) ATF temperature sensor (for AT vehicles)
(6) Brake light switch
EN-22

Solenoid Valve and Switch (AT vehicles)
B2M2246F
B2M2264F
(1) Inhibitor switch

(2) Shift solenoid valve 1
(4) Line pressure duty solenoid
(5) Lock-up duty solenoid
(6) Transfer duty solenoid
(7) 2-4 brake duty solenoid
(8) Low clutch timing solenoid valve
(9) 2-4 brake timing solenoid valve
Solenoid Valve and Switch (MT vehicles)
B2M2265A
(1) Neutral position switch
EN-23
B2M2263K
ENGINE CONTROL MODULE (ECM) I/O SIGNAL

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

A: ELECTRICAL SPECIFICATION
B2M2267A
Content
Connector
No.
Signal (+)
Crankshaft posi- Signal ()
tion sensor Shield
Camshaft Signal (+)
position
Signal ()
sensor
Shield
B135
B135
B135
B135
B135
B135
Signal
Throttle
position
sensor
Rear oxygen sensor
Power
supply
GND (sensor)
Signal
Shield
GND (sensor)
Signal 1
Front oxygen (A/F)

sensor
Signal 2
heater
Rear oxygen sensor
heater signal
Engine
Signal
coolant
temperaGND (senture sensor)
sor
Vehicle speed signal
Terminal
No.
2*
9*
1
8
10
1*
8*
2
9
10
Signal (V)
Ignition SW ON
Engine ON (Idling)
(Engine OFF)
0
7 +7
0
0
0
0
0
7 +7
0
0
0
0
Fully closed: 0.2 1.0
Fully opened: 4.2 4.7
Note
Sensor output waveform
B136
17
B136
15
B136
16
B136
B136
18
24
0
0
0 0.9
0
B136
16
B134
23
0 1.0
0 1.0
B134
22
0 1.0
0 1.0
B134
21
0 1.0
0 1.0
B136
14
1.0 1.4
1.0 1.4
After warm-up the engine.
B136
16
B135
24
0 or 5
0 or 5
*: With immobilizer
EN-24
5 and 0 are repeatedly displayed when vehicle is driven.

Signal (V)
Ignition SW ON
Engine ON (Idling)
(Engine OFF)
0
0
ON: 10 13
ON: 13 14
OFF: 0
OFF: 0
10 13
13 14
ON: 120.5
OFF: 0
Connector
No.
Terminal
No.
Starter switch
B135
28
A/C switch
B135
27
Ignition switch
B135
MT
B135
26
AT
B135
26
B135
B136
B136
B136
B136
B136
B136
B135
B134
B134
B134
B134
B134
B134
B134
B134
B134
B134
14
4
25
9
1
2
15
20
25
26
4
13
14
15
5
6
19
20
5
2.8
0
10 13
10 13
10 13
5
0
0
0
10 13
10 13
10 13
10 13
5
2.8
0
13 14
13 14
13 14
5
0
1 3.4
1 3.4
1 14
1 14
1 14
1 14
1 13
1 13
1 13
1 13
On MT vehicle; Switch is ON
when gear is in neutral position.
ON AT vehicle; Switch is ON
when shift is in N or P position.
When connected: 0
Ignition switch OFF: 10 13
Waveform
Waveform
Waveform
Waveform
Waveform
Waveform
Waveform
Waveform
Waveform
Waveform
B136
10 13
13 14
0.5, or less
Content
Neutral
position
switch
Test mode connector

Signal
Knock
sensor
Shield
Back-up power supply
Control unit power supply
Sensor power supply
Line end check 1
#1, #2
Ignition
control
#3, #4
#1
Fuel injec- #2
tor
#3
#4
Signal 1
Signal 2
Idle air
Signal 3
control
solenoid
Signal 4
valve
Power
supply
ON: 0.5, or less

OFF: 10 13
ON: 0.5, or less
OFF: 10 13
ON: 0.5, or less
OFF: 10 13
ON: 0.5, or less
OFF: 10 13
ON: 0.5, or less

OFF: 13 14
ON: 0.5, or less
OFF: 13 14
ON: 0.5, or less
OFF: 13 14
11
B134
B135
B135
30
16
17
5
5
0 13, or more
More than 4 V
More than 4 V
B134
31
B134
B136
29
ON: 1, or less
OFF: 10 13
3.9 4.1
ON: 1, or less
OFF: 13 14
2.0 2.3
B136
15
B136
16
Fuel pump relay control
B134
A/C relay control
B134
17
B134
B134
12
B134
Radiator fan relay 1

control
control
Malfunction indicator
lamp
Engine speed output
Torque control 1 signal
Torque control cut signal
Purge control solenoid
valve
Signal
AtmoPower
spheric
supply
pressure
GND (sensensor
sor)
ON: 0
OFF: 120.5
29*
16
*: With immobilizer
EN-25
Note
Cranking: 8 14
With A/C vehicles only

Light ON: 1, or less
Light OFF: 10 14
Waveform

Signal (V)
Ignition SW ON
Engine ON (Idling)
(Engine OFF)
0.12 4.75
0.12 4.75
Less than 1
Less than 1
More than 4
More than 4
ON: 0
ON: 0
OFF: 10 13
OFF: 13 14
ON: 0
ON: 0
OFF: 10 13
OFF: 13 14
ON: 0
ON: 0
OFF: 10 13
OFF: 13 14
Connector
No.
Terminal
No.
Fuel level sensor

AT diagnosis input signal
B136
27
B135
Small light switch
B136
Blower fan switch
B136
30
Rear defogger switch
B135
21
B136
19
2.8 3.2
2.8 3.2
B136
2.4 2.7
2.4 2.7
B136
0.2 4.9
0.2 4.9
B136
20
0.2 4.9
0.2 4.9
B136
2.4 4.8
0.4 1.8
B136
13
2.3 2.5
1.4 1.6
B135
B136
B134
B134
B134
B136
B136
16
7
27
8
21
22
Less than 1
More than 4
0
0
0
0
0
0
Less than 1
More than 4
0
0
0
0
0
0
B134
35
B134
34
Content
Front oxygen (A/F) sensor signal 1

Pressure sensor
Intake air temperature
sensor
SSM/GST communication line
GND (sensors)
GND (injectors)
GND (ignition system)
GND (power supply)
GND (control systems)
GND (oxygen sensor
heater 1)
GND (oxygen sensor
heater 2)
EN-26
Note
For europe model
Waveform
ENGINE CONDITION DATA

6. Engine Condition Data

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

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

to B54
9
18
24
8
17
23
7
16
22
6 5
15 14
to B55
9
18
24
4 3 2 1
13 12 11 10
21 20 19
8
17
23
7
16
22
6 5
15 14
4 3 2 1
13 12 11 10
21 20 19
to B56
9
18
24
8
17
23
7
16
22
6 5
15 14
4 3 2 1
13 12 11 10
21 20 19
TR0532
Check with ignition switch ON.

Content
Ignition power supply
Connector
No.
B56
B54
B54
Terminal No.
1
23
24
P range
switch
B55
N range
switch
B55
14
R range
switch
B55
D range
switch
B55
3 range
switch
B55
2 range
switch
B55
1 range
switch
B55
Brake switch
B55
12
ABS signal
B55
21
Inhibitor
switch
Measuring conditions
Voltage (V)
Resistance to
body (ohms)
Ignition switch OFF
10 13
Ignition switch ON (with

engine OFF)
10 13
Select lever in P range

Select lever in any other than
P range (except N range)
Select lever in N range
N range (except P range)
Select lever in R range
R range
Select lever in D range
D range
Select lever in 3 range
3 range
2 range
1 range
Brake pedal depressed.
Brake pedal released.
ABS switch ON
ABS switch OFF
EN-28
Less than 1
More than 8
Less than 1
More than 8
Less than 1
More than 8
Less than 1
More than 8
Less than 1
More than 8
Less than 1
More than 8
Less than 1
More than 8
More than 10.5
Less than 1
Less than 1
6.5 15

Connector
No.
Terminal No.
Hold switch
B55
16
Power switch
B55
23
Kick-down switch
B55
11
POWER indicator light
B56
11
AT OIL TEMP indicator light
B56
10
B54
Throttle position sensor power

supply
B54
ATF temperature sensor
B54
11
Content
Voltage (V)
Less than 1
More than 8
Less than 1
More than 10
Less than 1
More than 6.5
Less than 1
More than 9
Less than 1
More than 9
0.3 0.7
4.0 4.6
Torque control signal 1
B56
B56
14

Intake manifold pressure signal
B55
10
Hold switch ON
Hold switch OFF
Power switch ON
Power switch OFF
Throttle fully opened.
Throttle fully closed.
Light ON
Light OFF
Light ON
Light OFF
Throttle fully open.
Ignition switch ON (With
engine OFF)
ATF temperature 20C
(68F)
ATF temperature 80C
(176F)
Vehicle stopped.
Vehicle speed at least 20
km/h (12 MPH)
km/h (12 MPH)
Engine idling after warm-up.
(D range)
(N range)
Vehicle speed at most 10
km/h (6 MPH)
engine OFF)
engine ON)
When cruise control is set.
(SET lamp ON)
When cruise control is not
set. (SET lamp OFF)
engine ON)
engine ON)
Ignition switch ON
B54
Shift solenoid 1
B54
22
Shift solenoid 2
B54
Rear vehicle speed sensor
B55
24
Front vehicle speed sensor
B55
18
Torque converter turbine

speed sensor
B55
Vehicle speed output signal
B56
17
Engine speed signal
B55
17
Cruise set signal
B55
22
Resistance to
body (ohms)
4.8 5.3
1.6 2.0
2.1 2.9 k
0.4 0.9
275 375
0
More than 1 (AC range)
450 650
450 650
0
450 650
Less than 1
More than 4
More than 10.5
8 11
Less than 1
More than 6.5

4
0.4 1.8
1st or 4th gear

2nd or 3rd gear
1st or 2nd gear
3rd or 4th gear
More than 9
Less than 1
More than 9
Less than 1
EN-29
10 16
10 16

Content
Line pressure duty solenoid
Connector
No.
B54
Terminal No.
Lock-up duty solenoid
B54
Transfer duty solenoid
B54
2-4 brake duty solenoid
B54
18
2-4 brake timing solenoid
B54
16
Low clutch timing solenoid
B54
15
Sensor ground line 1

B54
B55
B54
B54
B56
B54
20
9
10
19
19
21
FWD switch
B55
20
FWD indicator light
B56
Data link signal (Subaru

Select Monitor)
B56
15
System ground line
engine OFF)
Throttle fully closed after
warm-up.
engine OFF)
Throttle fully open after
warm-up.
When lock up occurs.
When lock up is released.
Fuse on FWD switch
Fuse removed from FWD
switch (with throttle fully
open and with select lever in
1st gear).
engine OFF)
warm-up.
engine OFF)
warm-up.
1st gear
3rd gear
2nd gear
4th gear
Voltage (V)
Resistance to
body (ohms)
1.5 4.0
2.0 4.5
Less than 0.5
More than 8.5
Less than 0.5
More than 8.5
Less than 0.5
10 17
10 17
1.5 4.0
2.0 4.5
Less than 0.5
Less than 1
More than 9
Less than 1
More than 9
0
0
0
0
Less than 1
Less than 1
Less than 1
Less than 1
Less than 1
Fuse removed.
Fuse installed.
Fuse on FWD switch
switch
6 9.1
Less than 1
Less than 1
EN-30
More than 9
10 16
10 16
DATA LINK CONNECTOR

8. Data Link Connector

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

9. OBD-II General Scan Tool

A: OPERATION
1. HOW TO USE OBD-II GENERAL SCAN
TOOL
1) Prepare a general scan tool (OBD-II general
scan tool) required by SAE J1978.
2) Connect the OBD-II general scan tool to data
link connector located in the lower portion of instrument panel (on the driver's side).
3) Using the OBD-II general scan tool, call up diagnostic trouble code(s) (DTC(s)) and freeze frame
data.
OBD-II general scan tool functions consist of:
(1) MODE $01: Current powertrain diagnostic
data
(2) MODE $02: Powertrain freeze frame data
(3) MODE $03: Emission-related powertrain diagnostic trouble codes (DTCs)
(4) MODE $04: Clear/Reset emission-related
diagnostic information
Read out the data according to repair procedures.
(For detailed operation procedures, refer to the
OBD-II General Scan Tool Operation Manual.)
NOTE:
For details concerning diagnostic trouble codes
(DTCs), refer to the List of Diagnostic Trouble Code
(DTC). <Ref. to EN-83, List of Diagnostic Trouble
Code (DTC).>
EN0768
2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)

Refers to data denoting the current operating condition of analog input/output, digital input/output and/or the
powertrain system.
A list of the support data and PID (Parameter Identification) codes are shown in the following table.
PID
01
03
04
05
06
07
0B
0C
0D
0E
0F
10
11
13
15
24
1C
Data
Number of emission-related powertrain trouble codes and MIL status
Fuel system control status
Calculated engine load value
Short term fuel trim
Long term fuel trim
Intake manifold absolute pressure
Engine revolution
Vehicle speed
Ignition timing advance
Air flow rate from pressure sensor
Throttle valve opening angle
Check whether oxygen sensor is installed.
Oxygen sensor output voltage and short term fuel trim associated with oxygen sensorbank
1 sensor 2
A/F sensor 1 output voltage and short term fuel trim associated with A/F sensor 1
On-board diagnosis system
Unit of measure
ON/OFF
%
C
%
%
kPa
rpm
km/h
C
g/sec
%
V and %
V and %
NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to access generic OBD-II PIDs (MODE
$01).
EN-32

3. MODE $02 (POWERTRAIN FREEZE FRAME DATA)

Refers to data denoting the operating condition when trouble is sensed by the on-board diagnosis system.
PID
02
03
04
05
06
07
0B
0C
0D
Data
Trouble code that caused CARB required freeze frame data storage
Long term fuel trim
Engine revolution
Vehicle speed
Unit of measure
%
C
%
%
kPa
rpm
km/h
NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to access freeze frame data (MODE
$02).
4. MODE $03 (EMISSION-RELATED POWERTRAIN DIAGNOSTIC TROUBLE CODE)

Refer to Read Diagnostic Trouble Code for information about data denoting emission-related powertrain diagnostic trouble codes. <Ref. to EN-41, Read Diagnostic Trouble Code (DTC).>
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION)

Refers to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic
information).
NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to clear or reset emission-related diagnostic information (MODE $04).
EN-33
SUBARU SELECT MONITOR

10.Subaru Select Monitor
(2) Connect the diagnosis cable to data link

connector.
A: OPERATION
1. HOW TO USE SUBARU SELECT MONITOR
1) Prepare the Subaru Select Monitor kit. <Ref. to
EN-9, PREPARATION TOOL, General Description.>
CAUTION:
Do not connect the scan tools except for Subaru Select Monitor and OBD-II general scan tool.
5) Turn the ignition switch to ON (engine OFF) and
Subaru Select Monitor switch to ON.
S2M0288E
S2M0285
(A) Power switch
2) Connect the diagnosis cable to Subaru Select

Monitor.
3) Insert the cartridge into Subaru Select Monitor.
<Ref. to EN-9, PREPARATION TOOL, General
Description.>
6) Using the Subaru Select Monitor, call up diagnostic trouble code(s) (DTC(s)) and various data,
then record them.
2. READ DIAGNOSTIC TROUBLE CODE

(DTC) FOR ENGINE. (NORMAL MODE)
Refer to Read Diagnostic Trouble Code for information about how to indicate DTC. <Ref. to EN-41,
Read Diagnostic Trouble Code (DTC).>

(DTC) FOR ENGINE. (OBD MODE)
Refer to Read Diagnostic Trouble Code for information about how to indicate DTC. <Ref. to EN-41,
S2M0286A
4) Connect the Subaru Select Monitor to data link

connector.
(1) Data link connector located in the lower portion of instrument panel (on the driver's side).
EN0768
EN-34

4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE)

1) On the Main Menu display screen, select the {Each System Check} and press [YES] key.
2) On the System Selection Menu display screen, select the {Engine Control System} and press [YES]
key.
3) Press the [YES] key after displayed the information of engine type.
4) On the Engine Diagnosis display screen, select the {Current Data Display & Save} and press [YES] key.
5) On the Data Display Menu display screen, select the {Data Display} and press [YES] key.
6) Using the scroll key, move the display screen up or down until desired data is shown.
A list of the support data is shown in the following table.
Contents
Battery voltage
Engine speed signal
Engine coolant temperature signal
Ignition timing signal
Throttle position signal
Injection pulse width
Idle air control signal
Engine load data
Front oxygen (A/F) sensor output signal
Rear oxygen sensor output signal
Knock sensor signal
Display
Battery Voltage
Vehicle Speed
Engine Speed
Coolant Temp.
Ignition Timing
Throttle Opening Angle
Throttle Sensor Voltage
Fuel Injection #1 Pulse
ISC Valve Step
Engine Load
A/F Sensor #1
Rear O2 Sensor
A/F Correction #1
Knocking Correction
Atmospheric absolute pressure signal
Atmosphere Pressure
Intake manifold relative pressure signal
Mani. Relative Pressure
Intake manifold absolute pressure signal
Mani. Absolute Pressure
A/F correction (short term fuel trim) by rear oxygen sensor

Long term whole fuel trim
Front oxygen (A/F) sensor heater current
Rear oxygen sensor heater current
Canister purge control solenoid valve duty ratio
Fuel level signal
Intake air temperature signal
Learned ignition timing
Ignition switch signal
Test mode connector signal
Neutral position switch signal
Air conditioning switch signal
Air conditioning signal
Radiator main fan relay signal
Fuel pump relay signal
Knocking signal
Radiator sub fan relay signal
Power steering switch signal
Engine torque control signal #1
Engine torque control permission signal
Rear oxygen sensor rich signal
A/F Correction #3
A/F Learning #1
Front O2 Heater #1
Rear O2 Heater Current
CPC Valve Duty Ratio
Fuel Level
Intake Air Temp.
Learned Ignition Timing
Ignition Switch
Test Mode Signal
Neutral Position Switch
A/C Switch
A/C Compressor Signal
Radiator Fan Relay #1
Fuel Pump Relay
Knocking Signal
P/S Switch
Torque Control Signal #1
Torque Permission Signal
Rear O2 Rich Signal
EN-35
Unit of measure
V
km/h or MPH
rpm
C or F
deg
%
V
ms
STEP
%
V
%
deg
mmHg or kPa or inHg or
psi
psi
psi
%
%
A
A
%
V
C or F
deg
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF

Contents
Starter switch signal
Idle switch signal
Crankshaft position sensor signal
Camshaft position sensor signal
Rear defogger switch signal
Blower fan switch signal
Small light switch signal
Air assist injector solenoid valve signal
AT vehicle ID signal
Display
Starter Switch Signal
Idle Switch Signal
Crankshaft Position Sig.
Camshaft Position Sig.
Rear Defogger Switch
Blower Fan Switch
Light Switch
Assist Air Sol. Valve
AT Vehicle ID Signal
Unit of measure
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
NOTE:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
EN-36

5. READ CURRENT DATA FOR ENGINE. (OBD MODE)

key.
4) On the Engine Diagnosis display screen, select the {OBD System} and press [YES] key.
5) On the OBD Menu display screen, select the {Current Data Display & Save} and press [YES] key.
Contents
Number of diagnosis code
Malfunction indicator lamp status
Monitoring test of misfire
Monitoring test of fuel system
Monitoring test of comprehensive component
Test of catalyst
Test of heated catalyst
Test of evaporative emission purge control system
Test of secondary air system
Test of air conditioning system refrigerant
Test of oxygen sensor
Test of oxygen sensor heater
Test of EGR system
Air fuel ratio control system for bank 1
Engine load data
Short term fuel trim by front oxygen (A/F) sensor
Long term fuel trim by front oxygen (A/F) sensor
Display
Number of Diagnosis Code
MI (MIL)
Misfire monitoring
Fuel system monitoring
Component monitoring
Catalyst Diagnosis
Heated catalyst
Evaporative purge system
Secondary air system
A/C system refrigerant
Oxygen sensor
O2 Heater Diagnosis
EGR system
Fuel System for Bank 1
Calculated load value
Coolant Temp.
Short term fuel trim B1
Long term fuel trim B1
Engine speed signal

Ignition timing advance for #1 cylinder
Intake air amount
A/F sensor equipment
Air fuel ratio correction by rear oxygen sensor
On-board diagnostic system
Engine Speed
Vehicle Speed
Ignition timing adv. #1
Intake Air Temp.
Mass Air Flow
A/F sensor
Oxygen Sensor #12
Short term fuel trim #12
OBD System
Unit of measure
ON or OFF
Complete or incomplete
No support
No support
No support
No support
No support
%
C or F
%
%
psi
rpm
km/h or MPH
C or F
g/s
%
ON or OFF
V
%
NOTE:
EN-37

6. READ FREEZE FRAME DATA FOR ENGINE. (OBD MODE)

key.
5) On the OBD Menu display screen, select the {Freeze Frame Data} and press [YES] key.
Contents
Diagnostic trouble code (DTC) for freeze frame data
Engine load data
Display
Freeze frame data
Fuel system for Bank1
Engine Load
Coolant Temp.
Engine speed signal

Engine Speed
Vehicle Speed
Unit of measure
DTC
ON or OFF
%
C or F
%
%
psi
rpm
km/h or MPH
NOTE:
7. READ OXYGEN SENSOR MONITORING TEST RESULTS DATA FOR ENGINE. (OBD
MODE)
key.
5) On the OBD Menu display screen, select the {O2 Sensor Monitor} and press [YES] key.
6) On the O2 Sensor Select display screen, select the {Bank 1-Sensor1} or {Bank 1-Sensor2} and press
[YES] key.
Bank 1-Sensor1 indicates the front oxygen or A/F sensor, and Bank 1-Sensor2 indicates the rear oxygen
sensor.
Contents
Oxygen sensor for monitoring test
Rich to lean oxygen sensor threshold voltage
Lean to rich oxygen sensor threshold voltage
Low oxygen sensor voltage for switch time calculation
High oxygen sensor voltage for switch time calculation
Rich to lean oxygen sensor switch time
Lean to rich oxygen sensor switch time
Maximum oxygen sensor voltage for test cycle
Minimum oxygen sensor voltage for test cycle
Display
<O2 Sensor Monitor (-------)>
Rich to lean sensor volt
Lean to rich sensor volt
Low sensor voltage
High sensor voltage
Rich to lean switch time
Lean to rich switch time
Maximum sensor Voltage
Minimum sensor Voltage
Unit of measure
V
V
V
V
sec
sec
V
V
NOTE:
EN-38

8. LED OPERATION MODE FOR ENGINE

key.
5) On the Data Display Menu display screen, select the {Data & LED Display} and press [YES] key.
6) Using the scroll key, move the display screen up or down until the desired data is shown.
Contents
Air conditioning relay signal
Knocking signal
Display
Ignition Switch
Test Mode Signal
A/C Switch
A/C Relay
Fuel Pump Relay
Knocking Signal
Message
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
Engine torque control permission

Torque Control Permit
signal
Front oxygen (A/F) sensor rich sigFront O2 Rich Signal #1
nal
ON or OFF
ON or OFF
Rear O2 Rich Signal
ON or OFF

Idle switch signal

Idle Switch Signal
ON or OFF
ON or OFF
ON or OFF
ON or OFF
LED ON requirements
When ignition switch is turned to ON.
When test mode connector is connected.
When neutral position signal is entered.
When air conditioning switch is turned ON.
When air conditioning relay is in function.
When radiator main fan relay is in function.
When fuel pump relay is in function.
When knocking signal is entered.
When radiator sub fan relay is in function.
When engine torque control signal 1 is
entered.
entered.
When engine torque control permission signal is entered.
When front oxygen (A/F) sensor mixture ratio
is rich.
When rear oxygen sensor mixture ratio is
rich.
When starter switch signal is entered.
When idle switch signal is entered.
When crankshaft position sensor signal is
entered.
When camshaft position sensor signal is
entered.
NOTE:
EN-39

9. READ CURRENT DATA FOR AT.

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

11.Read Diagnostic Trouble

Code (DTC)
3. OBD-II GENERAL SCAN TOOL

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

MODE)
{2. Each System Check} and press [YES] key.
press [YES] key.
5) On the OBD Menu display screen, select the
{Diagnosis Code(s) Display} and press [YES] key.
6) Make sure that a diagnostic trouble code (DTC)
is shown on the display screen.
NOTE:
For detailed concerning diagnostic trouble codes
Code (DTC).>
EN-41
INSPECTION MODE
12.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-47, Drive Cycle.>
DTC
No.
P0031
P0032
P0037
P0038
P0066
P0067
P0106
P0107
P0108
P0112
P0113
P0117
P0118
P0122
P0123
P0131
P0132
P0136
P0327
P0328
P0335
P0336
P0340
P0341
P0444
P0462
P0463
P0480
P0500
P0512
P0513
P0562
P0563
P0604
P0703
P0705
P0710
P0715
P0720
P0725
P0731
P0732
P0733
P0734
P0741
Item
Front oxygen (A/F) sensor heater circuit low input
Front oxygen (A/F) sensor heater circuit high input
Rear oxygen sensor heater circuit malfunction
Rear oxygen sensor heater circuit high input
Air assist injector solenoid valve circuit low input
Air assist injector solenoid valve circuit high input
Pressure sensor circuit range/performance problem (low input)
Pressure sensor circuit low input
Pressure sensor circuit high input
Intake air temperature sensor circuit low input
Intake air temperature sensor circuit high input
Engine coolant temperature sensor circuit low input
Engine coolant temperature sensor circuit high input
Throttle position sensor circuit low input
Throttle position sensor circuit high input
Front oxygen (A/F) sensor circuit malfunction (open circuit)
Front oxygen (A/F) sensor circuit malfunction (short circuit)
Rear oxygen sensor circuit malfunction
Knock sensor circuit low input
Knock sensor circuit high input
Crankshaft position sensor circuit malfunction
Crankshaft position sensor circuit range/performance problem
Camshaft position sensor circuit malfunction
Camshaft position sensor circuit range/performance problem
Evaporative emission control system purge control valve circuit low input
Fuel level sensor circuit low input
Fuel level sensor circuit high input
Cooling fan relay 1 circuit low input
Vehicle speed sensor malfunction
Starter switch circuit high input
Incorrect immobilizer key
Charge system circuit low input
Charge system circuit high input
Internal control module memory check sum error
Brake switch input malfunction
Transmission range sensor circuit malfunction
Transmission fluid temperature sensor circuit malfunction
Torque converter turbine speed sensor circuit malfunction
Output speed sensor (vehicle speed sensor 2) circuit malfunction
Engine speed input circuit malfunction
Gear 1 incorrect ratio
Torque converter clutch system malfunction
EN-42
INSPECTION MODE
DTC
No.
P0743
P0748
P0753
P0758
P0778
P0785
P1110
P1111
P1112
P1146
P1480
P1507
P1510
P1511
P1512
P1513
P1514
P1515
P1516
P1517
P1518
P1540
P1560
P1570
P1571
P1572
P1574
P1576
P1577
P1590
P1591
P1592
P1594
P1595
P1596
P1698
P1699
P1700
P1701
P1703
P1711
P1712
Item
Torque converter clutch system (Lock-up duty solenoid) electrical
Pressure control solenoid (Line pressure duty solenoid) electrical
Shift solenoid A (Shift solenoid 1) electrical
Shift solenoid B (Shift solenoid 2) electrical
2-4 brake pressure control solenoid valve circuit malfunction
2-4 brake timing control solenoid valve circuit malfunction
Atmospheric pressure sensor low input
Atmospheric pressure sensor high input
Atmospheric pressure sensor range/performance problem
Pressure sensor circuit range/performance problem (high input)
Cooling fan relay 1 circuit high input
Idle control system malfunction (fail-safe)
Idle air control solenoid valve signal 1 circuit low input
Idle air control solenoid valve signal 1 circuit high input
Starter switch circuit low input
Vehicle speed sensor malfunction 2
Back-up voltage circuit malfunction
Antenna
Reference code incompatibility
IMM circuit failure except antenna circuit
Key communication failure
EGI control module EEPROM
IMM control module EEPROM
Neutral position switch circuit high input (AT model)
Neutral position switch circuit low input (AT model)
Neutral position switch circuit (MT model)
Automatic transmission diagnosis input signal circuit malfunction
Automatic transmission diagnosis input signal circuit low input
Automatic transmission diagnosis input signal circuit high input
Engine torque control cut signal circuit low input
Engine torque control cut signal circuit high input
Throttle position sensor circuit malfunction for automatic transmission
Cruise control set signal circuit malfunction for automatic transmission
Low clutch timing control solenoid valve circuit malfunction
Engine torque control signal 1 circuit malfunction
Engine torque control signal 2 circuit malfunction
EN-43
INSPECTION MODE
1. PREPARATION FOR THE INSPECTION

MODE
2. SUBARU SELECT MONITOR
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 the battery voltage is 12 V or more.
2) Raise the vehicle using a garage jack and place
on safety stands or drive the vehicle onto free rollers.
WARNING:
Before raising the vehicle, ensure the parking
brake is applied.
Do not use a pantograph jack in place of a
safety stand.
Secure a rope or wire to the front and rear
towing or tie-down hooks to prevent the lateral
runout of front wheels.
Do not abruptly depress/release the clutch
pedal or accelerator pedal during works even
when engine is operating at low speeds since
this may cause vehicle to jump off free rollers.
In order to prevent the vehicle from slipping
due to vibration, do not place any wooden
blocks or similar items between the safety
stands and the vehicle.
Since the rear wheels will also rotate, do not
place anything near them. Also, make sure that
nobody goes in front of the vehicle.
1) After performing the diagnostics and clearing the

memory, check for any remaining unresolved trouble data. <Ref. to EN-49, Clear Memory Mode.>
2) Warm up the engine.
S2M0285

Monitor.
Description.>
S2M0286A
6) Connect the test mode connector (A) at the lower portion of instrument panel (on the driver's side).
(A)
EN0773
B2M2969C
(A) Safety stand

(B) Free rollers
EN-44
INSPECTION MODE

connector.
link connector located in the lower portion of the
instrument panel (on the driver's side).
EN0768

connector.
CAUTION:
14) Perform subsequent procedures as instructed

on the display screen.
If trouble still remains in the memory, the corresponding diagnostic trouble code (DTC) appears
NOTE:
For detailed concerning the diagnostic trouble
codes (DTCs), refer to the List of Diagnostic Trouble Code (DTC).
<Ref. to EN-83, List of Diagnostic Trouble Code
(DTC).>
Release the parking brake.
The speed difference between front and rear
wheels may light either the ABS warning light, but
this indicates no malfunctions. When the engine
control diagnosis is finished, perform the ABS

1) After performing the diagnostics and clearing
memory, check for any remaining unresolved trouble data: <Ref. to EN-49, Clear Memory Mode.>
2) Warm up the engine.
3) Connect the test mode connector (A) at the lower side of instrument panel (on the driver's side).
S2M0288C
(A) Power switch

{2. Each System Check} and press the [YES] key.
press the [YES] key.
12) On the Engine Diagnosis display screen, select the {Dealer Check Mode Procedure} and press
the [YES] key.
13) When the Perform Inspection (Dealer Check)
Mode? is shown on the display screen, press the
[YES] key.
EN-45
(A)
EN0773
INSPECTION MODE
4) Connect the OBD-II general scan tool to its data

link connector in the lower portion of instrument
panel (on the driver's side).
CAUTION:
EN0768

NOTE:
Ensure the selector lever is placed in P position
before starting. (AT vehicles)
Depress the clutch pedal when starting engine.
(MT vehicles)
6) Using the selector 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 vehicles)
8) Keep the engine speed in 2,500 3,000 rpm
range for 40 seconds.
9) Place the selector lever or shift lever in D position (AT vehicles) or 1st gear (MT vehicles) and
drive the vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
On AWD vehicles, release the parking brake.
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 OBD-II general scan tool, check for
diagnostic trouble code(s) (DTC(s)) and record the
result(s).
NOTE:
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
(DTC).
<Ref. to EN-83, List of Diagnostic Trouble Code
(DTC).>
EN-46
DRIVE CYCLE
13.Drive Cycle
A: OPERATION
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 12V or more.
2) After performing the diagnostics and cleaning memory, check for any remaining unresolved trouble data.
<Ref. to EN-49, 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
No.
*P0111
*P0125
*P0130
*P0133
*P0170
*P0420
P0445
P0461
*P0464
*P1137
*P1442
Item
Condition
Intake air temperature sensor circuit range/performance problem

Insufficient coolant temperature for closed loop
fuel control
Front oxygen (A/F) sensor circuit range/performance problem (Lean)
Front oxygen (A/F) sensor circuit slow response
Fuel trim malfunction
Catalyst system efficiency below threshold
Evaporative emission control system purge control valve circuit high input
Fuel level sensor circuit range/performance problem
Fuel level sensor intermittent input
Front oxygen (A/F) sensor circuit range/performance problem
Fuel level sensor circuit range/performance problem 2
Coolant temperature at start is less than 30C (86F).

Coolant temperature at start is less than 20C (68F).
EN-47
DRIVE CYCLE
3. IDLE FOR 10 MINUTES

NOTE:
Before the diagnosis, drive the vehicle at 4 km/h (6 MPH) or more.
DTC No.
*P0483
*P0506
*P0507
Item
Condition
Cooling fan function problem

Idle control system RPM lower than expected
Idle control system RPM higher than expected
4. DRIVE ACCORDING TO THE FOLLOWING DRIVE PATTERN

Vehicle speed km/h (MPH)
96 (60)
65 (40)
0
50
150
100
(Seconds)
B2M4775
(A)
(B)
(C)
Idle engine for 1 minute.

Accelerate to 97 km/h (60 MPH)
within 20 seconds.
Drive vehicle at 97 km/h (60 MPH)
for 20 seconds.
DTC No.
*P0121
*P0139
*P0301
*P0302
*P0303
*P0304
*P1142
(D)
(E)
(F)
Decelerate with fully closed throttle to 64 km/h (40 MPH).

Drive vehicle at 64 km/h (40 MPH)
for 10 seconds.
Accelerate to 97 km/h (60 MPH)
within 10 seconds.
Item
Throttle position sensor circuit range/performance problem (high input)
Rear oxygen sensor circuit slow response
Cylinder 1 misfire detected
Throttle position sensor circuit range/performance problem (low input)
EN-48
(G)
Stop vehicle with throttle fully

closed.Stop vehicle with throttle
fully closed.Stop vehicle with
throttle fully closed.
Condition
CLEAR MEMORY MODE

14.Clear Memory Mode
A: OPERATION
For clear memory procedures using the OBD-II

general scan tool, refer to the OBD-II General Scan
Tool Instruction Manual.
After the memory has been cleared, the idle air
control solenoid valve must be initialized. To do
this, turn the ignition switch to ON. Wait 3 seconds
before starting the engine.

MODE)
press [YES] key.
4) On the Engine Diagnosis display screen, select the {Clear Memory} and press [YES] key.
5) When the Done and Turn Ignition Switch OFF
are shown on the display screen, turn the Subaru
Select Monitor and ignition switch to OFF.
NOTE:

MODE)
press [YES] key.
{4. Diagnosis Code(s) Cleared} and press [YES]
key.
6) When the `Clear Diagnostic Code?' is shown on
the display screen, press [YES] key.
7) Turn the Subaru Select Monitor and ignition
switch to OFF.
NOTE:
EN-49
COMPULSORY VALVE OPERATION CHECK MODE

15.Compulsory Valve Operation

Check Mode
A: OPERATION

connector.
EN0768

connector.
S2M0285

Monitor.
Description.>
CAUTION:
S2M0286A
S2M0288E
(A)
EN0773
(A) Power switch

press [YES] key.
10) On the Engine Diagnosis display screen, select the {System Operation Check Mode} and press
[YES] key.
11) On the System Operation Check Mode display screen, select the {Actuator ON/OFF Operation} and press [YES] key.
12) Select the desired compulsory actuator on the
Actuator ON/OFF Operation display screen and
press [YES] key.
EN-50

13) Pressing the [NO] key completes the compulsory operation check mode. The display will then return to
the Actuator ON/OFF Operation screen.
Contents
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 air assist injector solenoid valve operation check
Display
Fuel Pump Relay
Radiator Fan Relay
A/C Compressor Relay
CPC Solenoid Valve
AAI Solenoid Valve
NOTE:
The following parts will be displayed but not functional because they are not installed on the vehicle.
Display
EGR Solenoid Valve
ASV Solenoid Valve
PCV Solenoid Valve
Vent Control Solenoid Valve
FICD Solenoid
Pressure Switching Sol. 1
Fuel Tank Sensor Control Valve
EN-51
ENGINE MALFUNCTION INDICATOR LAMP (MIL)

16.Engine Malfunction Indicator Lamp (MIL)

A: PROCEDURE
1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN-53, ACTIVATION OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).>
2. Check that engine malfunction indicator lamp (MIL) does not come on. <Ref. to EN-54, CHECK ENGINE MALFUNCTION
INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).>
3. Check that engine malfunction indicator lamp (MIL) does not go off. <Ref. to EN-56, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT GO OFF., Engine Malfunction Indicator Lamp (MIL).>
4. Check that engine malfunction indicator lamp (MIL) does not blink at a cycle of 3 Hz. <Ref. to EN-58, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 HZ., Engine Malfunction Indicator Lamp (MIL).>
5. Check that engine malfunction indicator lamp (MIL) remains blinking at a cycle of 3 Hz. <Ref. to EN-60, CHECK ENGINE
MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 HZ., Engine Malfunction Indicator Lamp
(MIL).>
EN-52

B: ACTIVATION OF CHECK ENGINE

MALFUNCTION INDICATOR
LAMP (MIL)
4) When the ignition switch is turned to ON (engine

OFF) or to START with the test mode connector
connected, the MIL blinks at a cycle of 3 Hz.

OFF), the CHECK ENGINE malfunction indicator
lamp (MIL) in the combination meter illuminates.
NOTE:
If the MIL does not illuminate, perform diagnostics
of the CHECK ENGINE light circuit or the combination meter circuit. <Ref. to EN-54, CHECK ENGINE
MALFUNCTION INDICATOR LAMP (MIL) DOES
NOT COME ON., Engine Malfunction Indicator
Lamp (MIL).>
EN0774
2) After starting the engine, the MIL goes out. If it

does not, either the engine or the emission control
system is malfunctioning.
OBD0053A
3) If the diagnosis system senses a misfire which

could damage the catalyzer, the MIL will blink at a
cycle of 1 Hz.
OBD0054A
EN-53
OBD0055A

C: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME

ON.
DIAGNOSIS:
The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), MIL does not come on.
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
No.13
SBF-4
4
LHD
RHD
B36
B38
i1
i3
B36
4
22
23
MT
AT
i1
MT
AT
LHD
SBF-1
RHD
A7
C6
1 LHD :16
COMBINATION
METER
RHD :13
i2
B37
11
A: i10
C: i12
B134 ECM
A:
B72
B36
B134
i1
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
1 2
3 4
5 6
7 8
9 10 11 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
LHD:
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
RHD:
C:
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
i10
1 2 3 4 5 6 7 8 9 10
i3
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
EN1395
Step
Check
CHECK OUTPUT SIGNAL FROM ECM.
Is the voltage less than 1 V?
2)Measure the voltage between ECM connector and chassis ground.
(B134) No. 11 (+) Chassis ground ():
CHECK POOR CONTACT.
Does the MIL come on when
shaking or pulling ECM connector and harness?
EN-54
Yes
Go to step 4.
No
Go to step 2.
Repair the poor

contact in ECM
connector.
Go to step 3.

Step
CHECK ECM CONNECTOR.
CHECK HARNESS BETWEEN COMBINATION METER AND ECM CONNECTOR.

2)Remove the combination meter. <Ref. to IDI15, Combination Meter Assembly.>
3)Disconnect the connector from ECM and
combination meter.
ECM and combination meter connector.
(B134) No. 11 (i12) No. 6:
Check
Yes
Is the ECM connector correctly Replace the ECM.
connected?
<Ref. to FU-51,
Engine Control
Module.>
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.
CHECK HARNESS BETWEEN COMBINATION METER AND IGNITION SWITCH CONNECTOR.
2)Measure the voltage between combination
meter connector and chassis ground.
(i10) No. 7 (+) Chassis ground ():
No
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
(i2)
Go to step 6.
Check the following and repair if

necessary.
NOTE:
Broken down
ignition relay
Blown out fuse
(No. 5)
If replaced fuse
(No. 5) blows easily, check the harness for short
circuit of harness
between fuse (No.
5) and ignition
relay connector.
Open or short
circuit in harness
between fuse (No.
5) and battery terminal
Open circuit in
harness between
fuse (No. 5) and
ignition relay connector
Poor contact in
Poor contact in
ignition switch
connector
Is the lamp bulb condition OK? Repair the combi- Replace the lamp
CHECK LAMP BULB.
Remove the engine malfunction indicator lamp
nation meter con- bulb.
bulb.
nector.
EN-55

D: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT GO

OFF.
DIAGNOSIS:
The CHECK ENGINE malfunction indicator lamp (MIL) circuit is shorted.
TROUBLE SYMPTOM:
Although MIL comes on when engine runs, but trouble code is not shown on Subaru Select Monitor or
OBD-II general scan tool display.
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
No.13
SBF-4
4
LHD
RHD
B36
B38
i1
i3
B36
4
22
23
MT
AT
i1
MT
AT
LHD
SBF-1
RHD
A7
C6
1 LHD :16
COMBINATION
METER
RHD :13
i2
B37
11
A: i10
C: i12
B134 ECM
A:
B72
B36
B134
i1
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
1 2
3 4
5 6
7 8
9 10 11 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
LHD:
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
RHD:
C:
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
i10
1 2 3 4 5 6 7 8 9 10
i3
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
EN1395
Step
Check
Does the MIL come on?
EN-56
Yes
Repair the short
circuit in harness
between combination meter and
ECM connector.
No
Replace the ECM.
<Ref. to FU-51,
Engine Control
Module.>

EN-57

E: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK

AT A CYCLE OF 3 HZ.
DIAGNOSIS:
Test mode connector circuit is open.
TROUBLE SYMPTOM:
During inspection mode, MIL does not blink at a cycle of 3 Hz.
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
No.13
SBF-4
4
LHD
RHD
B36
B38
i1
i3
B36
4
22
23
MT
AT
i1
MT
AT
LHD
SBF-1
RHD
A7
C6
1
0
1 LHD :16
i2
B125
B126
16
B75
B76
B22
E3
B37
RHD :13
A11
A: i10
B14
COMBINATION
METER
C: i12
A: B134
ECM
B: B135
B75
B125
1
2
B72
1 2
3 4
A:
i10
C:
1 2 3 4 5 6 7 8 9 10
B135
i1
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
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B22
i12
1
5
9
13
1 2 3
4 5 6
7 8 9 10 11 12 13 14
RHD:
2
6
10
14
3
7
11
15
B36
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
i2
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
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
LHD:
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
i3
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
EN1396
EN-58

Step
Check
CHECK STATUS OF CHECK ENGINE MAL- Does the MIL come on?
FUNCTION INDICATOR LAMP (MIL).
2)Disconnect the test mode connector.

CHECK HARNESS BETWEEN TEST MODE Is the resistance less than 1

CONNECTOR AND CHASSIS GROUND.
?
test mode connector and chassis ground.
(B76) No. 1 Chassis ground:
CHECK POOR CONTACT.

Check poor contact in ECM connector.
Is there poor contact in ECM

connector?
CHECK HARNESS BETWEEN ECM AND

TEST MODE CONNECTOR.
1)Connect the test mode connector.
ECM and chassis ground.
CHECK POOR CONTACT.

?

connector?
EN-59
Yes
Go to step 2.
No
Repair the MIL circuit. <Ref. to EN54, CHECK
ENGINE MALFUNCTION INDICATOR LAMP
(MIL) DOES NOT
COME ON.,
Engine Malfunction Indicator
Lamp (MIL).>
Repair the ground Go to step 3.
short circuit in harness between
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 chassis
ground
Go to step 5.
Repair the open

circuit in harness
between ECM and
test mode connector.
Replace the ECM.

<Ref. to FU-51,
Engine Control
Module.>

F: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 HZ.
DIAGNOSIS:
Test mode connector circuit is shorted.
TROUBLE SYMPTOM:
MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON.
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
No.13
SBF-4
4
LHD
RHD
B36
B38
i1
i3
B36
4
22
23
MT
AT
i1
MT
AT
LHD
SBF-1
RHD
A7
C6
1
0
1 LHD :16
i2
B125
B126
16
B75
B76
B22
E3
B37
RHD :13
A11
A: i10
B14
COMBINATION
METER
C: i12
A: B134
ECM
B: B135
B75
B125
1
2
B72
1 2
3 4
B135
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
A:
i10
C:
1 2 3 4 5 6 7 8 9 10
1
5
9
13
1 2 3
4 5 6
7 8 9 10 11 12 13 14
i1
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B22
i12
RHD:
2
6
10
14
3
7
11
15
B36
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
i2
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
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
LHD:
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
i3
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
EN1396
EN-60

Step
CHECK TEST MODE CONNECTOR.
Check
Yes
Does the MIL flash on and off? Go to step 2.
CHECK HARNESS BETWEEN ECM CONIs the resistance less than 5

NECTOR AND ENGINE GROUNDING TER- ?
MINAL.
ECM connector and chassis ground.
EN-61
No
System is in good
order.
NOTE:
MIL 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-51,
between ECM and Engine Control
test mode connec- Module.>
tor.
DIAGNOSTICS FOR ENGINE STARTING FAILURE

17.Diagnostics for Engine Starting Failure

A: PROCEDURE
1.
Inspection of starter motor circuit. <Ref. to EN-64, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
2. Inspection of ECM power supply and ground line. <Ref. to EN-68, CONTROL MODULE POWER SUPPLY AND GROUND
LINE, Diagnostics for Engine Starting Failure.>
3. Inspection of ignition control system. <Ref. to EN-72, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.>
4. Inspection of fuel pump circuit. <Ref. to EN-76, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
5. Inspection of fuel injector circuit. <Ref. to EN-80, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
EN-62

EN-63

B: STARTER MOTOR CIRCUIT

CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN-49, Clear
Memory Mode.> and INSPECTION MODE <Ref. to EN-42, Inspection Mode.> .
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-4
IGNITION
SWITCH
B72
INHIBITOR SWITCH
P
12
AT
MT
12
11
7
T3
T7
MT
B12
R N D
B135 ECM
28
AT
B14
STARTER
MOTOR
B72
B12
T7
B135
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
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
EN0862
1
2
Step
Check
CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate when the switch starts?
CHECK DIAGNOSTIC TROUBLE CODE
Is the DTC stored in memory?
(DTC).
<Ref. to EN-83, LIST, List of
<Ref. to EN-41, OPERATION, Read Diagnos- Diagnostic Trouble Code
tic Trouble Code (DTC).>
(DTC).>
EN-64
Yes
Go to step 2.
No
Go to step 3.
Record the DTC. Go to step 3.

Repair the trouble
case. <Ref. to EN90, Diagnostic
Procedure with
Diagnostic Trouble Code (DTC).>

Step
Check
Yes
CHECK INPUT SIGNAL FOR STARTER MO- Is the voltage more than 10 V? Go to step 4.
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:
On AT vehicles, place the selector lever in the
P or N position.
CHECK GROUND CIRCUIT OF STARTER
MOTOR.
2)Disconnect the terminal from starter motor.
3)Measure the resistance of ground cable
between ground cable terminal and engine
ground.
STARTER MOTOR CIRCUIT.
2)Measure the resistance between starter
motor and ECM.
(B14) No. 1 Engine ground:
2)Measure the resistance of fuse.
CHECK HARNESS BETWEEN BATTERY
AND IGNITION SWITCH CONNECTOR.
2)Disconnect the connector from ignition
switch.
ignition switch connector and chassis ground.
1)Connect the connector to ignition switch.
3)Measure the voltage between ignition switch
and chassis ground.
CHECK TRANSMISSION TYPE.
No
Go to step 5.

?
Check the starter

motor. <Ref. to
SC-5, Starter.>
Repair the open

circuit of ground
cable.

?

short circuit.

?
Go to step 7.
Repair the ground

short circuit.
Repair the open

circuit in harness
between ignition
switch and battery.
Replace the ignition switch.
Is the vehicle AT?
Repair the open

circuit between
ignition switch and
starter motor circuit.
EN-65
Go to step 10.

10
11
12
Step
CHECK INHIBITOR SWITCH CIRCUIT.
2)Place the selector lever in the P or N position.
3)Separate the transmission harness connector.
4)Measure the resistance between transmission harness connector receptacle's terminals.
(T3) No. 11 No. 12:
CHECK TRANSMISSION HARNESS.
1)Disconnect the connector from inhibitor
switch.
transmission harness and inhibitor switch connector.
(T3) No. 11 (T7) No. 7:
CHECK POOR CONTACT.
Check poor contact in inhibitor switch connector.
Check
?
Yes
No
Repair the open
Go to step 11.
circuit in harness
between starter
motor and ignition
switch connector.

?
Go to step 12.
Is there poor contact in inhibitor switch connector?
Repair the poor

Replace the inhibicontact in inhibitor tor switch.
switch connector.
EN-66
Repair the open

circuit in harness
between transmission harness and
inhibitor switch
connector.

EN-67

C: CONTROL MODULE POWER SUPPLY AND GROUND LINE

CAUTION:
Memory Mode.> and INSPECTION MODE. <Ref. to EN-42, Inspection Mode.>
WIRING DIAGRAM:
RHD
TO FRONT OXYGEN (A/F) SENSOR
4
6
RHD
MAIN RELAY
LHD
5
3
B61
2
1
SBF-5
LHD
2
F44
IGNITION
B72
SWITCH
B47
BATTERY
No.11
SBF-4
1
B19
C1
C2
C9
B7
SBF-1
A: B134
B: B135 ECM
1 AT MODEL: B6
MT MODEL: B25
13
15
14
16
C21
A34
A35
A7
A8
A27
C22
C: B136
B22
E3
B72
1 2
3 4
F44
1 2 3 4
5 6 7 8
B47
1
3
5
2
4
6
B: B135
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
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
C: B136
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
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
EN1397
Step
Check
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:
EN-68
Yes
Go to step 2.
No
Replace the main
relay.

Step
CHECK GROUND CIRCUIT OF ECM.
(B135) No. 25 Chassis ground: (MT
vehicle)
(B135) No. 6 Chassis ground: (AT
vehicle)
CHECK INPUT VOLTAGE OF ECM.
Measure the voltage between ECM connector
and chassis ground.
MAIN RELAY CONNECTOR.
2)Measure the resistance between ECM and
chassis ground.
CHECK OUTPUT VOLTAGE FROM ECM.
1)Connect the connector to ECM.
CHECK INPUT VOLTAGE OF MAIN RELAY.
Check the voltage between main relay connector and chassis ground.
Check
?
Yes
Go to step 3.
No
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


M?
Repair the ground

ECM connector
and main relay
connector, then
replace the ECM.
Replace the ECM.
Go to step 6.
CHECK GROUND CIRCUIT OF MAIN REIs the resistance less than 5

Go to step 9.
LAY.
?
CHECK INPUT VOLTAGE OF MAIN RELAY. Is the voltage more than 10 V? Go to step 10.
Measure the voltage between main relay connector and chassis ground.
EN-69
Repair the open

circuit in harness
between ECM
connector and
main relay connector.
Repair the open
circuit between
main relay and
chassis ground.
Repair the open or

ground short circuit in harness of
power supply circuit.

10
Step
Check
1)Connect the main relay connector.
EN-70
Yes
Check the ignition
control system.
<Ref. to EN-72,
IGNITION CONTROL SYSTEM,
Diagnostics for
Engine Starting
Failure.>
No
Repair the open or
ground short circuit in harness
between ECM
connector and

EN-71

D: IGNITION CONTROL SYSTEM

CAUTION:
WIRING DIAGRAM:
27
26
25
B134 ECM
B72
IGNITION
SWITCH
BATTERY
SBF-1
SBF-4
NO.11
4
14
6
5
4
B22
E3
2.0L AND 2.5L: 1

1.6L: 4
2.0L AND 2.5L: 2

1.6L: 1
E12
3
1
2
3
3
1 2.0L AND 2.5L: 4

1.6L: 2
IGNITOR
&
IGNITION COIL ASSY
E12
B72
1 2 3 4
1 2
3 4
B134
B22
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 32 33
34 35
EN1398
Step
CHECK IGNITION SYSTEM FOR SPARKS.
1)Remove the plug cord cap from each spark
plug.
2)Install new spark plug on plug cord cap.
Check
Does spark occur at each cylinder?
CAUTION:
Do not remove spark plug from engine.
3)Contact the spark plug's thread portion on
engine.
4)While opening the throttle valve fully, crank
engine to check that spark occurs at each cylinder.
EN-72
Yes
No
Check the fuel
Go to step 2.
pump system.
<Ref. to EN-76,
FUEL PUMP CIRCUIT, Diagnostics
for Engine Starting Failure.>

Step
Check
Yes
CHECK POWER SUPPLY CIRCUIT FOR IG- Is the voltage more than 10 V? Go to step 3.
NITION COIL & IGNITOR ASSEMBLY.
2)Disconnect the connector from ignition coil &
ignitor assembly.
ignition coil & ignitor assembly connector and
engine ground.
2.0 L and 2.5 L
(E12) No. 2 (+) Engine ground ():
1.6 L
CHECK HARNESS OF IGNITION COIL & IG- Is the resistance between less Go to step 4.
NITOR ASSEMBLY GROUND CIRCUIT.
than 5 ?
2)Measure the resistance between ignition coil
& ignitor assembly connector and engine
ground.
(E12) No. 3 Engine ground:
CHECK IGNITION COIL & IGNITOR ASSEMBLY.

1)Remove the spark plug cords.
2)Measure the resistance between spark plug
cord contact portions to check secondary coil.
Terminals
2.0 L and 2.5 L
No. 1 No. 2:
1.6 L
No. 4 No. 1:
Measure the resistance between spark plug
Terminals
2.0 L and 2.5 L
No. 3 No. 4:
1.6 L
No. 3 No. 2:
CHECK INPUT SIGNAL FOR IGNITION COIL
& IGNITOR ASSEMBLY.
1)Connect the connector to ignition coil & ignitor assembly.
2)Check if the voltage varies synchronously
with engine speed when cranking, while monitoring voltage between ignition coil & ignitor
assembly connector and engine ground.
2.0 L and 2.5 L
1.6 L
No
NOTE:
the following:
Open circuit in
harness between
ignition coil & ignitor assembly, and
ignition switch
connector
Poor contact in
coupling connectors (B22)
NOTE:
the following:
Open circuit in
harness between
ignition coil & ignitor assembly connector and engine
grounding terminal
Replace the ignition coil & ignitor
assembly. <Ref. to
IG-8, Ignition Coil
and Ignitor Assembly.>
Is the resistance between 10

and 15 k?
Go to step 5.

and 15 k?
Go to step 6.

assembly. <Ref. to
IG-8, Ignition Coil

assembly. <Ref. to
IG-8, Ignition Coil
EN-73

10
11
Step
Check
Yes
CHECK INPUT SIGNAL FOR IGNITION COIL Is the voltage more than 10 V? Go to step 8.
& IGNITOR ASSEMBLY.
Check if the voltage varies synchronously with
engine speed when cranking, while monitoring
voltage between ignition coil & ignitor assembly connector and engine ground.
2.0 L and 2.5 L
1.6 L
CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1
Go to step 9.
NITION COIL & IGNITOR ASSEMBLY CON- ?
NECTOR.
ignitor assembly.
ECM and ignition coil & ignitor assembly connector.
2.0 L and 2.5 L
(B134) No. 25 (E12) No. 1:
1.6 L
(B134) No. 25 (E12) No. 4:
NECTOR.
2.0 L and 2.5 L
(B134) No. 26 (E12) No. 4:
1.6 L
(B134) No. 26 (E12) No. 2:
Go to step 10.
CHECK HARNESS BETWEEN ECM AND IGNITION COIL & IGNITOR ASSEMBLY CONNECTOR.
ECM and engine ground.
Connector & terminal:

M?
Go to step 11.

M?
Go to step 12.
EN-74
No
assembly. <Ref. to
IG-8, Ignition Coil

NOTE:
the following:
Open circuit in
harness between
ECM and ignition
coil & ignitor
assembly connector
Poor contact in
coupling connector
(B22)
NOTE:
the following:
Open circuit in
harness between
ECM and ignition
coil & ignitor
assembly connector
Poor contact in
coupling connector
(B22)
Repair the ground
ECM and ignition
coil & ignitor
assembly connector.
Repair the ground
ECM and ignition
coil & ignitor
assembly connector.

12
Step
CHECK POOR CONTACT.
Check
connector?
EN-75
Yes
Repair the poor
contact in ECM
connector.
No
Check the fuel
pump circuit. <Ref.
to EN-76, FUEL
PUMP CIRCUIT,
Diagnostics for
Engine Starting
Failure.>

E: FUEL PUMP CIRCUIT
RHD
RHD
CAUTION:
WIRING DIAGRAM:
LHD
B61
SBF-5
LHD
B72
F44
IGNITION
SWITCH
BATTERY
No.11
SBF-4
4
FUEL PUMP
RELAY
SBF-1
2
1
3
4
B134 ECM
B46
B97
1 LHD :7
R1
RHD :5
2 WITH
IMMOBILIZER :29
WITHOUT
IMMOBILIZER :16
FUEL PUMP
1
4
R58
B46
1 2
3 4
B72
1 2
3 4
1
3
R57
R15
R58
1 2 3
4 5 6
F44
1 2 3 4
5 6 7 8
B97
1 2 3 4
5 6 7 8
R15
B134
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
EN1399
Step
Check
CHECK OPERATING SOUND OF FUEL
Does the fuel pump produce
PUMP.
operating sound?
Make sure that the fuel pump is in operation for
2 seconds when turning ignition switch to ON.
NOTE:
Fuel pump operation can also be executed using the Subaru Select Monitor (Function mode:
FD01).
For the procedure, refer to Compulsory Valve
Operation Check Mode. <Ref. to EN-50, Compulsory Valve Operation Check Mode.>
EN-76
Yes
No
Check the fuel
Go to step 2.
injector circuit.
<Ref. to EN-80,
FUEL INJECTOR
CIRCUIT, Diagnostics for Engine
Starting Failure.>

Step
Check
CHECK GROUND CIRCUIT OF FUEL PUMP. Is the resistance less than 5
?
2)Remove the fuel pump access hole lid
located on the right rear of trunk compartment
floor (Sedan) or luggage compartment floor
(Wagon).
3)Disconnect the connector from fuel pump.
4)Measure the resistance of harness connector between fuel pump and chassis ground.
(R58) No. 4 Chassis ground:
CHECK POWER SUPPLY TO FUEL PUMP.

2)Measure the voltage of power supply circuit
between fuel pump connector and chassis
ground.
(R58) No. 1 (+) Chassis ground ():
CHECK HARNESS BETWEEN FUEL PUMP
AND FUEL PUMP RELAY CONNECTOR.
2)Measure the resistance of harness connector between fuel pump and fuel pump relay.
(R58) No. 1 (B46) No. 4:

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. 1 and No. 3.
4)Measure the resistance between connector
terminals of fuel pump relay.
Terminals
No. 2 No. 4:
Yes
Go to step 3.
Is the voltage more than 10 V? Replace the fuel

pump. <Ref. to
FU-62, Fuel
Pump.>

?
Go to step 5.

M?
Go to step 6.

?
Go to step 7.
EN-77
No
NOTE:
the following:
Open circuit in
harness between
fuel pump connector and chassis
grounding terminal
Poor contact in
coupling connector
(R15)
Go to step 4.

NOTE:
the following:
Open circuit in
harness between
grounding terminal
Poor contact in
coupling connectors
(R15 and B97)
Repair the short
circuit in harness
between fuel
pump and fuel
pump relay connector.
Replace the fuel
pump relay. <Ref.
to FU-53, Fuel
Pump Relay.>

Step
FUEL PUMP RELAY CONNECTOR.
1)Disconnect the connectors from ECM.
ECM and fuel pump relay connector.
With immobilizer
(B134) No. 29 (B46) No. 3:
Without immobilizer
(B134) No. 16 (B46) No. 3:
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-80,
FUEL INJECTOR
Starting Failure.>
EN-78

EN-79

F: FUEL INJECTOR CIRCUIT

CAUTION:
Check or repair only faulty parts.
Memory Mode.> and INSPECTION MODE. <Ref. to EN-42, Inspection Mode.>
WIRING DIAGRAM:
RHD
4
6
5
3
RHD
MAIN RELAY
LHD
B61
BATTERY
SBF-5
LHD
F44
2
1
C1
A15
A14
11
10
A4
9
C: B136 ECM
A13
A: B134
B22
12
C2
B47
E3
FUEL INJECTOR
No.1
E5
E16
E6
E17
1 2
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
FUEL INJECTOR
No.2
B47
1
3
5
FUEL INJECTOR
No.3
FUEL INJECTOR
No.4
B22
F44
2
4
6
E17
2
E6
E16
E5
1 2 3 4
5 6 7 8
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
A: B134
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
EN0866
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 attach a screwdriver to injector
for this check.
EN-80
Yes
No
Check the fuel
Go to step 2.
pressure. <Ref. to
ME-29, INSPECTION, Fuel Pressure.>

Step
Check
Yes
CHECK POWER SUPPLY TO EACH FUEL
INJECTOR.
2)Disconnect the connector from #1 cylinder
fuel injector.
the fuel injector terminal and engine ground.
#1 (E5) No. 2 (+) Engine ground ():

and 20 ?
FUEL INJECTOR CONNECTOR.
ECM and fuel injector connector.
(B134) No. 4 (B136) No. 2:

(B134) No. 13 (B136) No. 2:


?

and 20 ?

?
EN-81
Go to step 4.
No
NOTE:
the following:
Open circuit in
harness between
main relay and fuel
injector connector
Poor contact in
main relay connector
Poor contact in
coupling connector
(B22)
Poor contact in
fuel injector connector
NOTE:
the following:
Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
coupling connector
(B22)
ECM and fuel
injector connector.
Go to step 6.
NOTE:
the following:
Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
coupling connector
(B22)
ECM and fuel
injector connector.

10
11
12
Step
(B134) No. 14 (B136) No. 2:
Check
and 20 ?

(B134) No. 15 (B136) No. 2:

?

CHECK EACH FUEL INJECTOR.
2)Measure the resistance between each fuel
injector terminals.
Terminals
No. 1 No. 2:
CHECK POOR CONTACT.

and 20 ?

?
Yes
Go to step 8.
No
NOTE:
the following:
Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
coupling connector
(B22)
ECM and fuel
injector connector.
Go to step 10.
NOTE:
the following:
Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
coupling connector
(B22)
ECM and fuel
injector connector.

and 20 ?
Go to step 12.
Replace the faulty

fuel injector.

connector?
Repair the poor

contact in ECM
connector.
Inspection using
General Diagnostic Table. <Ref. to
EN-292, INSPECTION, General
Diagnostic Table.>
EN-82
LIST OF DIAGNOSTIC TROUBLE CODE (DTC)

18.List of Diagnostic Trouble Code (DTC)

A: LIST
DTC
No.
P0031
P0032
P0037
P0038
P0066
P0067
P0106
P0107
P0108
P0111
P0112
P0113
P0117
P0118
P0121
P0122
P0123
P0125
Item
Index
Front oxygen (A/F) sensor heater cir- <Ref. to EN-90, DTC P0031 FRONT OXYGEN (A/F) SENSOR HEATER
cuit low input
CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Front oxygen (A/F) sensor heater cir- <Ref. to EN-94, DTC P0032 FRONT OXYGEN (A/F) SENSOR HEATER
cuit high input
CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Rear oxygen sensor heater circuit
<Ref. to EN-96, DTC P0037 REAR OXYGEN SENSOR HEATER CIRmalfunction
CUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN-100, DTC P0038 REAR OXYGEN SENSOR HEATER CIRhigh input
CUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Air assist injector solenoid valve cir- <Ref. to EN-102, DTC P0066 AIR ASSIST INJECTOR SOLENOID
cuit low input
VALVE CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
Air assist injector solenoid valve cir- <Ref. to EN-104, DTC P0067 AIR ASSIST INJECTOR SOLENOID
cuit high input
VALVE CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic
Pressure sensor circuit range/perfor- <Ref. to EN-106, DTC P0106 PRESSURE SENSOR CIRCUIT RANGE/
mance problem (low input)
PERFORMANCE PROBLEM (LOW INPUT) , Diagnostic Procedure with
<Ref. to EN-110, DTC P0107 PRESSURE SENSOR CIRCUIT LOW
INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN-114, DTC P0108 PRESSURE SENSOR CIRCUIT HIGH
Intake air temperature sensor circuit <Ref. to EN-118, DTC P0111 INTAKE AIR TEMPERATURE SENSOR
range/performance problem
CIRCUIT RANGE/PERFORMANCE PROBLEM , Diagnostic Procedure
with Diagnostic Trouble Code (DTC).>
low input
Code (DTC).>
high input
Code (DTC).>
<Ref. to EN-126, DTC P0117 ENGINE COOLANT TEMPERATURE SENcircuit low input
SOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN-128, DTC P0118 ENGINE COOLANT TEMPERATURE SENcircuit high input
SOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Throttle position sensor circuit range/ <Ref. to EN-132, DTC P0121 THROTTLE POSITION SENSOR CIRCUIT
performance problem (high input)
RANGE/PERFORMANCE PROBLEM (HIGH INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Throttle position sensor circuit low
<Ref. to EN-134, DTC P0122 THROTTLE POSITION SENSOR CIRCUIT
input
LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Throttle position sensor circuit high
<Ref. to EN-138, DTC P0123 THROTTLE POSITION SENSOR CIRCUIT
input
HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Insufficient coolant temperature for
<Ref. to EN-140, DTC P0125 INSUFFICIENT COOLANT TEMPERAclosed loop fuel control
TURE FOR CLOSED LOOP FUEL CONTROL , Diagnostic Procedure
EN-83

DTC
No.
P0130
P0131
P0132
P0133
P0136
P0139
P0170
P0301
P0302
P0303
P0304
P0327
P0328
P0335
P0336
P0340
P0341
P0420
P0444
P0445
P0461
Item
Index
Front oxygen (A/F) sensor circuit

range/performance problem (Lean)
<Ref. to EN-142, DTC P0130 FRONT OXYGEN (A/F) SENSOR CIRCUIT

RANGE/PERFORMANCE PROBLEM (LEAN) , Diagnostic Procedure with
malfunction (open circuit)
MALFUNCTION (OPEN CIRCUIT) , Diagnostic Procedure with Diagnostic
malfunction (short circuit)
MALFUNCTION (SHORT CIRCUIT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
slow response
SLOW RESPONSE , Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Rear oxygen sensor circuit malfunc- <Ref. to EN-150, DTC P0136 REAR OXYGEN SENSOR CIRCUIT MALtion
FUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Rear oxygen sensor circuit slow
<Ref. to EN-154, DTC P0139 REAR OXYGEN SENSOR CIRCUIT SLOW
response
RESPONSE , Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Fuel trim malfunction
<Ref. to EN-156, DTC P0170 FUEL TRIM MALFUNCTION , Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN-158, DTC P0301 CYLINDER 1 MISFIRE DETECTED ,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN-166, DTC P0327 KNOCK SENSOR CIRCUIT LOW INPUT
, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN-168, DTC P0328 KNOCK SENSOR CIRCUIT HIGH INPUT
Crankshaft position sensor circuit
<Ref. to EN-170, DTC P0335 CRANKSHAFT POSITION SENSOR CIRmalfunction
CUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN-172, DTC P0336 CRANKSHAFT POSITION SENSOR CIRrange/performance problem
CUIT RANGE/PERFORMANCE PROBLEM , Diagnostic Procedure with
Camshaft position sensor circuit mal- <Ref. to EN-174, DTC P0340 CAMSHAFT POSITION SENSOR CIRCUIT
function
MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Camshaft position sensor circuit
<Ref. to EN-176, DTC P0341 CAMSHAFT POSITION SENSOR CIRCUIT
RANGE/PERFORMANCE PROBLEM , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Catalyst system efficiency below
<Ref. to EN-179, DTC P0420 CATALYST SYSTEM EFFICIENCY
threshold
BELOW THRESHOLD , Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Evaporative emission control system <Ref. to EN-184, DTC P0444 EVAPORATIVE EMISSION CONTROL
purge control valve circuit low input
SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT , Diagnostic
Evaporative emission control system <Ref. to EN-188, DTC P0445 EVAPORATIVE EMISSION CONTROL
purge control valve circuit high input SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT , Diagnostic
Fuel level sensor circuit range/perfor- <Ref. to EN-190, DTC P0461 FUEL LEVEL SENSOR CIRCUIT RANGE/
mance problem
PERFORMANCE PROBLEM , Diagnostic Procedure with Diagnostic
EN-84

DTC
No.
P0462
P0463
P0464
P0480
P0483
P0500
P0506
Idle control system RPM lower than

expected
P0507
Idle control system RPM higher than

expected
P0512
P0513
P0562
Charge system circuit low input
P0563
Charge system circuit high input
P0604
Internal control module memory

check sum error
P0703
P0705
P0731
Transmission range sensor circuit

malfunction
Transmission fluid temperature sensor circuit malfunction
Torque converter turbine speed sensor circuit malfunction
Output speed sensor (vehicle speed
sensor 2) circuit malfunction
Engine speed input circuit malfunction
P0732
P0733
P0734
P0741
Torque converter clutch system malfunction
P0743
Torque converter clutch system

(Lock-up duty solenoid) electrical
P0710
P0715
P0720
P0725
Item
Index
<Ref. to EN-192, DTC P0462 FUEL LEVEL SENSOR CIRCUIT LOW
<Ref. to EN-196, DTC P0463 FUEL LEVEL SENSOR CIRCUIT HIGH
<Ref. to EN-200, DTC P0464 FUEL LEVEL SENSOR INTERMITTENT
INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN-203, DTC P0480 COOLING FAN RELAY 1 CIRCUIT LOW
<Ref. to EN-207, DTC P0483 COOLING FAN FUNCTION PROBLEM ,
<Ref. to EN-210, DTC P0500 VEHICLE SPEED SENSOR MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN-212, DTC P0506 IDLE CONTROL SYSTEM RPM LOWER
THAN EXPECTED , Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN-214, DTC P0507 IDLE CONTROL SYSTEM RPM HIGHER
THAN EXPECTED , Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN-216, DTC P0512 STARTER SWITCH CIRCUIT HIGH INPUT
<Ref. to IM-22, DTC P0153 INCORRECT IMMOBILIZER KEY (USE OF
UNREGISTERED KEY), Diagnostics Chart with Diagnostic Trouble Code
(DTC).>
<Ref. to EN-218, DTC P0562 CHARGE SYSTEM CIRCUIT LOW INPUT
<Ref. to EN-220, DTC P0563 CHARGE SYSTEM CIRCUIT HIGH INPUT
<Ref. to EN-222, DTC P0604 INTERNAL CONTROL MODULE MEMORY
CHECK SUM ERROR , Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN-224, DTC P0703 BRAKE SWITCH INPUT MALFUNCTION
<Ref. to AT-119, CHECK INHIBITOR SWITCH., Diagnostic Procedure for
No-diagnostic Trouble Code (DTC).>
<Ref. to AT-46, DTC 27 ATF TEMPERATURE SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to AT-62, DTC 36 TORQUE CONVERTER TURBINE SPEED SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to AT-57, DTC 33 FRONT VEHICLE SPEED SENSOR, Diagnostic
<Ref. to AT-42, DTC 11 ENGINE SPEED SIGNAL, Diagnostic Procedure
<Ref. to EN-226, DTC P0731 GEAR 1 INCORRECT RATIO , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN-228, DTC P0741 TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to AT-94, DTC 77 LOCK-UP DUTY SOLENOID, Diagnostic Procedure
EN-85

DTC
No.
P0748
P0753
P0758
P0778
P0785
P1110
P1111
P1112
P1137
P1142
P1146
P1442
P1480
P1507
P1510
P1511
P1512
P1513
P1514
P1515
Item
Index
Pressure control solenoid (Line pressure duty solenoid) electrical

Shift solenoid A (Shift solenoid 1)
electrical
Shift solenoid B (Shift solenoid 2)
electrical
2-4 brake pressure control solenoid
valve circuit malfunction
2-4 brake timing control solenoid
Atmospheric pressure sensor circuit
low input
<Ref. to AT-86, DTC 75 LINE PRESSURE DUTY SOLENOID, Diagnostic

<Ref. to AT-70, DTC 71 SHIFT SOLENOID 1, Diagnostic Procedure with
<Ref. to AT-90, DTC 76 2-4 BRAKE DUTY SOLENOID, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to AT-82, DTC 74 2-4 BRAKE TIMING SOLENOID, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN-230, DTC P1110 ATMOSPHERIC PRESSURE SENSOR
Code (DTC).>
Atmospheric pressure sensor circuit <Ref. to EN-234, DTC P1111 ATMOSPHERIC PRESSURE SENSOR
high input
Code (DTC).>
Atmospheric pressure sensor circuit <Ref. to EN-238, DTC P1112 ATMOSPHERIC PRESSURE SENSOR
Throttle position sensor circuit range/ <Ref. to EN-242, DTC P1142 THROTTLE POSITION SENSOR CIRCUIT
performance problem (low input)
RANGE/PERFORMANCE PROBLEM (LOW INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Pressure sensor circuit range/perfor- <Ref. to EN-244, DTC P1146 PRESSURE SENSOR CIRCUIT RANGE/
mance problem (high input)
PERFORMANCE PROBLEM (HIGH INPUT) , Diagnostic Procedure with
Fuel level sensor circuit range/perfor- <Ref. to EN-247, DTC P1442 FUEL LEVEL SENSOR CIRCUIT RANGE/
mance problem 2
PERFORMANCE PROBLEM 2 , Diagnostic Procedure with Diagnostic
Cooling fan relay 1 circuit high input <Ref. to EN-249, DTC P1480 COOLING FAN RELAY 1 CIRCUIT HIGH
Idle control system malfunction (fail- <Ref. to EN-252, DTC P1507 IDLE CONTROL SYSTEM MALFUNCTION
safe)
(FAIL-SAFE) , Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Idle air control solenoid valve signal
<Ref. to EN-254, DTC P1510 IDLE AIR CONTROL SOLENOID VALVE
1 circuit low input
SIGNAL 1 CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic
1 circuit high input
SIGNAL 1 CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic
2 circuit low input
3 circuit low input
EN-86

DTC
No.
P1516
Item
4 circuit low input
P1517

P1518
P1540
Vehicle speed sensor malfunction 2
P1560
P1570
Antennna
P1571
P1572
P1574
IMM circuit failure except antenna

circuit
P1576
P1577
P1590
Neutral position switch circuit high

input (AT model)
P1591
Neutral position switch circuit low

input (AT model)
P1592

input (MT model)
P1594
Automatic transmission diagnosis

input signal circuit malfunction
P1595

input signal circuit low input
P1596

input signal circuit high input
P1698
P1699
P1700

P1701
P1703
Low clutch timing control solenoid

Index
<Ref. to EN-262, DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT
<Ref. to EN-264, DTC P1540 VEHICLE SPEED SENSOR MALFUNCTION 2 , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN-266, DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to IM-24, DTC P1570 ANTENNA, Diagnostics Chart with Diagnostic
<Ref. to IM-17, DTC P1571 REFERENCE CODE INCOMPATIBILITY, Diagnostics Chart with Diagnostic Trouble Code (DTC).>
<Ref. to IM-18, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA
CIRCUIT), Diagnostics Chart with Diagnostic Trouble Code (DTC).>
<Ref. to IM-21, DTC P1574 KEY COMMUNICATION FAILURE, Diagnostics
Chart with Diagnostic Trouble Code (DTC).>
<Ref. to IM-22, DTC P1576 EGI CONTROL MODULE EEPROM, Diagnostics Chart with Diagnostic Trouble Code (DTC).>
<Ref. to IM-22, DTC P1577 IMM CONTROL MODULE EEPROM, Diagnostics Chart with Diagnostic Trouble Code (DTC).>
<Ref. to EN-268, DTC P1590 NEUTRAL POSITION SWITCH CIRCUIT
HIGH INPUT (AT MODEL) , Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
LOW INPUT (AT MODEL) , Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
LOW INPUT (MT MODEL) , Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN-276, DTC P1594 AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT MALFUNCTION , Diagnostic Procedure
<Ref. to EN-278, DTC P1595 AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT LOW INPUT , Diagnostic Procedure with
<Ref. to EN-280, DTC P1596 AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT HIGH INPUT , Diagnostic Procedure with
<Ref. to EN-282, DTC P1698 ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN-284, DTC P1699 ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to AT-50, DTC 31 THROTTLE POSITION SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN-286, DTC P1701 CRUISE CONTROL SET SIGNAL CIRCUIT
MALFUNCTION FOR AUTOMATIC TRANSMISSION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to AT-78, DTC 73 LOW CLUTCH TIMING SOLENOID, Diagnostic
EN-87

DTC
No.
P1711
P1712
Item
Index
Engine torque control signal 1 circuit

malfunction
<Ref. to EN-288, DTC P1711 ENGINE TORQUE CONTROL SIGNAL 1

CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN-290, DTC P1712 ENGINE TORQUE CONTROL SIGNAL 2
Code (DTC).>

malfunction
EN-88

EN-89
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)

19.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC P0031 FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT LOW INPUT
DTC DETECTING CONDITION:
Immediately at fault recognition
RHD
MAIN RELAY
RHD
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION,
Clear Memory Mode.> and Inspection Mode <Ref. to EN-42, OPERATION, Inspection Mode.> .
WIRING DIAGRAM:
6
4
B47
1
3
5
LHD
LHD
BATTERY
SBF-5
F44
B61
2
4
6
5
3
B47
B18
2
1
1 2 3
4 5 6
FRONT OXYGEN
(A/F) SENSOR
4
6
3
1
B18
F44
1 2 3 4
5 6 7 8
B22
C7
C20
C6
C19
C23
A22
A23
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
A: B134
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
A: B134
ECM
A34
A35
C: B136
C: B136
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
B22
E3
EN1400
Step
CHECK ANY OTHER DIAGNOSTIC TROUBLE CODE (DTC) ON DISPLAY.
Check
Yes
Does the Subaru Select Moni- Go to step 2.
indicate DTC P0031 and
P0037 at the same time?
EN-90
No
Go to step 5.

Step
Check
Yes
CHECK POWER SUPPLY TO FRONT OXY- Is the voltage more than 10 V? Go to step 3.
GEN (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.


?
Is the value more than 0.2 A?

CHECK CURRENT DATA.
1)Start the engine.
2)Read the data of front oxygen (A/F) sensor
heater current using Subaru Select Monitor or
OBD-II general scan tool.
NOTE:
Subaru Select Monitor
READ CURRENT DATA FOR ENGINE.
<Ref. to EN-34, Subaru Select Monitor.>
OBD-II scan tool
1)Start and idle the engine.
and chassis ground.
and chassis ground.
Go to step 4.
Repair the poor

contact in connector.
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
NOTE:
the following:
Open circuit in
harness between
ECM and engine
ground terminal
Poor contact in
ECM connector
Poor contact in
coupling connector
(B22)
Go to step 5.
NOTE:
the following:
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Is the voltage less than 1.0 V? Go to step 7.
Go to step 6.
Does the voltage change less

than 1.0 V by shaking harness
and connector of ECM while
monitoring the value with voltage meter?
Is the voltage less than 1.0 V?
Repair the poor

contact in ECM
connector.
Go to step 7.
Go to step 9.
Go to step 8.
EN-91

Step
and chassis ground.
CHECK FRONT OXYGEN (A/F) SENSOR.
2)Measure the resistance between front oxygen (A/F) sensor connector terminals.
Terminals
No. 2 No. 5:
Check
?
EN-92
Yes
Repair the poor
contact in ECM
connector.
No
Go to step 9.
Repair the harReplace the front

ness and connec- oxygen (A/F) sentor.
sor. <Ref. to FU54, Fuel.>
NOTE:
the following:
Open or ground
front oxygen (A/F)
sensor and ECM
connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector

EN-93

B: DTC P0032 FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT HIGH INPUT
RHD
MAIN RELAY
RHD
CAUTION:
Clear Memory Mode.> and Inspection Mode <Ref. to EN-42, Inspection Mode.> .
WIRING DIAGRAM:
6
4
B47
1
3
5
LHD
LHD
BATTERY
SBF-5
F44
B61
2
4
6
5
3
B47
B18
2
1
1 2 3
4 5 6
FRONT OXYGEN
(A/F) SENSOR
4
6
3
1
B18
F44
1 2 3 4
5 6 7 8
B22
C7
C20
C6
C19
C23
A22
A23
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
A: B134
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
A: B134
ECM
A34
A35
C: B136
C: B136
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
B22
E3
EN1400
Step
Check
EN-94
Yes
Go to step 3.
No
Go to step 2.

Step
Check
and chassis ground.
CHECK FRONT OXYGEN (A/F) SENSOR
HEATER CURRENT.
2)Repair the battery short circuit in harness
between ECM and front oxygen (A/F) sensor
connector.
NOTE:
OBD-II general scan tool
and chassis ground.
Does the voltage change more

than 8 V by shaking harness
Yes
Go to step 3.
No
Go to step 4.
Replace the ECM. END

<Ref. to FU-51,
Engine Control
Module.>
Repair the battery Go to step 5.

ECM and front
oxygen (A/F) sensor connector.
Does the voltage change more Repair the battery END
short circuit in harMeasure the voltage between ECM connector than 8 V by shaking harness
ness between
and chassis ground.
monitoring the value with volt- ECM and front
oxygen (A/F) sen(B134) No. 22 (+) Chassis ground (): age meter?
sor connector.
EN-95

C: DTC P0037 REAR OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION

Two consecutive driving cycles with fault
CAUTION:
WIRING DIAGRAM:
6
4
BATTERY
RHD
RHD
MAIN RELAY
B61
1
3
5
LHD
LHD
F44
B19
B47
1 2
3 4
(LHD)
2
4
6
5
3
2 1
4 3
2
1
(RHD)
B47
REAR OXYGEN
SENSOR
B83
B19
3
1 2 3 4
B122
1 2 3
4 5 6
LHD
RHD
LHD
RHD
1 2 3 4
5 6 7 8
B22
C16
C24
C18
B83
A21
B122
F44
1
5
9
13
A: B134
ECM
C21
C22
A34
A35
C: B136
2
6
10
14
3
7
11
15
4
8
12
16
C: B136
16
8
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
B22
A: B134
E3
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
EN1401
Step
Check
?
EN-96
Yes
Go to step 3.
No
Go to step 2.

Step
Check
1)Repair the harness and connector.
?
Yes
Go to step 3.

CHECK CURRENT DATA.
1)Start the engine.
2)Read the data of rear oxygen sensor heater
current using Subaru Select Monitor or OBD-II
general scan tool.
Repair the connector.
No
NOTE:
the following:
Open circuit in
harness between
ECM and engine
ground terminal
Poor contact in
ECM connector
Poor contact in
coupling connector
(B22)
Go to step 4.
NOTE:
the following:
Poor contact in
NOTE:
rear oxygen senFor detailed operation procedure, refer to the
sor connector
Poor contact in
rear oxygen senOBD-II scan tool
sor connecting
harness connector
Poor contact in
ECM connector
Go to step 5.
Does the voltage change less Repair the poor
Go to step 6.
Measure the voltage between ECM connector than 1.0 V by shaking harness contact in ECM
and chassis ground.
connector.
monitoring the value with volt(B134) No. 21 (+) Chassis ground (): age meter?
Is the voltage less than 1.0 V? Contact with your Repair the battery
Subaru distributor short circuit in har1)Disconnect the connector from rear oxygen
sensor.
service.
ness between
2)Measure the voltage between ECM connecECM and rear oxytor and chassis ground.
gen sensor conConnector & terminal
nector.
Repair the power
CHECK POWER SUPPLY TO REAR OXYsupply line.
GEN SENSOR.
NOTE:
2)Disconnect the connector from rear oxygen
sensor.
the following:
Open circuit in
4)Measure the voltage between rear oxygen
harness between
sensor connector and engine ground or chasmain relay and
sis ground.
rear oxygen senConnector & terminal
sor connector
Poor contact in
rear oxygen sensor connector
EN-97

Step
CHECK REAR OXYGEN SENSOR.
2)Measure the resistance between rear oxygen sensor connector terminals.
Terminals
No. 1 No. 2:
Check
?
EN-98
Yes
No
Replace the rear
Repair the harness and connec- oxygen sensor.
<Ref. to FU-49,
tor.
Rear Oxygen SenNOTE:
In this case, repair sor.>
the following:
Open circuit in
harness between
rear oxygen sensor and ECM connector
Poor contact in
Poor contact in
ECM connector

EN-99

D: DTC P0038 REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT

CAUTION:
WIRING DIAGRAM:
6
4
BATTERY
RHD
RHD
MAIN RELAY
LHD
LHD
B61
F44
B19
B47
1
3
5
1 2
3 4
(LHD)
2
4
6
5
3
2 1
4 3
2
1
(RHD)
B47
REAR OXYGEN
SENSOR
B83
B19
3
1 2 3 4
B122
1 2 3
4 5 6
LHD
RHD
LHD
RHD
1 2 3 4
5 6 7 8
B22
C16
C24
C18
B83
A21
B122
F44
1
5
9
13
A: B134
ECM
C21
C22
A34
A35
C: B136
2
6
10
14
3
7
11
15
4
8
12
16
C: B136
16
8
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
B22
A: B134
E3
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
EN1401
Step
Check
CHECK INPUT SIGNAL FOR ECM.
and chassis ground.
EN-100
Yes
Go to step 2.
No
Go to step 3.

Step
Check
CHECK CURRENT DATA.
Is the value more than 7 A?
between ECM and rear oxygen sensor connector.
general scan tool.
NOTE:
CHECK POOR CONTACT.
connector?
EN-101
Yes
<Ref. to FU-51,
Engine Control
Module.>
Repair the poor

contact in ECM
connector.
END
No

E: DTC P0066 AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT LOW INPUT
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
RHD
4
6
RHD
MAIN RELAY
LHD
5
3
2
1
LHD
2
B61
BATTERY
SBF-5
F44
AIR ASSIST
INJECTOR
SOLENOID
VALVE
2
1
B47
E42
1
7
E3
24
B22
B134 ECM
E42
1 2
B47
1
3
5
2
4
6
F44
1 2 3 4
5 6 7 8
B134
B22
1
5
9
13
2
6
10
14
3
7
11
15
1 2
3 4
5 6
7 8
9 10 11 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
8
12
16
EN1402
EN-102

Step
Check
2)Measure the voltage between ECM and
chassis ground.
CHECK POWER SUPPLY TO AIR ASSIST IN- Is the voltage more than 10 V?
JECTOR SOLENOID VALVE.
2)Disconnect the connector from air assist
4)Measure the voltage between air assist
injector solenoid valve and engine ground.
Yes
Repair the poor
contact in ECM
connector.
No
Go to step 2.
Go to step 3.
CHECK HARNESS BETWEEN ECM AND AIR Is the resistance less than 1
ASSIST INJECTOR SOLENOID VALVE CON- ?
NECTOR.
ECM and air assist injector solenoid valve connector.
(B134) No. 24 (E42) No. 1:
Go to step 4.
CHECK HARNESS BETWEEN ECM AND AIR

ASSIST INJECTOR SOLENOID VALVE CONNECTOR.
CHECK POOR CONTACT.
Check poor contact in ECM and air assist
injector solenoid valve connectors.

?
NOTE:
the following:
Open circuit in
harness between
ECM and air assist
injector solenoid
valve connector
Poor contact in
coupling connector
(B22)
ECM and air assist
injector solenoid
valve connector.

Repair the poor
and air assist injector solenoid contact in ECM
valve connectors?
and air assist
injector solenoid
valve connectors.
EN-103
NOTE:
the following:
Open circuit in
harness between
air assist injector
solenoid valve and
Poor contact in
coupling connector
(B22)
Replace the air

assist injector
solenoid valve.
<Ref. to FU-40, Air
Assist Injector
Solenoid Valve.>

F: DTC P0067 AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT HIGH INPUT
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
RHD
4
6
RHD
MAIN RELAY
LHD
5
3
2
1
LHD
2
B61
BATTERY
SBF-5
F44
AIR ASSIST
INJECTOR
SOLENOID
VALVE
2
1
B47
E42
1
7
E3
24
B22
B134 ECM
E42
1 2
B47
1
3
5
2
4
6
F44
1 2 3 4
5 6 7 8
B134
B22
1
5
9
13
2
6
10
14
3
7
11
15
1 2
3 4
5 6
7 8
9 10 11 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
8
12
16
EN1402
EN-104

Step
chassis ground.
2)Disconnect the connector from air assist
chassis ground.
Check
Yes
Is the voltage more than 10 V? Repair the battery

ECM and air assist
injector solenoid
valve connector.
After repair,
replace the ECM.
<Ref. to FU-51,
Engine Control
Module.>
Does the voltage change more Repair the battery
Measure the voltage between ECM and chas- than 10 V by shaking harness short circuit in harand connector of ECM while
sis ground.
ness between
monitoring the value with volt- ECM and air assist
injector solenoid
(B134) No. 24 (+) Chassis ground (): age meter?
valve connector.
After repair,
replace the ECM.
<Ref. to FU-51,
Engine Control
Module.>
EN-105
No
Go to step 3.
Replace the air

assist injector
solenoid valve
<Ref. to FU-40, Air
Assist Injector
Solenoid Valve.>
and ECM <Ref. to
FU-51, Engine
Control Module.>
Contact with your

Subaru distributor
service.
NOTE:
Inspection by DTM
is required, because
probable
cause is deterioration of multiple
parts.

G: DTC P0106 PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (LOW INPUT)
CAUTION:
WIRING DIAGRAM:
E20
1 2 3 4
1
3
2
INTAKE AIR
TEMPERATURE
AND
PRESSURE
SENSOR
E20
LHD:
B83
1 2 3
4 5 6
15
9
12
14
B122
E2
1 2 3
4 5 6
B21
B122
B83
LHD
RHD
LHD
RHD
RHD:
B83
1 2 3 4
LHD
B21
1
B83
1 2
3
6 7
9 10
11
13
14 15
17 18
19
25 LHD
16
15
13
B136 ECM
4
8
12
16
20
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
EN1403
EN-106

Step
Check
Is any other DTC displayed?
Yes
No
Inspect the releGo to step 2.
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
CHECK AIR INTAKE SYSTEM.
CHECK PRESSURE SENSOR.

1)Start the engine and warm-up engine until
coolant temperature is greater than 60C
(140F).
2)Place the shift lever in the selector lever in
N or P position.
4)Turn all accessory switches to OFF.
5)Read the data of intake manifold pressure
sensor signal using Subaru Select Monitor or
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0106.
Are there holes, loose bolts or Repair the air
Go to step 3.
disconnection of hose on air
intake system.
intake system?
Is the value within the specifi- Go to step 4.
Replace the intake
cations?
air temperature
sensor and pressure sensor. <Ref.
to FU-37, Intake
Air Temperature
and Pressure Sensor.>
NOTE:
Specification:
Ignition ON
73.3 106.6 kPa (550 800 mmHg,
21.65 31.50 inHg)
Idling
20.0 46.7 kPa (150 350 mmHg, 5.91
13.78 inHg)
Is the throttle positioning ratio Go to step 5.
CHECK THROTTLE POSITION.
Read the data of throttle position signal using equal to or less than 5 % when
Subaru Select Monitor or OBD-II general scan throttle is fully closed?
tool.
NOTE:
EN-107
Adjust or replace
the throttle position sensor. <Ref.
to FU-35, Throttle
Position Sensor.>

Step
Check
Is the throttle positioning ratio
equal to or more than 85 %
when throttle is fully open?
EN-108
Yes
Replace the intake
air temperature
and pressure sensor. <Ref. to FU37, Intake Air
Temperature and
Pressure Sensor.>
No
Replace the throttle position sensor.
<Ref. to FU-35,
Throttle Position
Sensor.>

EN-109

H: DTC P0107 PRESSURE SENSOR CIRCUIT LOW INPUT

CAUTION:
WIRING DIAGRAM:
E20
1 2 3 4
1
3
2
INTAKE AIR
TEMPERATURE
AND
PRESSURE
SENSOR
E20
LHD:
B83
1 2 3
4 5 6
15
9
12
14
B122
E2
1 2 3
4 5 6
B21
B122
B83
LHD
RHD
LHD
RHD
RHD:
B83
1 2 3 4
LHD
B21
1
B83
1 2
3
6 7
9 10
11
13
14 15
17 18
19
25 LHD
16
15
13
B136 ECM
4
8
12
16
20
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
EN1403
EN-110

Step
Check
Yes
CHECK CURRENT DATA.
Is the value less than 13.3 kPa Go to step 3.
1)Start the engine.
(100 mmHg, 3.94 inHg)?
2)Read the data of intake manifold absolute
pressure signal using Subaru Select Monitor or
NOTE:
CHECK POOR CONTACT.
Is there poor contact in ECM or Repair the poor
Check poor contact in ECM and pressure sen- pressure sensor connector?
contact in ECM or
sor connector.
pressure sensor
connector.
and chassis ground.
and chassis ground.
Is the voltage more than 4.5 V? Go to step 5.

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.
Does the voltage change more Repair the poor

than 4.5 V by shaking harness contact in ECM
connector.
Does the value change more Repair the poor

than 13.3 kPa (100 mmHg,
contact in ECM
3.94 inHg) by shaking harness connector.
monitoring the value with Subaru Select Monitor?
NOTE:
CHECK HARNESS BETWEEN ECM AND IN- Is the voltage more than 4.5 V? Go to step 8.
TAKE AIR TEMPERATURE AND PRESSURE
SENSOR CONNECTOR.
2)Disconnect the connector from intake air
temperature and pressure sensor.
4)Measure the voltage between intake air temperature sensor and pressure sensor connector and engine ground.
EN-111
No
Go to step 2.
Even if MIL lights

up, the circuit has
returned to a normal condition at
this time.
Go to step 4.
Contact with your

Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.
Go to step 6.
Go to step 7.
Repair the open

circuit in harness
between ECM and
intake air temperature and pressure
sensor connector.

10
Step
CHECK HARNESS BETWEEN ECM AND INTAKE AIR TEMPERATURE AND PRESSURE
SENSOR CONNECTOR.
ECM and intake air temperature and pressure
sensor connector.
(B136) No. 16 (E20) No. 1:
SENSOR CONNECTOR.
intake air temperature and pressure sensor
connector and engine ground.
CHECK POOR CONTACT.
Check poor contact in intake manifold pressure
sensor connector.
Check
?
Yes
Go to step 9.
No
Repair the open
circuit in harness
between ECM and
sensor connector.
Is the resistance more than

500 k?
Go to step 10.
Repair the ground

ECM and intake
air temperature
and pressure sensor connector.
Is there poor contact in intake Repair the poor

manifold pressure sensor con- contact in intake
nector?
air temperature
EN-112
Replace the intake

air temperature
Temperature and
Pressure Sensor.>

EN-113

I:
DTC P0108 PRESSURE SENSOR CIRCUIT HIGH INPUT

CAUTION:
Clear Memory Mode.> and Inspection Mode <Ref. to EN-42, Operation.> .
WIRING DIAGRAM:
E20
1 2 3 4
1
3
2
INTAKE AIR
TEMPERATURE
AND
PRESSURE
SENSOR
E20
LHD:
B83
1 2 3
4 5 6
15
9
12
14
B122
E2
1 2 3
4 5 6
B21
B122
B83
LHD
RHD
LHD
RHD
RHD:
B83
1 2 3 4
LHD
B21
1
B83
1 2
3
6 7
9 10
11
13
14 15
17 18
19
25 LHD
16
15
13
B136 ECM
4
8
12
16
20
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
EN1403
EN-114

Step
Check
CHECK CURRENT DATA.
Is the value more than 119.5
1)Start the engine.
kPa (896.5 mmHg, 35.29
inHg)?
NOTE:
and chassis ground.
and chassis ground.

and chassis ground.
Yes
Go to step 10.
No
Go to step 2.
Go to step 3.

connector.
Contact with your

Subaru distributor
service.
Does the value change more Repair the poor

contact in ECM
than 13.3 kPa (100 mmHg,
3.94 inHg) by shaking harness connector.
NOTE:
CHECK HARNESS BETWEEN ECM AND IN- Is the voltage more than 4.5 V? Go to step 7.
TAKE AIR TEMPERATURE AND PRESSURE
SENSOR CONNECTOR.
4)Measure the voltage between intake air temperature and pressure sensor connector and
engine ground.
EN-115
NOTE:
Inspection by DTM
probable
parts.
Go to step 5.
Go to step 6.
Repair the open

circuit in harness
between ECM and
sensor connector.

10
Step
SENSOR CONNECTOR.
sensor connector.
(B136) No. 5 (E20) No. 4:
SENSOR CONNECTOR.
sensor connector.
(B136) No. 16 (E20) No. 1:
CHECK POOR CONTACT.
Check poor contact in intake air temperature
Check
?
Yes
Go to step 8.
No
Repair the open
circuit in harness
between ECM and
sensor connector.

?
Go to step 9.
Repair the open

circuit in harness
between ECM and
sensor connector.
Is there poor contact in intake Repair the poor

manifold pressure sensor con- contact in intake
nector?
air temperature
CHECK HARNESS BETWEEN ECM AND IN- Is the value more than 119.5
TAKE AIR TEMPERATURE AND PRESSURE kPa (896.5 mmHg, 35.29
SENSOR CONNECTOR.
inHg)?
1)Turn the ignition switch to OFF and Subaru
switch to OFF.
Select Monitor or the OBD-II general scan tool
switch to ON.
NOTE:
EN-116
Replace the intake

air temperature
Temperature and
Pressure Sensor.>
Repair the battery Replace the intake
short circuit in harair temperature
ness between
and pressure senECM and intake
sor. <Ref. to FUair temperature
37, Intake Air
and pressure sen- Temperature and
sor connector.
Pressure Sensor.>

EN-117

J: DTC P0111 INTAKE AIR TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM

TROUBLE SYMPTOM:
Erroneous idling
Poor driving performance
CAUTION:
WIRING DIAGRAM:
E20
1 2 3 4
1
3
2
INTAKE AIR
TEMPERATURE
AND
PRESSURE
SENSOR
E20
LHD:
B83
1 2 3
4 5 6
15
9
12
14
B122
E2
1 2 3
4 5 6
B21
B122
B83
LHD
RHD
LHD
RHD
RHD:
B83
1 2 3 4
LHD
B21
1
B83
1 2
3
6 7
9 10
11
13
14 15
17 18
19
25 LHD
16
15
13
B136 ECM
4
8
12
16
20
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
EN1403
EN-118

Step
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0111.
Is the engine coolant tempera- Replace the intake
CHECK ENGINE COOLANT TEMPERAture between 75C (167F)
air temperature
TURE.
1)Start the engine and warm it up completely. and 95C (203F)?
and pressure sen2)Measure the engine coolant temperature
sor. <Ref. to FUusing Subaru Select Monitor or OBD-II general
37, Intake Air
scan tool.
Temperature and
Pressure Sensor.>
NOTE:
EN-119
Inspect the DTC

P0125 using 17.
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of

K: DTC P0112 INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
E20
1 2 3 4
1
3
2
INTAKE AIR
TEMPERATURE
AND
PRESSURE
SENSOR
E20
LHD:
B83
1 2 3
4 5 6
15
9
12
14
B122
E2
1 2 3
4 5 6
B21
B122
B83
LHD
RHD
LHD
RHD
RHD:
B83
1 2 3 4
LHD
B21
1
B83
1 2
3
6 7
9 10
11
13
14 15
17 18
19
25 LHD
16
15
13
B136 ECM
4
8
12
16
20
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
EN1403
EN-120

Step
Check
Yes
CHECK CURRENT DATA.
Is the value greater than 120C Go to step 2.
1)Start the engine.
(248F)?
2)Read the data of intake air temperature sensor signal using Subaru Select Monitor or
NOTE:
CHECK HARNESS BETWEEN INTAKE AIR Is the value less than 40C
TEMPERATURE AND PRESSURE SENSOR (40F)?
AND ECM CONNECTOR.
4)Read the data of intake air temperature sensor signal using Subaru Select Monitor or the
NOTE:
EN-121
No
Repair the poor
contact.
NOTE:
the following:
Poor contact in
sensor
Poor contact in
ECM
Poor contact in
coupling connector
(B21)
Poor contact in
joint connector
(B83), (B122)
Replace the intake Repair the ground
air temperature
short circuit in harand pressure sen- ness between
sor. <Ref. to FU- intake air tempera37, Intake Air
ture sensor and
Temperature and ECM connector.
Pressure Sensor.>

L: DTC P0113 INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
E20
1 2 3 4
1
3
2
INTAKE AIR
TEMPERATURE
AND
PRESSURE
SENSOR
E20
LHD:
B83
1 2 3
4 5 6
15
9
12
14
B122
E2
1 2 3
4 5 6
B21
B122
B83
LHD
RHD
LHD
RHD
RHD:
B83
1 2 3 4
LHD
B21
1
B83
1 2
3
6 7
9 10
11
13
14 15
17 18
19
25 LHD
16
15
13
B136 ECM
4
8
12
16
20
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
EN1403
EN-122

Step
Check
CHECK CURRENT DATA.
Is the value less than 40C
1)Start the engine.
(40F)?
2)Read the data of intake air temperature sensor signal using Subaru Select Monitor or
Yes
Go to step 2.
No
Repair the poor
contact.
NOTE:
the following:
Poor contact in
NOTE:
intake air temperaFor detailed operation procedure, refer to the
ture and pressure
sensor
Poor contact in
ECM
Poor contact in
coupling connector
(B21)
Poor contact in
joint connector
(B83), (B122)
CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 10 V? Repair the battery Go to step 3.
short circuit in harTEMPERATURE AND PRESSURE SENSOR
ness between
AND ECM CONNECTOR.
intake air tempera1)Turn the ignition switch to OFF.
ture and pressure
sensor and ECM
connector.
3)Measure the voltage between intake air temperature and pressure 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 AND PRESSURE SENSOR
ness between
AND ECM CONNECTOR.
intake air tempera1)Turn the ignition switch to ON.
ture and pressure
2)Measure the voltage between intake air temsensor and ECM
perature and pressure sensor connector and
connector.
engine ground.
EN-123

Step
Check
CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 3 V?
TEMPERATURE AND PRESSURE SENSOR
AND ECM CONNECTOR.
Measure the voltage between intake air temperature and pressure sensor connector and
engine ground.
CHECK HARNESS BETWEEN INTAKE AIR Is the resistance less than 5

TEMPERATURE AND PRESSURE SENSOR ?
AND ECM CONNECTOR.
intake air temperature and pressure sensor
connector and engine ground.
EN-124
Yes
Go to step 5.
No
NOTE:
the following:
Open circuit in
harness between
sensor and ECM
connector
Poor contact in
sensor
Poor contact in
ECM
Poor contact in
coupling connector
(B21)
Poor contact in
joint connector
(B83) and (B122)
Replace the intake Repair the harair temperature
ness and connecand pressure sentor.
sor. <Ref. to FU- NOTE:
37, Intake Air
Temperature and the following:
Pressure Sensor.> Open circuit in
harness between
sensor and ECM
connector
Poor contact in
sensor
Poor contact in
ECM
Poor contact in
coupling connector
(B21)
Poor contact in
joint connector
(B83) and (B122)

EN-125

M: DTC P0117 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW

INPUT
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
Clear Memory Mode.> and Inspection Mode <Ref. to EN-42, Operation.> .
WIRING DIAGRAM:
ENGINE
COOLANT
TEMPERATURE
SENSOR
E8
1
2
1 2
3
E8
B122
13
9
1 2 3
4 5 6
E2
B83
B21
1 2 3 4
B21
LHD
RHD
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
LHD
B122
RHD
1
B83
B136
14
16
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
B136 ECM
EN1404
EN-126

Step
Check
Yes
CHECK CURRENT DATA.
1)Start the engine.
(302F)?
2)Read the data of engine coolant temperature
NOTE:

CHECK HARNESS BETWEEN ENGINE
COOLANT TEMPERATURE SENSOR AND (40F)?
ECM CONNECTOR.
2)Disconnect the connector from engine coolant temperature sensor.
NOTE:
EN-127
Replace the
engine coolant
temperature sensor. <Ref. to FU31, Engine Coolant Temperature
Sensor.>
No
Repair the poor
contact.
NOTE:
the following:
Poor contact in
engine coolant
temperature sensor
Poor contact in
ECM
Poor contact in
coupling connector
(B21)
Poor contact in
joint connector
(B83) or (B122)
Repair the ground
engine coolant
temperature sensor and ECM connector.

N: DTC P0118 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH

INPUT
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
ENGINE
COOLANT
TEMPERATURE
SENSOR
E8
1
2
1 2
3
E8
B122
13
9
1 2 3
4 5 6
E2
B83
B21
1 2 3 4
B21
LHD
RHD
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
LHD
B122
RHD
1
B83
B136
14
16
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
B136 ECM
EN1404
EN-128

Step
Check
CHECK CURRENT DATA.
1)Start the engine.
(40F)?
NOTE:
Yes
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
(B21)
Poor contact in
joint connector
(B83) or (B122)
Is the voltage more than 10 V? Repair the battery Go to step 3.
ECM and engine
coolant temperature sensor connector.

COOLANT TEMPERATURE SENSOR AND
ECM CONNECTOR.
3)Measure the voltage between engine coolant
temperature sensor connector and engine
ground.
ECM CONNECTOR.
ground.
EN-129

ECM and engine

Step
ECM CONNECTOR.
Measure the voltage between engine coolant
ground.
Check

COOLANT TEMPERATURE SENSOR AND ?
ECM CONNECTOR.
engine coolant temperature sensor connector
and engine ground.
EN-130
Yes
Go to step 5.
Replace the
engine coolant
Sensor.>
No
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
(B21)
Poor contact in
joint connector
(B83) or (B122)
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
(B21)
Poor contact in
joint connector
(B83) or (B122)

EN-131

O: DTC P0121 THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT)
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
THROTTLE
POSITION
SENSOR
E13
4
3
2
1 2 3 4
E13
B122
12
11
9
1 2 3
4 5 6
E2
B21
B83
1 2 3 4
B21
LHD
RHD
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
LHD
B122
RHD
1
B83
B136
15
17
16
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
B136 ECM
EN1405
EN-132

Step
Check
Yes
Inspect the relevant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0121.
EN-133
No
<Ref. to FU-35,
Throttle Position
Sensor.>

P: DTC P0122 THROTTLE POSITION SENSOR CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
THROTTLE
POSITION
SENSOR
E13
4
3
2
1 2 3 4
E13
B122
12
11
9
1 2 3
4 5 6
E2
B21
B83
1 2 3 4
B21
LHD
RHD
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
LHD
B122
RHD
1
B83
B136
15
17
16
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
B136 ECM
EN1405
EN-134

Step
Check
CHECK CURRENT DATA.
Is the value less than 0.1 V?
1)Start the engine.
2)Read the data of throttle position sensor signal using Subaru Select Monitor or OBD-II
general scan tool.
Yes
Go to step 2.
NOTE:

and chassis ground while throttle valve is fully
closed.
and chassis ground.

and chassis ground.
and chassis ground.

connector.

connector.
EN-135
No
Even if MIL lights
up, the circuit has
this time. A temporary poor contact
of the connector
may be the cause.
NOTE:
the following:
Poor contact in
throttle position
sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connector
(B21)
Go to step 3.
Contact with your

Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.
Go to step 5.
Go to step 6.

Step
Check
Yes
THROTTLE POSITION SENSOR CONNECTOR.
2)Disconnect the connectors from throttle position sensor.
4)Measure the voltage between throttle position sensor connector and engine ground.

THROTTLE POSITION SENSOR CONNEC- ?
TOR.
ECM connector and throttle position sensor
connector.
(B136) No. 17 (E13) No. 3:

throttle position sensor connector and engine
ground.
CHECK POOR CONTACT.
Check poor contact in throttle position sensor
connector.

?
Go to step 8.
NOTE:
the following:
Open circuit in
harness between
throttle position
sensor and ECM
connector
Poor contact in
throttle position
sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connector
(B21)
Poor contact in
joint connector
(B83) or (B122)
NOTE:
the following:
Open circuit in
harness between
throttle position
sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
throttle position
sensor connector
Poor contact in
coupling connector
(B21)
throttle position
sensor and ECM
connector.
Is there poor contact in throttle Repair the poor

position sensor connector?
contact in throttle
position sensor
connector.
EN-136
No

<Ref. to FU-35,
Throttle Position
Sensor.>

EN-137

Q: DTC P0123 THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
THROTTLE
POSITION
SENSOR
E13
4
3
2
1 2 3 4
E13
B122
12
11
9
1 2 3
4 5 6
E2
B21
B83
1 2 3 4
B21
LHD
RHD
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
LHD
B122
RHD
1
B83
B136
15
17
16
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
B136 ECM
EN1405
EN-138

Step
Check
CHECK CURRENT DATA.
Is the value more than 4.9 V?
1)Start the engine.
general scan tool.
Yes
Go to step 2.
NOTE:
CHECK HARNESS BETWEEN THROTTLE

POSITION SENSOR AND ECM CONNEC?
TOR.
2)Disconnect the connector from throttle position sensor.
ground.

POSITION SENSOR AND ECM CONNECTOR.
Go to step 3.
No
Even if MIL lights
up, the circuit has
of the connector
may be the cause.
NOTE:
the following:
Poor contact in
throttle position
sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connector
(B21)
NOTE:
the following:
Open circuit in
harness between
throttle position
sensor and ECM
connector
Poor contact in
coupling connector
(B21)
Poor contact in
joint connector
(B83) or (B122)
Is the voltage more than 4.9 V? Repair the battery Replace the throtshort circuit in har- tle position sensor.
ness between
<Ref. to FU-35,
throttle position
Throttle Position
sensor and ECM Sensor.>
connector. After
repair, replace the
ECM. <Ref. to FU51, Engine Control Module.>
EN-139

R: 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
1
2
1 2
3
E8
B122
13
9
1 2 3
4 5 6
E2
B83
B21
1 2 3 4
B21
LHD
RHD
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
LHD
B122
RHD
1
B83
B136
14
16
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
B136 ECM
EN1404
EN-140

Step
CHECK THERMOSTAT.
Check
Does thermostat remain

opened?
EN-141
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
NOTE:
In this case, it is
not necessary to
inspect P0125.
Replace the thermostat. <Ref. to
CO-37, Thermostat.>
Replace the
engine coolant
Sensor.>

S: DTC P0130 FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LEAN)
RHD
MAIN RELAY
RHD
CAUTION:
WIRING DIAGRAM:
6
4
LHD
LHD
BATTERY
SBF-5
F44
B61
B47
1
3
5
2
4
6
5
3
B47
B18
2
1
1 2 3
4 5 6
FRONT OXYGEN
(A/F) SENSOR
4
6
3
1
B18
F44
1 2 3 4
5 6 7 8
B22
C7
C20
C6
C19
C23
A22
A23
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
A: B134
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
A: B134
ECM
A34
A35
C: B136
C: B136
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
B22
E3
EN1400
Step
Check
EN-142
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of

Step
Check
CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the value equal to or more
TA.
than 0.85 and equal to less
1)Start the engine.
than 1.15 in idling?
2)While observing the Subaru Select Monitor
or OBD-II general scan tool screen, warm-up
the engine until coolant temperature is above
70C (160F).
If the engine is already warmed-up, operate at
idle speed for at least 1 minute.
signal using Subaru Select Monitor or OBD-II
general scan tool.
Yes
Go to step 3.
NOTE:
CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the value more than 1.1 for a Go to step 6.
TA.
moment?
Race the engine at speeds from idling to 5,000
rpm for a total of 5 cycles.
NOTE:
To increase the 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.
front oxygen (A/F) sensor.
Connector & terminals
(B136) No. 6 (E24) No. 3:
(B136) No. 7 (E24) No. 4:
(B136) No. 19 (E24) No. 1:
(B136) No. 20 (E24) No. 6:
Measure the resistance between ECM and
chassis ground.
CHECK EXHAUST SYSTEM.
Check the exhaust system parts.
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.
Is there a fault in exhaust sys- Repair or replace

tem?
the faulty parts.
NOTE:
Check the following items.
Loose installation of portions
Damage (crack, hole etc.) of parts
Looseness of front oxygen (A/F) sensor
Looseness and ill fitting of parts between front
oxygen (A/F) sensor and rear oxygen sensor
EN-143
Replace the front

oxygen (A/F) sensor. <Ref. to FU47, Front Oxygen
(A/F) Sensor.>

T: DTC P0131 FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION

(OPEN CIRCUIT)
RHD
MAIN RELAY
RHD
CAUTION:
WIRING DIAGRAM:
6
4
LHD
LHD
BATTERY
SBF-5
F44
B61
B47
1
3
5
2
4
6
5
3
1 2 3
4 5 6
FRONT OXYGEN
(A/F) SENSOR
4
6
3
1
B18
5
F44
1 2 3 4
5 6 7 8
B22
1
5
9
13
C7
C20
C6
C19
C23
2
6
10
14
3
7
11
15
4
8
12
16
A: B134
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
A: B134
ECM
A34
A35
C: B136
C: B136
B47
B18
A22
A23
2
1
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
B22
E3
EN1400
EN-144

Step
Check
FRONT OXYGEN (A/F) SENSOR CONNEC- ?
TOR.
2)Disconnect the connectors from ECM and
ECM and front oxygen (A/F) sensor connector.
(B136) No. 6 (E24) No. 3:
(B136) No. 7 (E24) No. 4:
(B136) No. 19 (E24) No. 1:
(B136) No. 20 (E24) No. 6:
CHECK POOR CONTACT.

Is there poor contact in front
Check poor contact in front oxygen (A/F) senoxygen (A/F) sensor connecsor connector.
tor?
EN-145
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 FUsor connector.
47, Front Oxygen
(A/F) Sensor.>

U: DTC P0132 FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION

(SHORT CIRCUIT)
RHD
MAIN RELAY
RHD
CAUTION:
WIRING DIAGRAM:
6
4
LHD
LHD
BATTERY
SBF-5
F44
B61
B47
1
3
5
2
4
6
5
3
1 2 3
4 5 6
FRONT OXYGEN
(A/F) SENSOR
4
6
3
1
B18
5
F44
1 2 3 4
5 6 7 8
B22
1
5
9
13
C7
C20
C6
C19
C23
2
6
10
14
3
7
11
15
4
8
12
16
A: B134
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
A: B134
ECM
A34
A35
C: B136
C: B136
B47
B18
A22
A23
2
1
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
B22
E3
EN1400
EN-146

Step
Check
TOR.
EN-147
Yes
Replace the front
(A/F) Sensor.>
No
Repair the ground
ECM and front

V: DTC P0133 FRONT OXYGEN (A/F) SENSOR CIRCUIT SLOW RESPONSE

RHD
MAIN RELAY
RHD
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, Operation.>
and Inspection Mode <Ref. to EN-42, OPERATION, Inspection Mode.> .
WIRING DIAGRAM:
6
4
LHD
LHD
BATTERY
SBF-5
F44
B61
B47
1
3
5
2
4
6
5
3
1 2 3
4 5 6
FRONT OXYGEN
(A/F) SENSOR
4
6
3
1
B18
5
F44
1 2 3 4
5 6 7 8
B22
1
5
9
13
C7
C20
C6
C19
C23
2
6
10
14
3
7
11
15
4
8
12
16
A: B134
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
A: B134
ECM
A34
A35
C: B136
C: B136
B47
B18
A22
A23
2
1
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
B22
E3
EN1400
EN-148

Step

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
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0133.
Is there a fault in exhaust sys- Repair the exhaust Replace the front
tem?
system.
(A/F) Sensor.>
EN-149

W: DTC P0136 REAR OXYGEN SENSOR CIRCUIT MALFUNCTION

CAUTION:
WIRING DIAGRAM:
6
4
BATTERY
RHD
RHD
MAIN RELAY
LHD
LHD
B61
F44
B19
B47
1
3
5
1 2
3 4
(LHD)
2
4
6
5
3
2 1
4 3
2
1
(RHD)
B47
REAR OXYGEN
SENSOR
B83
B19
3
1 2 3 4
B122
1 2 3
4 5 6
LHD
RHD
LHD
RHD
1 2 3 4
5 6 7 8
B22
C16
C24
C18
B83
A21
B122
F44
1
5
9
13
A: B134
ECM
C21
C22
A34
A35
C: B136
2
6
10
14
3
7
11
15
4
8
12
16
C: B136
16
8
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
B22
A: B134
E3
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
EN1401
Step
Check
Yes
indicate DTC P0131 or P0132?
EN-150
No
Go to step 3.

Step
Check
Is the failure cause of P0131 or
CHECK FAILURE CAUSE OF P0131 or
P0132 in the fuel system?
P0132.
Inspect the DTC P0131 or P0132 using 17.
List of Diagnostic Trouble Code (DTC). <Ref.
to EN-83, List of Diagnostic Trouble Code
(DTC).>
CHECK REAR OXYGEN SENSOR DATA.
Does the value fluctuate?
1)Warm-up the engine until engine coolant
temperature is above 70C (158F), and keep
the engine speed at 2,000 rpm to 3,000 rpm for
2 minutes.
2)Read the data of rear oxygen sensor signal
using Subaru Select Monitor or OBD-II general
scan tool.
NOTE:
READ CURRENT DATA SHOWN ON DISPLAY FOR ENGINE. <Ref. to EN-34, Subaru
Select Monitor.>
Read the data of rear oxygen sensor signal
scan tool.
1)Keep the engine speed at 4,500 rpm for 5
seconds.
2)Release the accelerator quickly and idle the
engine for 10 seconds.
3)Repeat this cycle for three times.
REAR OXYGEN SENSOR CONNECTOR.
rear oxygen sensor.
ECM and rear oxygen sensor connector.
(B136) No. 16 (B19) No. 3:
CHECK GROUND CIRCUIT ON ECM.
Yes
Check the fuel
system.
No
Go to step 3.
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0136.
Go to step 7.
Go to step 4.
Is the value fixed between 0.2 Go to step 5.

and 0.4 V?
Replace the rear

oxygen sensor.
<Ref. to FU-47,
Front Oxygen (A/
F) Sensor.>

?
Repair the open

Go to step 6.
circuit in harness
between ECM and
rear oxygen sensor connector.

?
Go to step 8.
EN-151
Go to step 7.

Step
Check
?
Yes
Go to step 8.
CHECK HARNESS BETWEEN REAR OXY- Is the voltage more than 0.2 V?
GEN SENSOR AND ECM CONNECTOR.
sensor.
sensor harness connector and engine ground
or chassis ground.
Replace the rear

oxygen sensor.
<Ref. to FU-47,
Front Oxygen (A/
F) Sensor.>


tem?
the faulty parts.
NOTE:
EN-152
No
NOTE:
the following:
Open circuit in
harness between
ECM and engine
ground terminal
Poor contact in
ECM connector
Poor contact in
coupling connector
(B22)
NOTE:
the following:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector
Replace the rear
oxygen sensor.
<Ref. to FU-47,
Front Oxygen (A/
F) Sensor.>

EN-153

X: DTC P0139 REAR OXYGEN SENSOR CIRCUIT SLOW RESPONSE

CAUTION:
WIRING DIAGRAM:
6
4
BATTERY
RHD
RHD
MAIN RELAY
LHD
LHD
B61
F44
B19
B47
1
3
5
1 2
3 4
(LHD)
2
4
6
5
3
2 1
4 3
2
1
(RHD)
B47
REAR OXYGEN
SENSOR
B83
B19
3
1 2 3 4
B122
1 2 3
4 5 6
LHD
RHD
LHD
RHD
1 2 3 4
5 6 7 8
B22
C16
C24
C18
B83
1
5
9
13
A: B134
ECM
C: B136
C21
C22
A34
A35
2
6
10
14
3
7
11
15
4
8
12
16
C: B136
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
16
8
A21
B122
F44
B22
A: B134
E3
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
EN1401
EN-154

Step
Check
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0139.
EN-155
No
Replace the rear
oxygen sensor.
<Ref. to FU-47,
Front Oxygen (A/
F) Sensor.>

Y: DTC P0170 FUEL TRIM MALFUNCTION

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
Step
CHECK FUEL PRESSURE.

Warning:
Place NO FIRE signs near the working
area.
1)Release the fuel pressure.
(1) Disconnect the connector from fuel
pump relay.
(2) Start the engine and run it until it stalls.
(3) After the engine stalls, crank it for 5
more seconds.
2)Connect the connector to fuel pump relay.
3)Disconnect the fuel delivery hose from fuel
filter, and connect fuel pressure gauge.
4)Install the fuel filler cap.
5)Start the engine and idle while gear position
is neutral.
6)Measure the fuel pressure while disconnecting pressure regulator vacuum hose from
intake manifold.
Check
Are there holes or loose bolts
on exhaust system?
Are there holes, loose bolts or
intake system?
Is the fuel pressure between
284 314 kPa (2.9 3.2
kg/cm2, 41 46 psi)?
Warning:
Before removing the fuel pressure gauge,
release the fuel pressure.
NOTE:
If the fuel pressure does not increase, squeeze
the fuel return hose 2 to 3 times, then measure
fuel pressure again.
EN-156
Yes
No
Repair the exhaust Go to step 2.
system.
Repair the air
Go to step 3.
intake system.
Go to step 4.
Repair the following items.

Fuel pressure too
high:
Clogged fuel
return line or
bent hose
Fuel pressure too
low:
Clogged fuel
supply line
Improper fuel
pump discharge

Step
After connecting the pressure regulator vacuum hose, measure the fuel pressure.
Check
206 235 kPa (2.1 2.4
kg/cm2, 30 34 psi)?
Yes
Go to step 5.
Warning:
release fuel pressure.
NOTE:
If the fuel pressure does not increase,
squeeze the fuel return hose 2 to 3 times, then
measure fuel pressure again.
If out of specification as measured at this
step, check or replace the pressure regulator
and pressure regulator vacuum hose.
CHECK ENGINE COOLANT TEMPERATURE Is the temperature between

70C (158F) and 100C
SENSOR.
1)Start the engine and warm-up completely.
(212F)?
NOTE:
CHECK INTAKE MANIFOLD PRESSURE
Is the voltage within the speciSENSOR SIGNAL.
fications?
(140F).
2)Place the selector lever in N or P position.
NOTE:
Specification:
Idling
24.0 41.3 kPa (180 310 mmHg, 7.09
12.20 inHg)
Ignition ON
73.3 106.6 kPa (550 800 mmHg,
21.65 31.50 inHg)
EN-157
Go to step 6.
No
Fuel pressure too
high:
Faulty pressure regulator
Clogged fuel
return line or
bent hose
Fuel pressure too
low:
Improper fuel
pump discharge
Clogged fuel
supply line
Replace the
engine coolant
Sensor.>
Contact with your Replace the intake

Subaru distributor air temperature
and pressure senservice.
sor. <Ref. to FUNOTE:
Inspection by DTM 37, Intake Air
is required, be- Temperature and
cause
probable Pressure Sensor.>
parts.

Z: DTC P0301 CYLINDER 1 MISFIRE DETECTED

NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN-160, DTC P0304 CYLINDER 4 MISFIRE
DETECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AA:DTC P0302 CYLINDER 2 MISFIRE DETECTED

NOTE:
AB:DTC P0303 CYLINDER 3 MISFIRE DETECTED

NOTE:
EN-158

EN-159

AC: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:
RHD
4
6
5
3
RHD
MAIN RELAY
LHD
B61
BATTERY
SBF-5
LHD
F44
2
1
C1
A15
A14
11
10
A4
9
C: B136 ECM
A13
A: B134
12
C2
B47
B22
E3
FUEL INJECTOR
No.1
E5
E16
E6
E17
1 2
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
FUEL INJECTOR
No.2
B47
1
3
5
FUEL INJECTOR
No.3
FUEL INJECTOR
No.4
B22
F44
2
4
6
1 2 3 4
5 6 7 8
E17
2
E6
E16
E5
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
A: B134
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
EN0866
EN-160

Step

2)Measure the voltage between ECM connector and chassis ground on faulty cylinders.
#1 (B134) No. 4 (+) 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. 4 (E5) No. 1:
#2 (B134) No. 13 (E16) No. 1:
#3 (B134) No. 14 (E6) No. 1:
#4 (B134) No. 15 (E17) No. 1:
CHECK FUEL INJECTOR.

Measure the resistance between fuel injector
terminals on faulty cylinder.
Terminals
No. 1 No. 2:
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
NOTE:
In this case, it is
not necessary to
inspect
P0301,
P0302,
P0303,
P0304.
Go to step 3.

?

short circuit in harness between fuel
injector and ECM
connector.

?
Go to step 5.

and 20 ?
EN-161
Go to step 6.

NOTE:
the following:
Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
coupling connector
(B22)
Replace the faulty
fuel injector. <Ref.
to FU-41, 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
CHECK HARNESS BETWEEN FUEL INJEC- Is the voltage more than 10 V? Repair the battery Go to step 8.
short circuit in harTOR AND ECM CONNECTOR.
ness between
ECM and fuel
injector. After
on faulty cylinder.
repair, replace
ECM. <Ref. to FU4)Measure the voltage between ECM connec51, Engine Contor and chassis ground on faulty cylinders.
trol Module.>
():
():
():
():
Replace the faulty Go to step 9.
?
fuel injector <Ref.
2)Measure the resistance between fuel injector
to FU-41, Fuel
Injector.> and
Terminals
ECM <Ref. to FUNo. 1 No. 2:
51, Engine Control Module.>
CHECK INSTALLATION OF CAMSHAFT PO- Is the camshaft position sensor Tighten the cam- Go to step 10.
SITION SENSOR/CRANKSHAFT POSITION or crankshaft position sensor shaft position senSENSOR.
loosely installed?
sor or crankshaft
position sensor.
Is the crankshaft sprocket
Replace the crank- Go to step 11.
CHECK CRANKSHAFT SPROCKET.
Remove the timing belt cover.
rusted or does it have broken shaft sprocket.
teeth?
<Ref. to ME-56,
Crankshaft
Sprocket.>
CHECK INSTALLATION CONDITION OF
Is the timing belt dislocated
Repair the installa- Go to step 12.
TIMING BELT.
from its proper position?
tion condition of
Turn the crankshaft using ST, and align the
timing belt. <Ref.
alignment mark on crankshaft sprocket with
to ME-49, Timing
alignment mark on cylinder block.
Belt Assembly.>
ST 499987500 CRANKSHAFT SOCKET
EN-162

12
13
14
15
16
17
Step
CHECK FUEL LEVEL.
Check
Yes
Is the fuel meter indication
Go to step 13.
higher than the Lower level?
CHECK STATUS OF CHECK ENGINE MAL- Is the MIL coming on or blinkFUNCTION INDICATOR LAMP (MIL).
ing?
1)Clear the memory using Subaru Select Monitor.
<Ref. to EN-49, Clear Memory Mode.>
2)Start engine, and drive the vehicle more than
10 minutes.
CHECK CAUSE OF MISFIRE DIAGNOSED. Was the cause of misfire diagnosed when the engine is running?
CHECK MISFIRE SYMPTOM.

2)Read the DTC.
OBD-II General Scan Tool Operation Manual.
Go to step 15.
Finish the diagnostics operation,

if the engine has
no abnormality.
No
Replenish the fuel
so fuel meter indication is higher
than the Lower
level. After replenishing fuel; Go to
step 13.
Go to step 14.
Repair the poor

contact.
NOTE:
the following:
NOTE:
Ex. Remove spark Poor contact in
ignitor connector
plug cord, etc.
Poor contact in
ignition coil connector
Poor contact in
cylinders
Poor contact in
ECM connector
Poor contact in
coupling connector
Go to step 16.
Is there a fault in air intake sys- Repair the air
tem?
intake system.
NOTE:
Check the following items:
Are there air
leaks or air suction
caused by loose or
dislocated nuts
and bolts?
Are there cracks
or any disconnection of hoses?
Go to step 17.
indicate only one DTC?
NOTE:
Perform diagnosis according to the items listed
below.
(DTC) ON DISPLAY.
P0302?
EN-163
Go to step 18.

18
Step
(DTC) ON DISPLAY.
19

(DTC) ON DISPLAY.
20

(DTC) ON DISPLAY.
21
ONLY ONE CYLINDER
22
GROUP OF #1 AND #2 CYLINDERS
Check
P0304?
P0303?
P0304?
Is there a fault in that cylinder?
Are there faults in #1 and #2

cylinders?
EN-164
Yes
Go to step 23.
No
Go to step 19.
Go to step 24.
Go to step 20.
Go to step 25.
Go to step 26.
Repair or replace
the faulty parts.
Go to DTC P0170.
<Ref. to EN-156,
DTC P0170
NOTE:
Check the follow- FUEL TRIM MALFUNCTION ,
ing items.
Diagnostic Proce Spark plug
Spark plug cord dure with Diagnostic Trouble Code
Fuel injector
(DTC).>
Compression
ratio
Repair or replace Go to DTC P0170.
<Ref. to EN-156,
the faulty parts.
DTC P0170
NOTE:
FUEL TRIM MAL Check the folFUNCTION ,
lowing items.
Spark plugs Diagnostic Proce Fuel injectors dure with Diagnostic Trouble Code
Ignition coil
(DTC).>
Compression ratio
If no abnormal is
discovered, check
for IGNITION
CONTROL SYSTEM of #1 and #2
cylinders side.
<Ref. to EN-72,
Diagnostics for
Engine Starting
Failure.>

23
Step
Check
cylinders?
24

cylinders?
25

cylinders?
26
CYLINDER AT RANDOM
Is the engine idle rough?
EN-165
Yes
Repair or replace
the faulty parts.
No
Go to DTC P0170.
<Ref. to EN-156,
DTC P0170
NOTE:
FUEL TRIM MAL Check the folFUNCTION ,
lowing items.
Spark plugs Diagnostic Proce Fuel injectors dure with Diagnostic Trouble Code
Ignition coil
If no abnormal is (DTC).>
discovered, check
for 16. D: IGNITION CONTROL
SYSTEM of #3
and #4 cylinders
side. <Ref. to EN72, IGNITION
CONTROL SYSTEM, Diagnostics
Repair or replace Go to DTC P0170.
the faulty parts.
<Ref. to EN-156,
DTC P0170
NOTE:
ing items.
Diagnostic Proce Spark plugs
dure with Diagnos Fuel injectors
Skipping timing tic Trouble Code
(DTC).>
belt teeth
Go to DTC P0170.
<Ref. to EN-156,
DTC P0170
NOTE:
ing items.
Diagnostic Proce Spark plugs
dure with Diagnos Fuel injectors
tic Trouble Code
Compression
(DTC).>
ratio
Skipping timing
belt teeth
Go to DTC P0170. Repair or replace
<Ref. to EN-156, the faulty parts.
DTC P0170
NOTE:
FUEL TRIM MAL- Check the followFUNCTION ,
ing items.
Diagnostic Proce- Spark plugs
dure with Diagnos- Fuel injectors
tic Trouble Code Compression
(DTC).>
ratio
Repair or replace
the faulty parts.

AD:DTC P0327 KNOCK SENSOR CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
WIRING DIAGRAM:
E14
1 2
KNOCK
SENSOR
B83
E14
1 2 3
4 5 6
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
16
E2
B21
B136
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
LHD
LHD
B83
RHD
25
RHD
B136 ECM
EN1406
EN-166

Step
Check
CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance more than
700 k?
SOR AND ECM CONNECTOR.
3)Measure the resistance between ECM harness connector and chassis ground.
Yes
Go to step 2.
CHECK KNOCK SENSOR.

1)Disconnect the connector from knock sen700 k?
sor.
2)Measure the resistance between knock sensor connector terminal and engine ground.
Terminal
No. 2 Engine ground:
Go to step 3.
CHECK CONDITION OF KNOCK SENSOR

INSTALLATION.
Is the knock sensor installation bolt tightened securely?
EN-167
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
(B21)
NOTE:
the following:
Open circuit in
harness between
knock sensor and
ECM connector
Poor contact in
Poor contact in
coupling connector
(B21)
Replace the knock Tighten the knock
sensor. <Ref. to
sensor installation
FU-34, Knock
bolt securely.
Sensor.>

AE:DTC P0328 KNOCK SENSOR CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
WIRING DIAGRAM:
E14
1 2
KNOCK
SENSOR
B83
E14
1 2 3
4 5 6
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
16
E2
B21
B136
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
LHD
LHD
B83
RHD
25
RHD
B136 ECM
EN1406
Step
Check
Yes
CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance less than 400 Go to step 2.
k?
EN-168
No
Go to step 3.

Step
Check
CHECK KNOCK SENSOR.
1)Disconnect the connector from knock senk?
sor.
Terminal

1)Connect the connectors to ECM and knock
sensor.
chassis ground.
Yes
Replace the knock
sensor. <Ref. to
FU-34, Knock
Sensor.>
NOTE:
The harness between both connectors
is
shielded. Repair
the short circuit of
harness together
with shield.
Even if MIL lights Repair the poor
up, the circuit has contact in ECM
returned to a nor- connector.
mal condition at
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
(B21)
EN-169
No
Repair the ground
knock sensor connector and ECM
connector.

AF:DTC P0335 CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

TROUBLE SYMPTOM:
Engine stalls.
Failure of engine to start
CAUTION:
WIRING DIAGRAM:
1 WITH
IMMOBILIZER:2
WITHOUT
IMMOBILIZER:1
CRANKSHAFT
POSITION
SENSOR
E10
1 2
2
1
2 LHD:19
RHD:20
E10
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
2
17
E2
B21
B135
9
1
10
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
B135 ECM
EN1407
EN-170

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.
crankshaft position sensor connector and
engine ground.
CHECK HARNESS BETWEEN CRANKIs the resistance less than 10

SHAFT POSITION SENSOR AND ECM CON- ?
NECTOR.
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
(B21)
ECM connector.
NOTE:
are
shielded. Repair
ground short circuit
in harness together 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
(B21)
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.
Repair the poor
Replace the crankCHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1
1)Remove the crankshaft position sensor.
and 4 k?
contact in crankshaft position sen2)Measure the resistance between connector
shaft position sensor. <Ref. to FUterminals of crankshaft position sensor.
sor connector.
32, Crankshaft
Terminals
Position Sensor.>
No. 1 No. 2:
EN-171

AG:DTC P0336 CRANKSHAFT POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
1 WITH
IMMOBILIZER:2
WITHOUT
IMMOBILIZER:1
CRANKSHAFT
POSITION
SENSOR
E10
1 2
2
1
2 LHD:19
RHD:20
E10
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
2
17
E2
B21
B135
9
1
10
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
B135 ECM
EN1407
EN-172

Step
Check
Yes
Does the Subaru Select Moni- Inspect DTC
tor or OBD-II general scan tool P0335 using List
indicate DTC P0335?
of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
SITION SENSOR.
Turn the ignition switch to OFF.
securely?

Remove the front belt cover.
Are the crankshaft sprocket

teeth cracked or damaged?

TIMING BELT.
Turn the crankshaft using ST, and align the
alignment mark on crankshaft sprocket with
alignment mark on cylinder block.
ST 499987500 CRANKSHAFT SOKET

EN-173
No
Go to step 2.
Tighten the crankshaft position sensor installation bolt

securely.
shaft sprocket.
<Ref. to ME-56,
Crankshaft
Sprocket.>
Repair the installa- Replace the cranktion condition of
shaft position sentiming belt. <Ref. sor. <Ref. to <Ref.
to ME-49, Timing to FU-32, CrankBelt Assembly.>
shaft Position Sensor.>

AH:DTC P0340 CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
CAMSHAFT
POSITION
SENSOR
WITH IMMOBILIZER:1
WITHOUT IMMOBILIZER:2
LHD:20
RHD:19
E15
2
1
1 2
E15
B21
1 2
3
6 7
9 10
11
13
14 15
17 18
19
2
18
4
8
12
16
20
E2
B21
B135
8
1
10
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
B135 ECM
EN1408
EN-174

Step
Check
CHECK HARNESS BETWEEN CAMSHAFT Is the resistance more than
POSITION SENSOR AND ECM CONNEC100 k?
TOR.
2)Disconnect the connector from camshaft
position sensor.
camshaft position sensor connector and
engine ground.
CHECK HARNESS BETWEEN CAMSHAFT

engine ground.

?

engine ground.

?
CHECK CONDITION OF CAMSHAFT POSITION SENSOR.
CHECK CAMSHAFT POSITION SENSOR.

1)Remove the camshaft position sensor.
terminals of camshaft position sensor.
Terminals
No. 1 No. 2:
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
(B21)
camshaft position
sensor and ECM
connector.
NOTE:
are
shielded. Repair
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
(B21)
Is the camshaft position sensor Go to step 5.
Tighten the caminstallation bolt tightened
securely.
Repair the poor
Replace the camand 4 k?
contact in camshaft position senshaft position sensor. <Ref. to FUsor connector.
33, Camshaft
Position Sensor.>
EN-175

AI: DTC P0341 CAMSHAFT POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
CAMSHAFT
POSITION
SENSOR
WITH IMMOBILIZER:1
WITHOUT IMMOBILIZER:2
LHD:20
RHD:19
E15
2
1
1 2
E15
B21
1 2
3
6 7
9 10
11
13
14 15
17 18
19
2
18
4
8
12
16
20
E2
B21
B135
8
1
10
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
B135 ECM
EN1408
EN-176

Step

position sensor.
engine ground.
Check
Yes
No
Go to step 2.
indicate DTC P0340?
of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
100 k?
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
(B21)
camshaft position
sensor and ECM
connector.

engine ground.

?

engine ground.

?

installation bolt tightened
securely?
EN-177
NOTE:
are
shielded. Repair
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
(B21)
Tighten the camshaft position sensor installation bolt
securely.

Step
Terminals
No. 1 No. 2:
Check
and 4 k?
Yes
Go to step 7.
No
Replace the camshaft position sensor. <Ref. to FU33, Camshaft
Position Sensor.>

securely?

securely.
Go to step 9.
CHECK CAMSHAFT SPROCKET.

Remove the front belt cover. <Ref. to ME-48,
Belt Cover.>
Are the camshaft sprocket


TIMING BELT.
Turn the camshaft using ST, and align the
alignment mark on camshaft sprocket with
alignment mark on timing belt cover LH.
WRENCH
NOTE:
(499207100) can be used.
EN-178
Replace the camshaft sprocket.

<Ref. to ME-54,
Camshaft
Sprocket.>
Repair the installation condition of
timing belt. <Ref.
to ME-49, Timing
Belt Assembly.>
Replace the camshaft position sensor. <Ref. to FU33, Camshaft

Position Sensor.>

AJ:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD

TROUBLE SYMPTOM:
Engine stalls.
Idle mixture is out of specifications.
CAUTION:
EN-179

WIRING DIAGRAM:
6
4
BATTERY
RHD
RHD
MAIN RELAY
LHD
LHD
B61
SBF-5
F44
5
3
2
1
B47
FRONT OXYGEN
(A/F) SENSOR
E18
RHD
LHD
RHD
C24
C18
B83
C16
A21
B122
4
6
3
1
LHD
C7
C20
C6
C19
C23
B19
A22
A23
3
1
REAR
OXYGEN
SENSOR
16
C21
C22
A: B134 C: B136 ECM
B22
E3
B19
1 2
3 4
(LHD)
2 1
4 3
(RHD)
B122
B18
1 2 3
4 5 6
1 2 3
4 5 6
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
B47
1
3
5
2
4
6
F44
E1
B83
1 2 3 4
5 6 7 8
1 2 3 4
6
5
7
9 10
8
1 2 3 4
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
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
EN1409
EN-180

Step

Check for gas leaks or air suction caused by
loose or dislocated nuts and bolts, and open
hole at exhaust pipes.
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0420.
Is there a fault in exhaust sys- Repair or replace Go to step 3.
tem?
the exhaust system. <Ref. to EX2, General
Description.>
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
Is there damage at rear face of Replace the front
CHECK REAR CATALYTIC CONVERTER.
catalytic converter
Separate the rear catalytic converter from rear rear catalyst?
exhaust pipe.
<Ref. to EC-3,
Front Catalytic
Converter.> and
rear catalytic converter <Ref. to EC6, Rear Catalytic
Converter.>.
CHECK FRONT CATALYTIC CONVERTER. Is there damage at rear face or Replace the front
Remove the front catalytic converter.
front face of front catalyst?
catalytic converter. <Ref. to
EC-3, Front Catalytic Converter.>
CHECK REAR OYXGEN SENSOR HARNESS Is there damage or open on
Repair the harSHIELD.
the rear oxygen sensor harness and connecVisually check the rear oxygen sensor harness ness shield?
tor
shield for damage or open.
Go to step 7.
CHECK GROUND CIRCUIT ON ECM.
?
EN-181
Go to step 4.
Go to step 5.
Go to step 6.

NOTE:
the following:
Open circuit in
harness between
ECM and engine
ground terminal
Poor contact in
ECM connector
Poor contact in
coupling connector
(B22)

Step
Check
?
EN-182
Yes
No
Contact with your Repair the harSubaru distributor ness and connector.
service.
NOTE:
Inspection by DTM
probable
parts.
NOTE:
the following:
Open circuit in
harness between
ECM and engine
ground terminal
Poor contact in
ECM connector
Poor contact in
coupling connector
(B22)

EN-183

AK:DTC P0444 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
5
3
RHD
4
6
RHD
MAIN RELAY
B61
E4
LHD
LHD
BATTERY
SBF-5
1 2
F44
2
1
B47
F44
1 2 3 4
5 6 7 8
B47
B134 ECM
2
4
6
1
3
5
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
1
2
B22
E3
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
1
2
E4
PURGE CONTROL
SOLENOID VALVE
EN1410
EN-184

Step
chassis ground.
CHECK HARNESS BETWEEN PURGE CONTROL SOLENOID VALVE AND ECM CONNECTOR.
2)Disconnect the connectors from purge control solenoid valve and ECM.
purge control solenoid valve connector and
engine ground.
ECM and purge control solenoid valve of harness connector.
(B134) No. 2 (E4) No. 2:
Check
Yes
No
Is the voltage more than 10 V? Even if MIL lights Go to step 2.
up, the circuit has
this time. Contact
with your Subaru
distributor service.

?

?
NOTE:
Inspection by DTM
probable
parts.
ECM and purge
control solenoid
valve connector.
Go to step 4.
CHECK PURGE CONTROL SOLENOID

Is the resistance between 10 Go to step 5.
VALVE.
and 100 ?
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 CON- Is the voltage more than 10 V? Go to step 6.
TROL SOLENOID VALVE.
2)Measure the voltage between purge control
solenoid valve and engine ground.
EN-185
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
(B22)
Replace the purge
control solenoid
valve. <Ref. to EC8, Purge Control
Solenoid Valve.>
Repair the open

circuit in harness
between main
relay and purge
control solenoid
valve connector.

Step
CHECK POOR CONTACT.
Check poor contact in purge control solenoid
valve connector.
Check
Yes
Is there poor contact in purge Repair the poor
control solenoid valve connec- contact in purge
tor?
control solenoid
valve connector.
EN-186
No
Contact with your
Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.

EN-187

AL:DTC P0445 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
5
3
RHD
4
6
RHD
MAIN RELAY
B61
E4
LHD
LHD
BATTERY
SBF-5
1 2
F44
2
1
B47
F44
1 2 3 4
5 6 7 8
B47
B134 ECM
2
4
6
1
3
5
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
1
2
B22
E3
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
1
2
E4
PURGE CONTROL
SOLENOID VALVE
EN1410
EN-188

Step
Check
Yes
Does voltage change between Go to step 2.
0 and 10 V?
2)Connect the test mode connector at the
lower portion of instrument panel (on the
driver's side).
4)While operating the purge control solenoid
valve, measure the voltage between ECM and
chassis ground.
NOTE:
Purge control solenoid valve operation can be
executed using the Subaru Select Monitor. For
procedure, refer to Compulsory Valve Operation Check Mode. <Ref. to EN-50, Compulsory
Valve Operation Check Mode.>
chassis ground.
CHECK POOR CONTACT.
Repair the poor
connector?
contact in ECM
connector.
No
Even if MIL light
up, 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-51,
Engine Control
Module.>
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
2)Disconnect the connector from purge control
control solenoid
solenoid valve.
valve connector.
After repair,
replace the ECM.
chassis ground.
<Ref. to FU-51,
Engine Control
Module.>
Replace the purge Go to step 6.
VALVE.
?
control solenoid
valve <Ref. to EC2)Measure the resistance between purge con8, Purge Control
trol solenoid valve terminals.
Solenoid Valve.>
Terminals
and ECM <Ref. to
No. 1 No. 2:
FU-51, Engine
Control Module.>
Repair the poor
Replace the ECM.
CHECK POOR CONTACT.
connector?
contact in ECM
<Ref. to FU-51,
connector.
Engine Control
Module.>
EN-189

AM:DTC P0461 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM
CAUTION:
WIRING DIAGRAM:
LHD model
BATTERY
No.13
SBF-4
23
4
B36
B72
SBF-1
1 2
3 4
1
B72
IGNITION
SWITCH
R58
i1
A7
1 2 3
4 5 6
R59
COMBINATION
METER
A: i10
i12
1
2
3 4 5 6
A:
i10
i2
1 2 3 4 5 6 7 8 9 10
B37
C:
B136 ECM
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B99
B36
R3
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
11
27
B99
R15
R57
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
16
1
B22
E3
R59
FUEL SUB
LEVEL
SENSOR
3
5
2
1
2
24
R15
2 : 2.5L MODEL
C2
A6
C:
1 : 1.6L AND 2.0L MODEL
R58
FUEL
LEVEL
SENSOR
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B136
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
EN1411
EN-190

RHD model
B72
BATTERY
No.13
SBF-4
4
SBF-1
1 2
3 4
MT
AT
B36
B38
i1
i3
1
2
3 4 5 6
MT
AT
R58
IGNITION
SWITCH
R15
1 2 3
4 5 6
A7
22
B72
R59
COMBINATION
METER
A: i10
i12
A:
C2
A6
C:
2 : 2.5L MODEL
2
i10
1 2 3 4 5 6 7 8 9 10
21
B22
i2
1
5
9
13
B37
27
B136 ECM
R3
3
7
11
15
C:
i1
B99
2
6
10
14
4
8
12
16
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
R15
B99
R57
16
B22
E3
B136
FUEL SUB
LEVEL
SENSOR
3
5
1
2
2
R59
i3
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
21 22
23 24 25
26 27
28 29 30
R58
FUEL
LEVEL
SENSOR
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1412
Step
Check
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
NOTE:
In this case, it is
not necessary to
inspect P0461.
EN-191
No
Replace the fuel
level sensor <Ref.
to FU-65, Fuel
Level Sensor.>

AN:DTC P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT

CAUTION:
WIRING DIAGRAM:
LHD model
BATTERY
No.13
SBF-4
23
4
B36
B72
SBF-1
1 2
3 4
1
B72
IGNITION
SWITCH
R58
i1
A7
1 2 3
4 5 6
R59
COMBINATION
METER
A: i10
i12
R15
2 : 2.5L MODEL
1
2
3 4 5 6
A:
i10
i2
1 2 3 4 5 6 7 8 9 10
B37
C:
B136 ECM
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B99
B36
R3
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
11
27
B99
R15
R57
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
16
1
B22
E3
R59
FUEL SUB
LEVEL
SENSOR
3
5
2
1
2
24
C2
A6
C:
R58
FUEL
LEVEL
SENSOR
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B136
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
EN1411
EN-192

RHD model
B72
BATTERY
No.13
SBF-4
4
SBF-1
1 2
3 4
MT
AT
B36
B38
i1
i3
1
2
3 4 5 6
MT
AT
R58
IGNITION
SWITCH
R15
1 2 3
4 5 6
A7
22
B72
R59
COMBINATION
METER
A: i10
i12
A:
C2
A6
C:
2 : 2.5L MODEL
2
i10
1 2 3 4 5 6 7 8 9 10
21
B22
i2
1
5
9
13
B37
27
B136 ECM
R3
3
7
11
15
C:
i1
B99
2
6
10
14
4
8
12
16
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
R15
B99
R57
16
B22
E3
B136
FUEL SUB
LEVEL
SENSOR
3
5
1
2
2
R59
i3
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
21 22
23 24 25
26 27
28 29 30
R58
FUEL
LEVEL
SENSOR
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1412
Step
CHECK SPEEDOMETER AND TACHOMETER OPERATION IN COMBINATION
METER.
Check
Yes
Does the speedometer and
Go to step 2.
tachometer operate normally?
Is the voltage less than 0.12

1)Turn the ignition switch to ON. (engine OFF) V?
EN-193
Go to step 6.
No
Repair or replace
the combination
meter. <Ref. to
IDI-4, Combination Meter System.>
Go to step 3.

Step
Read the data of fuel level sensor signal using
Subaru Select Monitor.
NOTE:

2)Separate the fuel tank cord connector (R57)
and rear wiring harness connector (R15).
4)Measure the voltage of harness between
COMBINATION METER.
2)Disconnect the connector from connector
(i10) and ECM connector.
chassis ground.
COMBINATION METER.
combination meter connector.
(B136) No. 27 (i12) No. 2:
CHECK ENGINE DISPLACEMENT.
CHECK FUEL TANK CORD.

1)Disconnect the connector from fuel pump
assembly.
2)Measure the resistance between fuel pump
assembly and chassis ground.
Check
Yes
Does the value change less
Repair the poor
than 0.12 V by shaking harcontact in ECM
ness and connector of ECM
connector.
while monitoring the value with
Subaru Select Monitor?
No
Even if MIL lights
up, the circuit has
of the connector
may be the cause.
NOTE:
the following:
Poor contact in
combination meter
connector
Poor contact in
ECM connector
Poor contact in
coupling connectors (B99)
Go to step 8.
Is the voltage more than 0.12

V?
Go to step 4.

M?
Go to step 6.
Repair the ground


?
Repair or replace
the combination
meter. <Ref. to
Repair the open

circuit between
Is the engine displacement 2.5 Go to step 10.

L?
Is the resistance more than 1 Go to step 9.
M?
EN-194
NOTE:
the following:
Poor contact in
coupling connector
(i2)
Go to step 8.
Repair the ground
short circuit in fuel
tank cord.

10
11
12
13
Step
CHECK FUEL LEVEL SENSOR.
1)Remove the fuel pump assembly. <Ref. to
FU-62, Fuel Pump.>
2)Measure the resistance between fuel level
sensor and terminals with its float set to the full
position.
Terminals
No. 5 No. 3:
2)Disconnect the connector from fuel sub level
sensor.
3)Measure the resistance between fuel sub
level sensor and chassis ground.
assembly.
FU-62, Fuel Pump.>
position.
Terminals
No. 3 No. 5:
CHECK FUEL SUB LEVLE SENSOR.
1)Remove the fuel sub level sensor. <Ref. to
FU-66, Fuel Sub Level Sensor.>
level sensor and terminals with its float set to
the full position.
Terminals
No. 1 No. 2:
Check
Is the resistance between 0.5
and 2.5 ?
Yes
No
Repair the poor
Replace the fuel
contact in harness level sensor.
between ECM and
combination meter
connector.

M?
Go to step 11.
Repair the ground

tank cord.

M?
Go to step 12.
Repair the ground

tank cord.

and 2.5 ?
Go to step 13.
Replace the fuel

level sensor.

and 2.5 ?
Repair the poor

Replace the fuel
contact in harness sub level sensor.
between ECM and
combination meter
connector.
EN-195

AO:DTC P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT

CAUTION:
WIRING DIAGRAM:
LHD model
BATTERY
No.13
SBF-4
23
4
B36
B72
SBF-1
1 2
3 4
1
B72
IGNITION
SWITCH
R58
i1
A7
1 2 3
4 5 6
R59
COMBINATION
METER
A: i10
i12
R15
2 : 2.5L MODEL
1
2
3 4 5 6
A:
i10
i2
1 2 3 4 5 6 7 8 9 10
B37
C:
B136 ECM
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B99
B36
R3
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
11
27
B99
R15
R57
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
16
1
B22
E3
R59
FUEL SUB
LEVEL
SENSOR
3
5
2
1
2
24
C2
A6
C:
R58
FUEL
LEVEL
SENSOR
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B136
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
EN1411
EN-196

RHD model
B72
BATTERY
No.13
SBF-4
4
SBF-1
1 2
3 4
MT
AT
B36
B38
i1
i3
1
2
3 4 5 6
MT
AT
R58
IGNITION
SWITCH
R15
1 2 3
4 5 6
A7
22
B72
R59
COMBINATION
METER
A: i10
i12
A:
C2
A6
C:
2 : 2.5L MODEL
2
i10
1 2 3 4 5 6 7 8 9 10
21
B22
i2
1
5
9
13
B37
27
B136 ECM
R3
3
7
11
15
C:
i1
B99
2
6
10
14
4
8
12
16
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
R15
B99
R57
16
B22
E3
B136
FUEL SUB
LEVEL
SENSOR
3
5
1
2
2
R59
i3
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
21 22
23 24 25
26 27
28 29 30
R58
FUEL
LEVEL
SENSOR
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1412
Step
METER.
Check
Yes
Go to step 2.
EN-197
No
Repair or replace
the combination
meter. <Ref. to

Step
Check

2)Disconnect the combination meter connector
FUEL TANK CORD.
fuel tank cord.
(B136) No. 27 (R15) No. 2:
CHECK HARNESS BETWEEN FUEL TANK
CORD AND CHASSIS GROUND.
Measure the resistance between fuel tank cord
and chassis ground.

1)Disconnect the connector from fuel level
sensor.
sensor and coupling connector.
(R57) No. 6 (R58) No. 5:
CHECK ENGINE DISPLACEMENT.
Yes
Go to step 3.
No
Even if MIL lights
up, the circuit has
of the connector
may be the cause.
NOTE:
the following:
Poor contact in
fuel pump connector
Poor contact in
coupling connector
(B22, B99 and
R15)
Repair the battery
short circuit
between ECM and
combination meter
connector.

V?
Go to step 4.

?
Go to step 5.
Repair the open

circuit between
ECM and fuel tank
cord.

?
Go to step 6.
Repair the open

circuit between
fuel tank cord and
chassis ground.

?
Go to step 7.
Is the engine displacement 2.5 Go to step 10.

L?
EN-198
NOTE:
the following:
Poor contact in
coupling connectors (B22 and B99)
Repair the open
circuit between
coupling connector
and fuel level sensor.
Go to step 7.

10
11
12
13
Step
sensor.
(R57) No. 2 (R58) No. 3:
FU-62, Fuel Pump.>
2)While moving the fuel level sensor float up
and down, measure the resistance between
fuel level sensor terminals.
Terminals
No. 3 No. 5:
sensor.
sensor and fuel sub level sensor.
(R58) No. 3 (R59) No. 2:
Measure the resistance between fuel sub level
(R57) No. 2 (R59) No. 1:
FU-62, Fuel Pump.>
and down, measure resistance between fuel
level sensor terminals.
Terminals
No. 3 No. 5:
CHECK FUEL SUB LEVEL SENSOR.
FU-66, Fuel Sub Level Sensor.>
2)While moving the fuel sub level sensor float
up and down, measure resistance between
fuel sub level sensor terminals.
Terminals
No. 1 No. 2:
Check
?
Yes
Go to step 9.
No
Repair the open
circuit between
coupling connector

100 ?
Replace the fuel

level sensor. <Ref.
to FU-65, Fuel
Level Sensor.>
Replace the combination meter.

<Ref. to IDI-15,
Combination
Meter Assembly.>

?
Go to step 11.
Repair the open

circuit between
fuel level sensor
and fuel sub level
sensor.

?
Go to step 12.
Repair the open

circuit between
coupling connector
and fuel sub level
sensor.
Go to step 13.
Is the resistance more than 53 Replace the fuel

?
level sensor. <Ref.
to FU(TURBO)-62,
Fuel Level Sensor.>

?
sub level sensor.
<Ref. to
FU(TURBO)-63,
Fuel Sub Level
Sensor.>
EN-199

<Ref. to IDI-15,
Combination
Meter Assembly.>

AP:DTC P0464 FUEL LEVEL SENSOR INTERMITTENT INPUT

CAUTION:
WIRING DIAGRAM:
LHD model
BATTERY
No.13
SBF-4
23
4
B36
B72
SBF-1
1 2
3 4
1
B72
IGNITION
SWITCH
R58
i1
A7
1 2 3
4 5 6
R59
COMBINATION
METER
A: i10
i12
R15
2 : 2.5L MODEL
1
2
3 4 5 6
A:
i10
i2
1 2 3 4 5 6 7 8 9 10
B37
C:
B136 ECM
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B99
B36
R3
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
11
27
B99
R15
R57
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
16
1
B22
E3
R59
FUEL SUB
LEVEL
SENSOR
3
5
2
1
2
24
C2
A6
C:
R58
FUEL
LEVEL
SENSOR
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B136
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
EN1411
EN-200

RHD model
B72
BATTERY
No.13
SBF-4
4
SBF-1
1 2
3 4
MT
AT
B36
B38
i1
i3
1
2
3 4 5 6
MT
AT
R58
IGNITION
SWITCH
R15
1 2 3
4 5 6
A7
22
B72
R59
COMBINATION
METER
A: i10
i12
A:
C2
A6
C:
2 : 2.5L MODEL
2
i10
1 2 3 4 5 6 7 8 9 10
21
B22
i2
1
5
9
13
B37
27
B136 ECM
R3
3
7
11
15
C:
i1
B99
2
6
10
14
4
8
12
16
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
R15
B99
R57
16
B22
E3
B136
FUEL SUB
LEVEL
SENSOR
3
5
1
2
2
R59
i3
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
21 22
23 24 25
26 27
28 29 30
R58
FUEL
LEVEL
SENSOR
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1412
Step

FU-62, Fuel Pump.>
and down, make sure that the resistance
between fuel level sensor terminals changes
smoothly.
Terminals
No. 3 No. 5:
Check
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
Does the resistance change
2.5 L: Go to step 3.
smoothly between approx. 0.5 1.6 L and 2.0 L:
Repair the poor
and approx. 52 ?
contact in ECM,
combination meter
and coupling connectors.
EN-201
No
Go to step 2.
Replace the fuel

level sensor. <Ref.
to FU-65, Fuel
Level Sensor.>

Step
1)Remove the fuel sub level sensor.
2)<Ref. to FU-66, Fuel Sub Level Sensor.>
up and down, make sure that the resistance
smoothly.
Terminals
No. 1 No. 2:
Check
Yes
Repair the poor
smoothly between approx. 0.5 contact in ECM,
and approx. 44 ?
combination meter
EN-202
No
Replace the fuel
sub level sensor.
<Ref. to FU-66,
Fuel Sub Level
Sensor.>

AQ:DTC P0480 COOLING FAN RELAY 1 CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
Radiator fan does not operate properly.
Overheating
CAUTION:
EN-203

WIRING DIAGRAM:
BATTERY
SBF-1
B72
IGNITION
SWITCH
SBF-4
No.17
No.18
AIR CONDITIONING
RELAY HOLDER
AIR CONDITIONING
RELAY HOLDER
26
28
27
25
18
20
19
17
F27 20A
MAIN
F66 FAN
RELAY
F27 20A
SUB
F29 FAN
RELAY
SUB FAN
MOTOR
MAIN FAN
MOTOR
F45
2
1
1
2
2
1
B62
F17
F16
1 LHD :2
RHD :7
2 LHD :12
3
12
RHD :17
B134 ECM
F16
LHD:
RHD:
F45
F45
F17
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
2 1
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
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
F27
1
F29
F66
5 6 9 13 14 17 21 22 25
7
10
15
18
23
26
8 11 12 16 19 20 24 27 28
29
30
EN1413
EN-204

Step
driver's side).
4)While operating the radiator fan relay, measure the voltage between ECM terminal and
ground.
NOTE:
Radiator fan relay operation can be executed
using the Subaru Select Monitor. For procedure, refer to Compulsory Valve Operation
Check Mode.<Ref. to EN-34, Subaru Select
Monitor.>
CHECK GROUND SHORT CIRCUIT IN RADIATOR MAIN FAN RELAY CONTROL CIRCUIT.
CHECK POWER SUPPLY FOR RELAY.
1)Remove the main fan relay from A/C relay
holder.
3)Measure the voltage between fuse and relay
box (F/B) connector and chassis ground.
relay terminals.
Terminal
No. 28 No. 27:
CHECK OPEN CIRCUIT IN MAIN FAN RELAY CONTROL CIRCUIT.
ECM and main fan relay connector.
(B134) No. 3 (F66) No. 27:
CHECK POOR CONTACT.

Check poor contact in ECM or main fan relay
connector.
Check
Yes
Does voltage change between Repair the poor
0 and 10 V?
contact in ECM
connector.

?
No
Go to step 2.

short circuit in radiator main fan relay
control circuit.
Repair the open

circuit in harness
between ignition
switch and fuse
and relay box (F/B)
connector.

and 107 ?
Go to step 5.
Replace the main

fan relay.

?
Go to step 6.
NOTE:
the following:
Open circuit in
harness between
ECM and main fan
relay connector
Poor contact in
coupling connector
(F45)
Contact with your
main fan relay connector?
contact in ECM or Subaru distributor
main fan relay
service.
connector.
EN-205

EN-206

AR:DTC P0483 COOLING FAN FUNCTION PROBLEM

TROUBLE SYMPTOM:
Occurrence of noise
Overheating
CAUTION:
NOTE:
If the vehicle, with the engine idling, is placed very close to a wall or another vehicle, preventing normal cooling function, the OBD system may detect malfunction.
EN-207

WIRING DIAGRAM:
BATTERY
SBF-1
B72
IGNITION
SWITCH
SBF-4
No.17
No.18
AIR CONDITIONING
RELAY HOLDER
AIR CONDITIONING
RELAY HOLDER
26
28
27
25
18
20
19
17
F27 20A
MAIN
F66 FAN
RELAY
F27 20A
SUB
F29 FAN
RELAY
SUB FAN
MOTOR
MAIN FAN
MOTOR
F45
2
1
1
2
2
1
B62
F17
F16
1 LHD :2
RHD :7
2 LHD :12
3
12
RHD :17
B134 ECM
F16
LHD:
RHD:
F45
F45
F17
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
2 1
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
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
F27
1
F29
F66
5 6 9 13 14 17 21 22 25
7
10
15
18
23
26
8 11 12 16 19 20 24 27 28
29
30
EN1413
EN-208

Step
Check
CHECK ENGINE COOLANT AMOUNT
Is the amount of engine coolant at specified level?
EN-209
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
Check the radiator Add engine coolfan and fan motor. ant.
<Ref. to CO-10,
Radiator Main Fan
System.> and
<Ref. to CO-18,
Radiator Sub Fan
System.>

AS:DTC P0500 VEHICLE SPEED SENSOR MALFUNCTION

CAUTION:
WIRING DIAGRAM:
B17
IGNITION
SWITCH
BATTERY
SBF-4
1 2 3
SBF-1
1
No.18
B72
4
B72
1 2
3 4
A:
i10
1 2 3 4 5 6 7 8 9 10
B56
TCM
B22
VEHICLE
SPEED
SENSOR
1
5
9
13
1
2
17
B17
2
6
10
14
3
7
11
15
4
8
12
16
B56
AT
MT
1 2 3 4
10 11 12 13
19 20 21
COMBINATION
METER
7
16
22
8 9
17 18
23 24
i10
1
i2
1 LHD :9
B22
B135
E3
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
16
A2
B37
LHD:
24
A:
5 6
14 15
l2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
RHD :7
B135 ECM
RHD:
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1414
Step
Check
Is the transmission type AT?
EN-210
Yes
Go to step 2.
No
Go to step 3.

Step
CHECK DTC P0720 ON DISPLAY.
CHECK SPEEDOMETER OPERATION IN

COMBINATION METER.

COMBINATION METER CONNECTOR.
2)Disconnect the connector from combination
meter.
combination meter.
(B135) No. 24 (i10) No. 2:
Check
Yes
No
Does the Subaru Select Moni- Check the front
Go to step 3.
tor or OBD-II general scan tool vehicle speed senindicate DTC P0720?
sor signal circuit.
<Ref. to AT-57,
DTC 33 FRONT
VEHICLE SPEED
SENSOR, Diagnostic Procedure
with Diagnostic
Trouble Code
(DTC).>
Does the speedometer operate Go to step 4.
Check the speednormally?
ometer and vehicle speed sensor.
<Ref. to IDI-17,
Speedometer.>
and <Ref. to AT32, Front Vehicle
Speed Sensor.>
and <Ref. to AT36, Rear Vehicle
Speed Sensor.>
and <Ref. to AT37, Torque Converter Turbine
Speed Sensor.>
Is the resistance less than 10 Repair the poor
Repair the har?
contact in ECM
ness and connecconnector.
tor.
NOTE:
the following:
Open circuit in
harness between
Poor contact in
ECM connector
Poor contact in
combination meter
connector
Poor contact in
coupling connector
(i2)
EN-211

AT:DTC P0506 IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED

TROUBLE SYMPTOM:
Engine is difficult to start.
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
B47
6
4
LHD
5
3
1
3
5
SBF-5
LHD
2
B61
BATTERY
2
4
6
F44
2
1
E7
B47
1 2 3
4 5 6
B22
E3
F44
5
2
1 2 3 4
5 6 7 8
IDLE
AIR CONTROL
SOLENOID
VALVE
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
6
3
4
1
E7
E2
3
4
1
2
B21
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
A19
A20
A5
A6
A: B134
C22
C21
C: B136 ECM
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
16
B22
E3
C: B136
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
EN1415
EN-212

Step
Check
CHECK AIR BY-PASS LINE.

Does air flow out?
2)Remove the idle air control solenoid valve
from throttle body. <Ref. to FU-39, REMOVAL,
Idle Air Control Solenoid Valve.>
3)Remove the throttle body from intake manifold. <Ref. to FU-16, REMOVAL, Throttle
Body.>
4)Using an air gun, force air into the idle air
control solenoid valve installation area. Confirm that forced air subsequently escapes from
the throttle body interior.
EN-213
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0506.
Replace the idle
air control solenoid
valve. <Ref. to FU39, INSTALLATION, Idle Air
Control Solenoid
Valve.>
Replace the throttle body. <Ref. to

FU-16, INSTALLATION, Throttle
Body.>

AU:DTC P0507 IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED

TROUBLE SYMPTOM:
Engine keeps running at higher revolution than specified idling revolution.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
B47
6
4
LHD
5
3
1
3
5
SBF-5
LHD
2
B61
BATTERY
2
4
6
F44
2
1
E7
B47
1 2 3
4 5 6
B22
E3
F44
5
2
1 2 3 4
5 6 7 8
IDLE
AIR CONTROL
SOLENOID
VALVE
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
6
3
4
1
E7
E2
3
4
1
2
B21
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
A19
A20
A5
A6
A: B134
C22
C21
C: B136 ECM
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
16
B22
E3
C: B136
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
EN1415
EN-214

Step
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0507.
Is there a fault in air intake sys- Repair the air suc- Go to step 3.
tem?
tion and leaks.

2)Start the engine, and idle it.
3)Check the following items.
Loose installation of intake manifold, idle air
control solenoid valve and throttle body
Cracks of intake manifold gasket, idle air control solenoid valve gasket and throttle body
gasket
Disconnections of vacuum hoses
CHECK THROTTLE CABLE.
Does the throttle cable have
play for adjustment?
Adjust the throttle

cable. <Ref. to SP9, INSTALLATION, Accelerator
Control Cable.>
Are foreign particles in by-pass Remove the forReplace the idle
air line?
eign particles from air control solenoid
by-pass air line.
valve. <Ref. to FUfrom throttle body. <Ref. to FU-39, REMOVAL,
39, INSTALLAIdle Air Control Solenoid Valve.>
TION, Idle Air
3)Confirm that there are no foreign particles in
Control Solenoid
by-pass air line.
Valve.>
EN-215
Go to step 4.

AV:DTC P0512 STARTER SWITCH CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-4
IGNITION
SWITCH
B72
INHIBITOR SWITCH
P
12
AT
MT
12
11
7
T3
T7
MT
B12
R N D
B135 ECM
28
AT
B14
STARTER
MOTOR
B72
1 2
3 4
B12
1 2 3 4
5 6 7 8
9 10 11 12
T7
B135
1 2 3 4 5 6
7 8 9 10 11 12
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
EN0862
EN-216

Step
Check
CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate when ignition switch is
NOTE:
turned to ON?
Place the inhibitor switch in each position.
EN-217
Yes
Repair the battery
short circuit in
No
Check the starter
motor circuit. <Ref.
to EN-64,
STARTER
MOTOR CIRCUIT, Diagnostics

AW:DTC P0562 CHARGE SYSTEM CIRCUIT LOW INPUT

Power source voltage of the ECM is low.
TROUBLE SYMPTOM:
Charge warning light comes on.
CAUTION:
WIRING DIAGRAM:
GENERATOR
SBF-1
MAIN RELAY
LHD
5
3
BATTERY
RHD
RHD
4
6
LHD
2
B61
SBF-5
F44
2
1
1
2
B47
B136 ECM
B47
1
3
5
2
4
6
F44
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
23 24 25
26 27
28 29 30
21 22
EN1416
EN-218

Step
CHECK GENERATOR.
1)Start the engine.
2)Idle after warm-up.
3)Measure the voltage between generator B
Terminal
Generator B terminal (+) Chassis
ground ():
CHECK GENERATOR.
1)Run the engine at 5,000 rpm.
Terminal
ground ():
CHECK BATTERY TERMINAL.
Check
V?
Yes
Go to step 2.
No
Repair the generator. <Ref. to CS21, General Diagnostic.>

V?
Go to step 3.
Are the positive and ground

battery terminals tightly
clamped?
V?
Go to step 4.
Tighten the clamp

of terminal.
Go to step 5.
Repair the harness connector

between battery,
main relay and
ECM.
Go to step 6.
Replace the generator.
Go to step 7.
Proceed with the

diagnosis corresponding to the
DTC.
A temporary poor
contact.

1)Run the engine at idle.
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in connectors between generator,
battery and ECM?
Is the same DTC as in the curCHECK ECM.
1)Connect all connectors.
rent diagnosis still being out2)Erase the memory. <Ref. to EN-49, Clear
put?
Memory Mode.>
3)Perform inspection mode. <Ref. to EN-42,
Inspection Mode.>
4)Read out the DTC. <Ref. to EN-41, Read
CHECK ANY OTHER TROUBLE CODES AP- Are other DTC being output?
PEARANCE.
EN-219

AX:DTC P0563 CHARGE SYSTEM CIRCUIT HIGH INPUT

Power source voltage of the ECM is high.
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
GENERATOR
SBF-1
MAIN RELAY
LHD
5
3
BATTERY
RHD
RHD
4
6
LHD
2
B61
SBF-5
F44
2
1
1
2
B47
B136 ECM
B47
1
3
5
2
4
6
F44
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
23 24 25
26 27
28 29 30
21 22
EN1416
EN-220

Step
CHECK GENERATOR.
1)Start the engine.
Terminal
ground ():
CHECK GENERATOR.
Terminal
ground ():
Check
V?
Yes
Go to step 2.
No

V?
Go to step 3.

clamped?
V?
Go to step 4.
Tighten the clamp

of terminal.
Go to step 5.

between battery,
main relay and
ECM.
Go to step 6.
Go to step 7.
Proceed with the

DTC.
A temporary poor
contact.

battery and ECM?
Is the same DTC as in the curCHECK ECM.
rent diagnosis still being out2)Erase the memory. <Ref. to EN-49, Clear
put?
Memory Mode.>
3)Perform the inspection mode. <Ref. to EN42, Inspection Mode.>
4)Read out the DTC. <Ref. to EN-41, Read
CHECK ANY OTHER TROUBLE CODES AP- Are other DTC being output?
PEARANCE.
EN-221

AY:DTC P0604 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR

Immediately at fault recognition.
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
RHD
4
6
RHD
MAIN RELAY
LHD
5
3
B61
2
1
B72
B47
F44
IGNITION
SWITCH
BATTERY
No.11
SBF-4
SBF-1
B19
C1
C2
C9
B7
SBF-5
LHD
A: B134
B: B135 ECM
1 AT MODEL: B6
MT MODEL: B25
13
15
14
16
C21
A34
A35
A7
A8
A27
C22
C: B136
B22
E3
B72
1 2
3 4
F44
1 2 3 4
5 6 7 8
B47
1
3
5
2
4
6
B: B135
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
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
C: B136
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
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
Step
EN1397
Check
Yes
No
Does the Subaru Select Moni- Replace the ECM. It is not necessary
tor or OBD-II general scan tool <Ref. to FU-51,
to inspect DTC
indicate DTC P0604?
Engine Control
P0604.
Module.>
EN-222

EN-223

AZ:DTC P0703 BRAKE SWITCH INPUT MALFUNCTION

CAUTION:
WIRING DIAGRAM:
BATTERY
No.16
SBF-2
SBF-1
2
1
OC WC
RHD
LHD
WC : WITH CRUISE CONTROL MODEL
BRAKE
LIGHT
SWITCH
STOP
LIGHT
SWITCH
B65
: WC
: OC
WC OC
B64
: WITHOUT CRUISE CONTROL MODEL
RHD
B64
OC
LHD
12
TO STOP LIGHTS
B55
B64
B65
1 2
1 2
3 4
TCM
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
EN1417
Step
CHECK OPERATION OF BRAKE LIGHT.
Check
Does the brake light come on
when depressing the brake
pedal?
EN-224
Yes
Go to step 2.
No
Repair or replace
the brake light circuit.

Step
Check
CHECK HARNESS BETWEEN TCM AND
?
BRAKE LIGHT SWITCH CONNECTOR.
1)Disconnect the connectors from TCM and
brake light switch.
TCM and brake light switch connector.
LHD
(B55) No. 12 (B64) No.1:
RHD
Without cruise control
(B55) No. 12 (B64) No. 2
With cruise control
(B55) No. 12 (B65) No. 3

TCM and chassis ground.
CHECK INPUT SIGNAL FOR TCM.
1)Connect the connectors to TCM and brake
light switch.
2)Measure the voltage between TCM and
chassis ground.
Yes
Go to step 3.

M?
Go to step 4.
Is the voltage less than 1 V

when releasing the brake
pedal?
Go to step 5.
Is the voltage more than 10 V

Measure the voltage between TCM and chas- when depressing the brake
sis ground.
pedal?
CHECK POOR CONTACT.

Check poor contact in TCM connector.
Is there poor contact in TCM

connector?
EN-225
Go to step 6.
Repair the poor

contact in TCM
connector.
No
Repair or replace
the harness and
connector.
NOTE:
the following:
Open circuit in
harness between
TCM and brake
light switch connector
Poor contact in
TCM connector
Poor contact in
brake light switch
connector
Repair the ground
TCM and brake
light switch connector.
Adjust or replace
the brake light
switch. <Ref. to LI8, STOP LIGHT
SWITCH,
INSPECTION,
Stop Light System.>
Adjust or replace
the brake light
SWITCH,
INSPECTION,
Stop Light System.>
Replace the TCM.
<Ref. to AT-46,
Transmission Control Module
(TCM).>

BA:DTC P0731 GEAR 1 INCORRECT RATIO

NOTE:
For the diagnostic procedure, refer to DTC P0734. <Ref. to EN-227, DTC P0734 GEAR 4 INCORRECT
RATIO , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BB:DTC P0732 GEAR 2 INCORRECT RATIO

NOTE:
BC:DTC P0733 GEAR 3 INCORRECT RATIO

NOTE:
EN-226

BD:DTC P0734 GEAR 4 INCORRECT RATIO

TROUBLE SYMPTOM:
Shift point too high or too low; engine brake not effected in 3 range; excessive shift shock; excessive
tight corner braking
CAUTION:
WIRING DIAGRAM:
Step
Check
CHECK THROTTLE POSITION SENSOR

CIRCUIT.
Check the throttle position sensor circuit. <Ref.
to AT-50, DTC 31 THROTTLE POSITION
SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
CHECK FRONT VEHICLE SPEED SENSOR
CIRCUIT.
Check the front vehicle speed sensor circuit.
<Ref. to AT-57, DTC 33 FRONT VEHICLE
SPEED SENSOR, Diagnostic Procedure with
CHECK TORQUE CONVERTER TURBINE
SPEED SENSOR CIRCUIT.
Check the torque converter turbine speed sensor circuit. <Ref. to AT-62, DTC 36 TORQUE
CONVERTER TURBINE SPEED SENSOR,
Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
CHECK POOR CONTACT.
Is there any trouble in throttle

position sensor circuit?
CHECK MECHANICAL TROUBLE.

Check mechanical trouble in automatic transmission.
Is there any trouble in front

vehicle speed sensor circuit?
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
Repair or replace Go to step 3.
the throttle position sensor circuit.
Repair or replace
the front vehicle
speed sensor circuit.
Go to step 4.
Is there any trouble in torque Repair or replace

converter turbine speed sensor the torque concircuit?
verter turbine
Go to step 5.

connector?
Go to step 6.
Repair the poor

contact in TCM
connector.
Is there any mechanical trou- Repair or replace
ble in automatic transmission? the automatic
transmission.
<Ref. to AT-12,
INSPECTION,
Road Test.>
EN-227
Replace the TCM.

<Ref. to AT-46,
(TCM).>

BE:DTC P0741 TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION

TROUBLE SYMPTOM:
No lock-up (after engine warm-up)
No shift or excessive tight corner braking
CAUTION:
Step
Check
CHECK LOCK-UP DUTY SOLENOID CIRCUIT.

Check the lock-up duty solenoid circuit. <Ref.
to AT-94, DTC 77 LOCK-UP DUTY SOLENOID, Diagnostic Procedure with Diagnostic
CIRCUIT.
Code (DTC).>
CHECK ENGINE SPEED INPUT CIRCUIT.
Check the engine speed input circuit. <Ref. to
AT-42, DTC 11 ENGINE SPEED SIGNAL,
Code (DTC).>
Check the inhibitor switch circuit. <Ref. to AT119, CHECK INHIBITOR SWITCH., Diagnostic
Procedure for No-diagnostic Trouble Code
(DTC).>
CHECK BRAKE LIGHT SWITCH CIRCUIT.
Check the brake light switch circuit. <Ref. to
AT-110, CHECK BRAKE SWITCH., Diagnostic
(DTC).>
CHECK ATF TEMPERATURE SENSOR CIRCUIT.
Check the ATF temperature sensor circuit.
<Ref. to AT-46, DTC 27 ATF TEMPERATURE
Is there any trouble in lock-up

duty solenoid circuit?

Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
the lock-up duty
solenoid circuit.


verter turbine
Go to step 5.
Is there any trouble in engine

speed input circuit?
Go to step 6.
Repair or replace
the engine speed
input circuit.
Is there any trouble in inhibitor Repair or replace Go to step 7.

switch circuit?
the inhibitor switch
circuit.
Is there any trouble in brake

light switch circuit?
Repair or replace
the brake light
switch circuit.
Is there any trouble in ATF

temperature sensor circuit?

the ATF temperature sensor circuit.
EN-228
Go to step 8.

10
Step
CHECK POOR CONTACT.
Check
connector?
Yes
Repair the poor
contact in TCM
connector.
transmission.
<Ref. to AT-12,
INSPECTION,
Road Test.>
EN-229
No
Go to step 10.
Replace the TCM.

<Ref. to AT-46,
(TCM).>

BF:DTC P1110 ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW INPUT

CAUTION:
WIRING DIAGRAM:
2
3
1
ATMOSPHERIC
PRESSURE
SENSOR
B2
LHD
RHD
LHD
RHD
1
B83
29
15
16
B122
B136 ECM
B2
1 2 3
B122
B83
B136
1 2 3
4 5 6
1 2 3 4
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
EN1418
EN-230

Step
Check
CHECK CURRENT DATA.
Is the value less than 0 kPa
1)Start the engine.
(0 mmHg, 0 inHg)?
Yes
Go to step 3.
NOTE:
CHECK POOR CONTACT.
contact in ECM or
sor connector.
atmospheric pressure sensor connector.
and chassis ground.
and chassis ground.
connector.

NOTE:
Does the value change more

than 0 kPa (0 mmHg, 0 inHg)
by shaking harness and connector of ECM while monitoring the value with Subaru
select monitor?
EN-231
Repair the poor

contact in ECM
connector.
No
Go to step 2.
Even if MIL lights

up, the circuit has
this time.
Go to step 4.
Contact with your

Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.
Go to step 6.
Go to step 7.

10
Step
Check
Yes
CHECK HARNESS BETWEEN ECM AND AT- Is the voltage more than 4.5 V? Go to step 8.
MOSPHERIC PRESSURE SENSOR CONNECTOR.
2)Disconnect the connector from atmospheric
pressure sensor.
4)Measure the voltage between atmospheric
pressure sensor connector and engine ground.
CHECK HARNESS BETWEEN ECM AND AT- Is the resistance less than 1
MOSPHERIC PRESSURE SENSOR CON?
NECTOR.
ECM and pressure sensor connector.
(B136) No. 16 (B2) No. 1:
CHECK HARNESS BETWEEN ECM AND ATMOSPHERIC PRESSURE SENSOR CONNECTOR.
CHECK POOR CONTACT.
Check poor contact in pressure sensor connector.
Go to step 9.

500 k?
Go to step 10.
Is there poor contact in pressure sensor connector?
Repair the poor

contact in atmospheric pressure
sensor connector.
EN-232
No
NOTE:
the following:
Open circuit in
harness between
ECM and atmospheric pressure
sensor connector
Poor contact in
joint connector
(B83) or (B122)
NOTE:
the following:
Open circuit in
harness between
ECM and pressure
sensor connector
Repair the ground
ECM and pressure
sensor connector.
Replace the atmospheric pressure

sensor. <Ref. to
FU-38, Atmospheric Pressure
Sensor.>

EN-233

BG:DTC P1111 ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH INPUT

CAUTION:
WIRING DIAGRAM:
2
3
1
ATMOSPHERIC
PRESSURE
SENSOR
B2
LHD
RHD
LHD
RHD
1
B83
29
15
16
B122
B136 ECM
B2
1 2 3
B122
1 2 3
4 5 6
B83
B136
1 2 3 4
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
EN1418
EN-234

Step
Check
Yes
CHECK CURRENT DATA.
Is the value more than 140 kPa Go to step 10.
1)Start the engine.
(1,050 mmHg, 41.34 inHg)?
NOTE:
and chassis ground.
and chassis ground.

and chassis ground.
No
Go to step 2.
Go to step 3.

connector.
Contact with your

Subaru distributor
service.
Does the value change more

than 0 kPa (0 mmHg, 0 inHg)
by shaking harness and connector of ECM while monitoring the value with Subaru
Select Monitor?
Repair the poor

contact in ECM
connector.
NOTE:
PRESSURE SENSOR CONNECTOR.
pressure sensor.
4)Measure the voltage between atmospheric
EN-235
NOTE:
Inspection by DTM
probable
parts.
Go to step 5.
Go to step 6.

NOTE:
the following:
Open circuit in
harness between
ECM and pressure
sensor connector
Poor contact in
joint connector
(B83) or (B122)

Step
Check
?
(B136) No. 29 (B2) No. 2:
Yes
Go to step 8.

(B136) No. 16 (B2) No. 1:

?
Go to step 9.
CHECK POOR CONTACT.

10
CHECK CURRENT DATA.

Is the value more than 140 kPa
(1,050 mmHg, 41.34 inHg)?
pressure sensor.
NOTE:
EN-236
Repair the poor

contact in atmospheric pressure
sensor connector.
Repair the battery

ECM and atmospheric pressure
sensor connector.
No
NOTE:
the following:
Open circuit in
harness between
ECM and pressure
sensor connector
NOTE:
the following:
Open circuit in
harness between
ECM and pressure
sensor connector
Poor contact in
joint connector
(B83), (B122)
sensor. <Ref. to
Sensor.>
sensor. <Ref. to
Sensor.>

EN-237

BH:DTC P1112 ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM

CAUTION:
WIRING DIAGRAM:
2
3
1
ATMOSPHERIC
PRESSURE
SENSOR
B2
LHD
RHD
LHD
RHD
1
B83
29
15
16
B122
B136 ECM
B2
1 2 3
B122
1 2 3
4 5 6
B83
B136
1 2 3 4
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
EN1418
EN-238

Step
CHECK ATMOSPHERIC PRESSURE SENSOR FILTER.

pressure sensor.
3)Remove the atmospheric pressure sensor.
4)Check the atmospheric pressure sensor filter.
CHECK CURRENT DATA.
Check
Is the atmospheric pressure

sensor filter non-functional?
(Check for contamination,
damage, water leakage, etc.)
Is the value between 73.3 kPa

(550 mmHg, 21.65 inHg) and
106.6 kPa (800 mmHg, 31.50
inHg)?
NOTE:
EN-239
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
NOTE:
In this case, it is
not necessary to
inspect P1112.
Replace the atmo- Go to step 3.
spheric pressure
sensor filter.

sensor. <Ref. to
Sensor.>
Replace the intake

air temperature
Temperature and
Pressure Sensor.>

BI: DTC P1137 FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM
RHD
MAIN RELAY
RHD
CAUTION:
WIRING DIAGRAM:
6
4
LHD
LHD
BATTERY
SBF-5
F44
B61
B47
1
3
5
2
4
6
5
3
B47
B18
2
1
1 2 3
4 5 6
FRONT OXYGEN
(A/F) SENSOR
4
6
3
1
B18
F44
1 2 3 4
5 6 7 8
B22
C7
C20
C6
C19
C23
A22
A23
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
A: B134
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
A: B134
ECM
A34
A35
C: B136
C: B136
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
B22
E3
EN1400
Step
Check
EN-240
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of

Step
Check
CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the value equal to or more
TA.
1)Start the engine.
70C (160F).
general scan tool.
Yes
Go to step 3.
NOTE:
CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the value more than 1.1 for a Go to step 6.
TA.
moment?
Race the engine at speeds from idling to 5,000
rpm for a total of 5 cycles.
NOTE:
slowly depress the accelerator pedal, taking
approx. 5 seconds, and quickly release the accelerator pedal to decrease engine speed.
(B136) No. 6 (E24) No. 3:
(B136) No. 7 (E24) No. 4:
(B136) No. 19 (E24) No. 1:
(B136) No. 20 (E24) No. 6:
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.

tem?
the faulty parts.
NOTE:
EN-241
Replace the front

(A/F) Sensor.>

BJ:DTC P1142 THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT)
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
THROTTLE
POSITION
SENSOR
E13
4
3
2
1 2 3 4
E13
B122
12
11
9
1 2 3
4 5 6
E2
B21
B83
1 2 3 4
B21
LHD
RHD
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
LHD
B122
RHD
1
B83
B136
15
17
16
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
B136 ECM
EN1405
EN-242

Step
Check
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
NOTE:
In this case, it is
not necessary to
inspect P1142.
EN-243
No
<Ref. to FU-35,
Throttle Position
Sensor.>

BK:DTC P1146 PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (HIGH INPUT)
CAUTION:
WIRING DIAGRAM:
E20
1 2 3 4
1
3
2
INTAKE AIR
TEMPERATURE
AND
PRESSURE
SENSOR
E20
LHD:
B83
1 2 3
4 5 6
15
9
12
14
B122
E2
1 2 3
4 5 6
B21
B122
B83
LHD
RHD
LHD
RHD
RHD:
B83
1 2 3 4
LHD
B21
1
B83
1 2
3
6 7
9 10
11
13
14 15
17 18
19
25 LHD
16
15
13
B136 ECM
4
8
12
16
20
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
EN1403
EN-244

Step

(140F).
N or P position.
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
NOTE:
In this case, it is
not necessary to
inspect P1146.
Go to step 3.
disconnection of hose on the intake system.
air intake system?
Is the value within the specifi- Go to step 4.
Replace the intake
cations?
air temperature
to FU-37, Intake
Air Temperature
and Pressure Sensor.>
NOTE:
Specification:
Ignition ON
73.3 106.6 kPa (550 800 mmHg,
21.65 31.50 inHg)
Idling
20.0 46.7 kPa (150 350 mmHg, 5.91
13.78 inHg)
Read the data of throttle position signal using equal to or less than 5 % when
tool.
NOTE:
EN-245
Adjust or replace
to FU-35, Throttle
Position Sensor.>

Step
Check
equal to or more than 85 %
EN-246
Yes
Replace the intake
air temperature
Temperature and
Pressure Sensor.>
No
<Ref. to FU-35,
Throttle Position
Sensor.>

BL:DTC P1442 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM 2
CAUTION:
WIRING DIAGRAM:
LHD model
BATTERY
No.13
SBF-4
23
4
B36
B72
SBF-1
1 2
3 4
1
B72
IGNITION
SWITCH
R58
i1
A7
1 2 3
4 5 6
R59
COMBINATION
METER
A: i10
i12
1
2
3 4 5 6
A:
i10
i2
1 2 3 4 5 6 7 8 9 10
B37
C:
B136 ECM
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B99
B36
R3
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
11
27
B99
R15
R57
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
16
1
B22
E3
R59
FUEL SUB
LEVEL
SENSOR
3
5
2
1
2
24
R15
2 : 2.5L MODEL
C2
A6
C:
R58
FUEL
LEVEL
SENSOR
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B136
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
EN1411
EN-247

RHD model
B72
BATTERY
No.13
SBF-4
4
SBF-1
1 2
3 4
MT
AT
B36
B38
i1
i3
1
2
3 4 5 6
MT
AT
R58
IGNITION
SWITCH
R15
1 2 3
4 5 6
A7
22
B72
R59
COMBINATION
METER
A: i10
i12
A:
C2
A6
C:
2 : 2.5L MODEL
2
i10
1 2 3 4 5 6 7 8 9 10
21
B22
i2
1
5
9
13
B37
27
B136 ECM
R3
3
7
11
15
C:
i1
B99
2
6
10
14
4
8
12
16
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
R15
B99
R57
16
B22
E3
B136
FUEL SUB
LEVEL
SENSOR
3
5
1
2
2
R59
i3
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
21 22
23 24 25
26 27
28 29 30
R58
FUEL
LEVEL
SENSOR
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1412
Step
Check
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
NOTE:
In this case, it is
not necessary to
inspect P1442.
EN-248
No
Replace the fuel
level sensor. <Ref.
to FU-65, Fuel
Level Sensor.>

BM:DTC P1480 COOLING FAN RELAY 1 CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
Overheating
CAUTION:
EN-249

WIRING DIAGRAM:
BATTERY
SBF-1
B72
IGNITION
SWITCH
SBF-4
No.17
No.18
AIR CONDITIONING
RELAY HOLDER
AIR CONDITIONING
RELAY HOLDER
26
28
27
25
18
20
19
17
F27 20A
MAIN
F66 FAN
RELAY
F27 20A
SUB
F29 FAN
RELAY
SUB FAN
MOTOR
MAIN FAN
MOTOR
F45
2
1
1
2
2
1
B62
F17
F16
1 LHD :2
RHD :7
2 LHD :12
3
12
RHD :17
B134 ECM
F16
LHD:
RHD:
F45
F45
F17
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
2 1
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
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
F27
1
F29
F66
5 6 9 13 14 17 21 22 25
7
10
15
18
23
26
8 11 12 16 19 20 24 27 28
29
30
EN1413
EN-250

Step
driver's side).
4)While operating the radiator fan relay, measure the voltage between ECM and chassis
ground.
NOTE:
Check Mode.<Ref. to EN-50, Compulsory
Valve Operation Check Mode.>
CHECK SHORT CIRCUIT IN RADIATOR FAN
RELAY CONTROL CIRCUIT.
2)Remove the main fan relay and sub fan
relay. (with A/C models)
chassis ground.
2)Remove the main fan relay.
relay terminals.
Terminal
No. 26 No. 25:
1)Remove the sub fan relay.
relay terminals.
Terminal
No. 18 No. 17
CHECK POOR CONTACT.
Check
Yes
No
Does voltage change between Even if MIL lights Go to step 2.
0 and 10 V?
up, the circuit has
this time. In this
case, repair the
poor contact in
ECM connector.

short circuit in radiator fan relay control circuit.

?
Replace the main

fan relay.
Go to step 4.

?
Replace the sub

fan relay.
Go to step 5.

connector?
Repair the poor

contact in ECM
connector.
Replace the ECM.

<Ref. to FU-51,
Engine Control
Module.>
EN-251

BN:DTC P1507 IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE)

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
B47
6
4
LHD
5
3
1
3
5
SBF-5
LHD
2
B61
BATTERY
2
4
6
F44
2
1
E7
B47
1 2 3
4 5 6
B22
E3
F44
5
2
1 2 3 4
5 6 7 8
IDLE
AIR CONTROL
SOLENOID
VALVE
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
6
3
4
1
E7
E2
3
4
1
2
B21
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
A19
A20
A5
A6
A: B134
C22
C21
C: B136 ECM
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
16
B22
E3
C: B136
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
EN1415
EN-252

Step
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
NOTE:
In this case, it is
not necessary to
inspect P1507.
Is there a fault in the air intake Repair the air suc- Go to step 3.
system?
tion and leaks.

gasket
Adjust the throttle

Control Cable.>
Are foreign particles in by-pass Remove the forCHECK AIR BY-PASS LINE.
Replace the idle
air line?
by-pass air line.
valve. <Ref. to FUfrom throttle body. <Ref. to FU-39, Idle Air
39, Idle Air ConControl Solenoid Valve.>
trol Solenoid
Valve.>
the by-pass air line.
EN-253
Go to step 4.

BO:DTC P1510 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1 CIRCUIT

LOW INPUT
NOTE:
For the diagnostic procedure, refer to DTC P1516. <Ref. to EN-256, DTC P1516 IDLE AIR CONTROL
SOLENOID VALVE SIGNAL 4 CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
BP:DTC P1511 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1 CIRCUIT

HIGH INPUT
NOTE:
SOLENOID VALVE SIGNAL 4 CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
BQ:DTC P1512 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 2 CIRCUIT

LOW INPUT
NOTE:
Code (DTC).>
BR:DTC P1513 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 2 CIRCUIT

HIGH INPUT
NOTE:
Code (DTC).>
BS:DTC P1514 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 3 CIRCUIT

LOW INPUT
NOTE:
Code (DTC).>
BT:DTC P1515 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 3 CIRCUIT

HIGH INPUT
NOTE:
Code (DTC).>
EN-254

EN-255

BU:DTC P1516 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Engine breathing
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
B47
6
4
LHD
5
3
1
3
5
SBF-5
LHD
2
B61
BATTERY
2
4
6
F44
2
1
E7
B47
1 2 3
4 5 6
B22
E3
F44
5
2
1 2 3 4
5 6 7 8
IDLE
AIR CONTROL
SOLENOID
VALVE
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
6
3
4
1
E7
E2
3
4
1
2
B21
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
A19
A20
A5
A6
A: B134
C22
C21
C: B136 ECM
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
16
B22
E3
C: B136
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
EN1415
EN-256

Step
Check
Yes
CHECK POWER SUPPLY TO IDLE AIR CON- Is the voltage more than 10 V? Go to step 2.
2)Disconnect the connector from idle air control solenoid valve.
4)Measure the voltage between idle air control
solenoid valve connector and engine ground.
Measure the voltage between idle air control

CONNECTOR.
idle air control solenoid valve connector.
DTC P1510; (B134) No. 5 (E7) No. 4:
DTC P1512; (B134) No. 6 (E7) No. 1:
DTC P1514; (B134) No. 19 (E7) No. 6:
DTC P1516; (B134) No. 20 (E7) No. 3:

?

CONNECTOR.
2)Measure the resistance between ECM connector and chassis ground.
DTC P1510; (B134) No. 5 Chassis
ground:
ground:
ground:
ground:

?
EN-257
Go to step 4.
No
NOTE:
the following:
Open circuit in
harness between
idle air control
solenoid valve and
Poor contact in
coupling connector
(B22)
NOTE:
the following:
Open circuit in
harness between
idle air control
solenoid valve and
Poor contact in
coupling connector
(B22)
NOTE:
the following:
Open circuit in
harness between
ECM and idle air
control solenoid
valve connector
Poor contact in
coupling connector
(B21)
ECM and idle air
control solenoid
valve connector.

Step
Check
CHECK POOR CONTACT.
Check poor contact in ECM connector and idle connector or idle air control
air control solenoid valve connector.
solenoid valve connector?
EN-258
Yes
Repair the poor
contact in ECM
connector or idle
valve connector.
No
Replace the idle
valve. <Ref. to FU39, Idle Air Control Solenoid
Valve.>

EN-259

BV:DTC P1517 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Engine breathing
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
B47
6
4
LHD
5
3
1
3
5
SBF-5
LHD
2
B61
BATTERY
2
4
6
F44
2
1
E7
B47
1 2 3
4 5 6
B22
E3
F44
5
2
1 2 3 4
5 6 7 8
IDLE
AIR CONTROL
SOLENOID
VALVE
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
6
3
4
1
E7
E2
3
4
1
2
B21
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
A19
A20
A5
A6
A: B134
C22
C21
C: B136 ECM
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
16
B22
E3
C: B136
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
EN1415
EN-260

Step
CHECK GROUND CIRCUIT FOR ECM.

Check
Yes
indicate DTC P1511, P1513,
P1515 and P1517 at same
time?
Go to step 3.
?
No
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
(B22)
Is the voltage more than 10 V? Repair the battery Replace the ECM.
short circuit in har- <Ref. to FU-51,
CONNECTOR.
ness between
Engine Control
ECM and idle air Module.>
2)Disconnect the connector from idle air concontrol solenoid
trol solenoid valve.
valve connector.
After repair,
4)Measure the voltage between ECM connecreplace the ECM.
tor and chassis ground.
<Ref. to FU-51,
Engine Control
DTC P1511; (B134) No. 5 (+) Chassis
Module.>
ground ():
DTC P1513; (B134) No. 6 (+) Chassis
ground ():
DTC P1515; (B134) No. 19 (+) Chassis
ground ():
DTC P1517; (B134) No. 20 (+) Chassis
ground ():
EN-261

BW:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
BATTERY
SBF-4
SBF-1
B72
1 2
3 4
IGNITION
SWITCH
B72
3
T7
1 2 3 4 5 6
7 8 9 10 11 12
INHIBITOR SWITCH
P
B135 ECM
26
12
12
11
B12
T3
R N D
1
B12
1 2 3 4
5 6 7 8
9 10 11 12
T7
B135
STARTER SWITCH
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
B14
EN1419
EN-262

Step
Check
CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate
when ignition switch is turned
NOTE:
Place the inhibitor switch in the P or N posi- to START?
tion.
EN-263
Yes
No
Repair the harCheck the starter
ness and connec- motor circuit. <Ref.
tor.
to EN-64,
STARTER
NOTE:
In this case, repair MOTOR CIRCUIT, Diagnostics
the following:
Open or ground for Engine Startshort circuit in har- ing Failure.>
ness between
ECM and starter
motor connector
Poor contact in
ECM connector

BX:DTC P1540 VEHICLE SPEED SENSOR MALFUNCTION 2

CAUTION:
WIRING DIAGRAM:
B17
IGNITION
SWITCH
BATTERY
SBF-4
1 2 3
SBF-1
1
No.18
B72
4
B72
1 2
3 4
A:
i10
1 2 3 4 5 6 7 8 9 10
B56
TCM
B22
VEHICLE
SPEED
SENSOR
1
5
9
13
1
2
17
B17
2
6
10
14
3
7
11
15
4
8
12
16
B56
AT
MT
1 2 3 4
10 11 12 13
19 20 21
COMBINATION
METER
7
16
22
8 9
17 18
23 24
i10
1
i2
1 LHD :9
B22
B135
E3
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
16
A2
B37
LHD:
24
A:
5 6
14 15
l2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
RHD :7
B135 ECM
RHD:
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1414
EN-264

Step

COMBINATION METER.

meter.
combination meter.
(B135) No. 24 (i10) No. 2:
Check
Yes
No
Go to step 2.
sor signal circuit.
<Ref. to AT-57,
DTC 33 FRONT
VEHICLE SPEED
with Diagnostic
Trouble Code
(DTC).>
<Ref. to IDI-17,
Speedometer.>
Repair the har?
contact in ECM
tor.
NOTE:
the following:
Open circuit in
harness between
Poor contact in
ECM connector
Poor contact in
combination meter
connector
Poor contact in
coupling connector
(i2)
EN-265

BY:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

RHD
RHD
CAUTION:
WIRING DIAGRAM:
LHD
LHD
2
F44
C9
B61
BATTERY
SBF-5
A: B134
1 AT MODEL : B6
MT MODEL : B25
B: B135 ECM
1
A34
A35
8
16
13
15
14
A7
A8
A27
C22
C21
C: B136
B22
E3
B: B135
B22
F44
1
5
9
13
1 2 3 4
5 6 7 8
2
6
10
14
3
7
11
15
4
8
12
16
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
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
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
EN1420
Step
chassis ground.
Check
Yes
contact in ECM
connector.
EN-266
No
Go to step 2.

Step
Check
?
MAIN FUSE BOX CONNECTOR.
CHECK FUSE SBF-5.
Is the fuse blown?
Yes
No
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
EN-267

BZ:DTC P1590 NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT (AT

MODEL)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
BATTERY
SBF-4
SBF-1
B72
1 2
3 4
IGNITION
SWITCH
B72
3
T7
1 2 3 4 5 6
7 8 9 10 11 12
INHIBITOR SWITCH
P
B135 ECM
26
12
12
11
B12
R N D
B12
7
T3
1 2 3 4
5 6 7 8
9 10 11 12
T7
B135
STARTER SWITCH
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
B14
EN1419
EN-268

Step

chassis ground in selector lever N and P
positions.
Measure the voltage between ECM and chassis ground in selector lever except for N and
P positions.
CHECK POOR CONTACT.
Check
Yes
No
Go to step 2.
indicate DTC P0705?
of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
Go to step 3.
Go to step 5.
Is the voltage between 4.5 and Go to step 4.

5.5 V?
Go to step 5.

connector?
Contact with your

Subaru distributor
service.
Repair the poor

contact in ECM
connector.
NOTE:
Inspection by DTM
probable
parts.
short circuit in harMeasure the voltage between ECM and chasness between
sis ground.
ECM and inhibitor
switch connector.
Go to step 7.
Repair the harCHECK HARNESS BETWEEN ECM AND IN- Is the resistance less than 1
?
ness and connecHIBITOR SWITCH CONNECTOR.
tor.
NOTE:
inhibitor switch.
the following:
ECM and inhibitor switch connector.
Open circuit in
harness between
(B135) No. 26 (T7) No. 12:
ECM and inhibitor
switch connector
Poor contact in
coupling connector
(B12)
Poor contact in
inhibitor switch
connector
Poor contact in
ECM connector
EN-269

Step
Check
CHECK INHIBITOR SWITCH GROUND LINE. Is the resistance less than 5
?
inhibitor switch connector and engine ground.
(T7) No. 7 Engine ground:
CHECK INHIBITOR SWITCH.

Measure the resistance between inhibitor
?
switch connector receptacle's terminals in
selector lever N and P positions.
Terminals
No. 7 No. 12:
CHECK SELECTOR CABLE CONNECTION. Is there any fault in selector
cable connection to inhibitor
switch?
EN-270
Yes
Go to step 8.
Go to step 9.
Repair the selector

cable connection.
<Ref. to CS-10,
INSPECTION,
Select Cable.>
No
Repair the open
circuit in harness
between inhibitor
switch connector
and starter motor
ground line.
NOTE:
the following:
Open circuit in
harness between
inhibitor switch
connector and
starter motor
ground line
Poor contact in
starter motor connector
Poor contact in
starter motor
ground
Starter motor
Replace the inhibitor switch. <Ref. to
AT-28, Inhibitor
Switch.>
Contact with your

Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.

EN-271

CA:DTC P1591 NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT (AT MODEL)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
BATTERY
SBF-4
SBF-1
B72
1 2
3 4
IGNITION
SWITCH
B72
3
T7
1 2 3 4 5 6
7 8 9 10 11 12
INHIBITOR SWITCH
P
B135 ECM
26
12
12
11
B12
R N D
B12
7
T3
1 2 3 4
5 6 7 8
9 10 11 12
T7
B135
STARTER SWITCH
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
B14
EN1419
EN-272

Step

chassis ground.
TRANSMISSION HARNESS CONNECTOR.
transmission harness connector (T3).
CHECK TRANSMISSION HARNESS CONNECTOR.
switch.
transmission harness connector and engine
ground.
selector lever except for N position.
Terminals
No. 7 No. 12:
CHECK SELECTOR CABLE CONNECTION.
Check
Yes
No
Does the Subaru Select Moni- Inspect the DTC
Go to step 2.
indicate DTC P0705?
of Diagnostic
Trouble Code
(DTC). <Ref. to
EN-83, List of
Is the voltage between 4.5 and Even if MIL lights Go to step 3.
5.5 V at except N and P
up, the circuit has
positions?
this time.
?

ECM and transmission harness
connector.

?

transmission harness and inhibitor
switch connector.

M at except N and P positions?

AT-28, Inhibitor
Switch.>
Is there any fault in selector

switch?
Contact with your

Subaru distributor
service.
EN-273
Repair the selector

cable connection.
<Ref. to CS-10,
INSPECTION,
Select Cable.>
NOTE:
Inspection by DTM
probable
parts.

CB:DTC P1592 NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT (MT

MODEL)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B135 ECM
B25
26
1 2
B25
B22
T2
1
5
9
13
NEUTRAL
POSITION
SWITCH
T2
B25
2
6
10
14
3
7
11
15
4
8
12
16
1 LHD : 16
RHD : 15
B135
B22
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
E3
EN1421
Step
chassis ground.
Check
Yes
Is the voltage more than 10V in Go to step 2.
neutral position?
EN-274
No
Go to step 4.

Step
CHECK POOR CONTACT.
CHECK NEUTRAL POSITION SWITCH.
2)Disconnect the connector from transmission
harness.
3)Measure the resistance between transmission harness and connector terminals.
(T2) No. 1 No. 2:
Measure the resistance between transmission
harness connector terminals.

NEUTRAL POSITION SWITCH CONNECTOR.
chassis ground.
ECM and transmission harness connector.
(B135) No. 26 (B25) No. 1:
ground.
CHECK POOR CONTACT.
Check poor contact in transmission harness
connector.
Check
Is the voltage less than 1V in
other position?
Yes
Go to step 3.
No
Go to step 4.
Is the poor contact in ECM

connector?
Repair the poor

contact in ECM
connector.
Go to step 5.
Contact with your

Subaru distributor
service.
Repair the short
circuit in transmission harness or
replace neutral
position switch.

1M in neutral position?

in other positions?

?
Go to step 6.
Repair the short

replace neutral
position switch.
connector.

?
Go to step 8.
Repair the open

circuit in harness
between ECM and
transmission harness connector.

?
Go to step 9.
Repair the open

circuit between
transmission harness connector
and engine ground
terminal.
Is there poor contact in transmission harness connector?
Repair the poor

contact in transmission harness
connector.
Contact with your

Subaru distributor
service.
EN-275

CC:DTC P1594 AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT MALFUNCTION
CAUTION:
WIRING DIAGRAM:
B56
TCM
5 6
14 15
7
16
22
8
17
23
9
18
24
21
B56
1 2 3 4
10 11 12 13
19 20 21
B135
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
B135 ECM
EN0889
Step
Check
Yes
CHECK DRIVING CONDITION.
Is the AT shift control function- Go to step 2.
1)Start and warm-up the engine until the radia- ing properly?
tor fan makes one complete rotation.
2)Drive the vehicle.
EN-276
No
Replace the TCM.
<Ref. to AT-46,
(TCM).>

Step
CHECK ACCESSORY.
Check
Are the car phone and/or CB
installed on vehicle?
EN-277
Yes
Repair the grounding line of car
phone or CB system.
No
Replace the TCM.
<Ref. to AT-46,
(TCM).>

CD:DTC P1595 AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT LOW INPUT
CAUTION:
WIRING DIAGRAM:
B56
TCM
5 6
14 15
7
16
22
8
17
23
9
18
24
21
B56
1 2 3 4
10 11 12 13
19 20 21
B135
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
B135 ECM
EN0889
EN-278

Step
TCM CONNECTOR.
chassis ground.
Check

TCM CONNECTOR.
TCM.
CHECK OUTPUT SIGNAL FOR ECM.
chassis ground.
CHECK TROUBLE CODE FOR AUTOMATIC
TRANSMISSION.
Read the DTC for automatic transmission.
<Ref. to AT-22, Read Diagnostic Trouble Code
(DTC).>

?
Yes
Go to step 2.
NOTE:
the following:
Poor contact in
ECM connector
Poor contact in
TCM connector
ECM and TCM
connector.
Go to step 4.
Does the DTC appear for auto- Inspect the DTC

matic transmission?
for automatic
transmission.
<Ref. to AT-42,
(DTC).>
EN-279
No
Even if MIL lights
up, the circuit has
this time.
Repair the poor

contact in ECM
connector.
Replace the TCM.

<Ref. to AT-46,
(TCM).>

CE:DTC P1596 AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT HIGH INPUT
CAUTION:
WIRING DIAGRAM:
B56
TCM
5 6
14 15
7
16
22
8
17
23
9
18
24
21
B56
1 2 3 4
10 11 12 13
19 20 21
B135
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
B135 ECM
EN0889
Step
TCM CONNECTOR.
chassis ground.
Check
Yes
No
Is the voltage more than 10 V? Repair battery
Go to step 2.
ECM and TCM
connector.
EN-280

Step
TCM CONNECTOR.
and chassis ground.
TCM CONNECTOR.
and chassis ground.
Check
Yes
Go to step 5.
No
Go to step 3.
Repair the poor

contact in ECM
connector.
Go to step 4.
Does the voltage change from Even if MIL lights

1 V to 4 V while monitoring the up, the circuit has
value with voltage meter?
this time.

TCM CONNECTOR.
Measure the voltage between TCM and chassis ground.
CHECK POOR CONTACT.
connector?
EN-281
Contact with your

Subaru distributor
service.
NOTE:
Inspection by DTM
is required, beNOTE:
In this case, repair cause
probable
the following:
cause is deteriora Poor contact in tion of multiple
ECM connector
parts.
Poor contact in
TCM connector
Go to step 6.
Repair the open
circuit in harness
between ECM and
TCM connector.
Repair the poor

contact in TCM
connector.
Check the TCM

power supply line
and grounding
line.

CF:DTC P1698 ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW INPUT
CAUTION:
WIRING DIAGRAM:
B55
TCM
5 6
14 15
7
16
22
8
17
23
9
18
24
10
B55
1 2 3 4
10 11 12 13
19 20 21
B135
31
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
B134 ECM
EN0890
Step
1)Start the engine and warm-up engine.
chassis ground.
Check
EN-282
Yes
Repair the poor
contact in ECM
connector.
No
Go to step 2.

Step
TCM CONNECTOR.
TCM.
TCM CONNECTOR.
ECM and TCM connector.
(B134) No. 31 (B55) No. 10:
Check
?
Yes
No
ECM and TCM
connector.

?
Repair the poor

Repair the open
contact in ECM or circuit in harness
TCM connector.
between ECM and
TCM connector.
EN-283

CG:DTC P1699 ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH INPUT
CAUTION:
WIRING DIAGRAM:
B55
TCM
5 6
14 15
7
16
22
8
17
23
9
18
24
10
B55
1 2 3 4
10 11 12 13
19 20 21
B135
31
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
B134 ECM
EN0890
EN-284

Step
3)Disconnect the connector from TCM.
chassis ground.
TCM CONNECTOR.
chassis ground.
Check
No
Repair the battery
ECM and TCM
connector. After
repair, replace the
ECM. <Ref. to FU51, Engine Control Module.>
Does the voltage change more Repair the battery Contact with your
than 10 V by shaking harness short circuit in har- Subaru distributor
ness between
service.
monitoring the value with volt- ECM and TCM
NOTE:
age meter?
connector. After
Inspection by DTM
repair, replace the is required, beECM. <Ref. to FU- cause
probable
51, Engine Concause is deterioratrol Module.>
tion of multiple
parts.
EN-285
Yes
Go to step 2.

CH:DTC P1701 CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION

FOR AUTOMATIC TRANSMISSION
CAUTION:
WIRING DIAGRAM:
B94
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
CCM
B94
B55
5 6
14 15
7
16
22
8
17
23
9
18
24
22
1 2 3 4
10 11 12 13
19 20 21
B55
TCM
EN1422
EN-286

Step
CCM CONNECTOR.
CCM.
TCM and CCM connector.
(B55) No. 22 (B94) No. 3:
CCM CONNECTOR.
1)Connect the connector to TCM and CCM.
2)Lift-up the vehicle or set the vehicle on free
rollers.
CAUTION:
On AWD models, raise all wheels off
ground.
3)Start the engine.
4)Cruise control main switch to ON.
5)Move the selector lever to D range and
slowly increase vehicle speed to 50 km/h (31
MPH).
6)Cruise control command switch to ON.
chassis ground.
CHECK POOR CONTACT.
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and
CCM connector.

?
Go to step 3.
Repair the short
circuit in harness
between TCM and
CCM connector.
Is the resistance less than 1 V? Go to step 4.
Check the cruise

control command
switch circuit.
<Ref. to CC-6,
INSPECTION,
Cruise Control
Command
Switch.>

connector?
Replace the TCM.

<Ref. to AT-46,
(TCM).>
EN-287
Repair the poor

contact in TCM
connector.

CI: DTC P1711 ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT MALFUNCTION

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
B56
TCM
5 6
14 15
7
16
22
8 9
17 18
23 24
B56
1 2 3 4
10 11 12 13
19 20 21
B135
16
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
B135 ECM
EN0892
Step
chassis ground.
Check
Yes
EN-288
No
Go to step 4.

Step
Check
CHECK POOR CONTACT.
connector?
Yes
Repair the battery
ECM and TCM
connector.
Repair the poor
contact in ECM
connector.

TCM CONNECTOR.
TCM.
(B135) No. 16 (B56) No. 5:
TCM CONNECTOR.
CHECK POOR CONTACT.

?
Go to step 5.

?

ECM and TCM
connector.

connector?
Repair the poor

contact in TCM
connector.
EN-289
No
Go to step 3.
Replace the ECM.

<Ref. to FU-51,
Engine Control
Module.>
Repair the open
circuit in harness
between ECM and
TCM connector.
Replace the TCM.

<Ref. to AT-46,
(TCM).>

CJ:DTC P1712 ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT MALFUNCTION

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
B56
TCM
5 6
14 15
7
16
22
8 9
17 18
23 24
14
B56
1 2 3 4
10 11 12 13
19 20 21
B135
17
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
B135 ECM
EN0893
Step
chassis ground.
Check
Yes
EN-290
No
Go to step 4.

Step
Check
CHECK POOR CONTACT.
connector?
Yes
Repair the battery
ECM and TCM
connector.
Repair the poor
contact in ECM
connector.

TCM CONNECTOR.
TCM.
(B135) No. 17 (B56) No. 14:
TCM CONNECTOR.
CHECK POOR CONTACT.

?
Go to step 5.

?

ECM and TCM
connector.

connector?
Repair the poor

contact in TCM
connector.
EN-291
No
Go to step 3.
Replace the ECM.

<Ref. to FU-51,
Engine Control
Module.>
Repair the open
circuit in harness
between ECM and
TCM connector.
Replace the TCM.

<Ref. to AT-46,
(TCM).>
GENERAL DIAGNOSTIC TABLE

20.General Diagnostic Table

A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME-95, Engine Trouble in General.>
Symptom
1. Engine stalls during idling.
2. Rough idling
3. Engine does not return to idle.
4. Poor acceleration
5. Engine stalls or engine sags or hesitates at

acceleration.
6. Surge
Problem parts
1) Idle air control solenoid valve
2) Intake air temperature and pressure sensor
3) Ignition parts (*1)
4) Engine coolant temperature sensor (*2)
5) Crankshaft position sensor (*3)
6) Camshaft position sensor (*3)
7) Fuel injection parts (*4)
5) Air intake system (*5)
7) Throttle position sensor
10) Oxygen sensor
11) Fuel pump and fuel pump relay
2) Engine coolant temperature sensor
3) Accelerator cable (*6)
8) A/C switch and A/C cut relay
9) Engine torque control signal circuit
5) Purge control solenoid valve
1) Intake manifold pressure sensor
2) Intake air temperature sensor
EN-292

Symptom
7. Spark knock
8. After burning in exhaust system
Problem parts
5) Knock sensor
*1: Check ignition coil & ignitor assembly and spark plug.
*2: Indicate the symptom occurring only in cold temperatures.
*3: Ensure the secure installation.
*4: Check fuel injector, fuel pressure regulator and fuel filter.
*5: Inspect air leak in air intake system.
*6: Adjust accelerator cable.
2. AUTOMATIC TRANSMISSION
NOTE:
Check general diagnostics table with non-conformity symptom for automatic transmission. <Ref. to AT-2, Basic Diagnostic Procedure.>
EN-293

EN-294
ENGINE 2 SECTION

of SUBARU vehicles.
FU(w/oOBD)
EMISSION CONTROL
EC(w/oOBD)
EXHAUST
EX(w/oOBD)
IGNITION
IG(w/oOBD)
ENGINE(DIAGNOSTICS)
EN(w/oOBD)
FU(TURBO)
EMISSION CONTROL
EC(TURBO)
INTAKE (INDUCTION)
IN(TURBO)
MECHANICAL
ME(TURBO)
EXHAUST
EX(TURBO)
IGNITION
IG(TURBO)
EN(TURBO)

approval.
G1840GE3
FU(w/oOBD)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Page
Throttle Body.............................................................................................16
Intake Manifold..........................................................................................17
Knock Sensor............................................................................................33
Intake Air Temperature and Pressure Sensor...........................................38
Fuel Injector ..............................................................................................40
Oxygen Sensor .........................................................................................46
Main Relay ................................................................................................49
Fuel Pump Relay.......................................................................................50
Fuel ...........................................................................................................51
Fuel Tank ..................................................................................................52
Fuel Filler Pipe ..........................................................................................55
Fuel Pump.................................................................................................59
Fuel Filter ..................................................................................................65
Fuel Cut Valve...........................................................................................66
GENERAL DESCRIPTION
A: SPECIFICATIONS
Model
Fuel tank
Fuel pump
Capacity
Location
Type
Discharge flow
Fuel filter
1600 cc and 2000 cc

2500 cc
50 2 (13.2 US gal, 11.0 Imp gal)
60 2 (15.9 US gal, 13.2 Imp gal)
Under rear seat
Impeller
370 677 kPa (3.77 6.9 kg/cm2, 53.6 98 psi)
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
Cartridge type
FU(w/oOBD)-2
GENERAL DESCRIPTION
FU(w/oOBD)-3
GENERAL DESCRIPTION
B: COMPONENT
1. INTAKE MANIFOLD
(2)
T5
(20)
T3
(4)
T5
(3)
T5
(23)
(7)
(5)
(8)
T3
T6
(2)
T4
(6)
T3
T2
(22)
T5
(13)
T5
(9)
(20)
T4
(4)
T6
(3)
(14)
(5)
T6
(16)
(1)
T6
(10)
(21)
T5
T6
(19)
T5
(15)
T1
(18)
T1
(18)
(21)
(11)
T1
T1
(12)
(17)
(19)
T1
(19)
T5
T1
T3
(18)
EN1385
FU(w/oOBD)-4
GENERAL DESCRIPTION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Intake manifold gasket RH

Fuel injector pipe
Fuel injector
O-ring
O-ring
Plug
PCV valve
Nipple
Intake manifold
Intake manifold gasket LH
(12)
(13)

(22)
(23)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
O-ring
Plug cord holder LH
Fuel pipe ASSY
Fuel hose
Clip
Clip
Guide pin

T1: 1.5 (0.15, 1.1)
T2: 3.4 (0.35, 2.5)
T3: 5.0 (0.51, 3.7)
T4: 17 (1.7, 12.5)
T5: 19 (1.9, 14.0)
T6: 25 (2.5, 18.4)
FU(w/oOBD)-5
Plug cord holder RH

GENERAL DESCRIPTION
B2M3455C
(1)
(2)
(3)
Gasket
(4)
Throttle body
FU(w/oOBD)-6

T1: 1.6 (0.16, 1.2)
T2: 22 (2.2, 16.2)
GENERAL DESCRIPTION
B2M2282B
(1)
(2)

Knock sensor
(3)
(4)

Camshaft position sensor support
FU(w/oOBD)-7

T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)
GENERAL DESCRIPTION
4. FUEL TANK
1600 CC and 2000 CC MODEL
T1
T1
(9)
(25)
(16)
(10)
(8)
(6)
(11)
(11)
D
A
(11)
(14)
(13)
(7)
(24)
T1
(12)
(24)
(11)
C
(9)
(11)
(8)
(5)
(15)
(11)
(17)
(19) (18)
(20)
A
(4)
(11)
(21)
(11)
(22)
(2)
T3
(18)
T3
(19)
(3)
(11)
(23)
(2)
T2
T2
(1)
T2
EN0439
FU(w/oOBD)-8
GENERAL DESCRIPTION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Heat shield cover

Fuel tank band
Protector RH
Fuel tank
Fuel pump gasket
Fuel pump ASSY
Fuel meter unit
Fuel cut valve
Evaporation hose A
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Clip
Evaporation hose B
Joint pipe
Evaporation hose C
Evaporation pipe
Evaporation hose D
Retainer
Quick connector
Evaporation hose E
FU(w/oOBD)-9
(21)
(22)
(23)
(24)
(25)
Fuel pipe ASSY

Evaporation hose F
Fuel return hose B
Evaporation hose G
Evaporation hose H

T1: 4.4 (0.45, 3.3)
T2: 7.4 (0.75, 5.4)
T3: 33 (3.4, 24.3)
GENERAL DESCRIPTION
2500 CC MODEL
T1
T1
(30)
(17)
(10)
(11)
(9)
(7)
(12)
(12)
D
(12)
(8)
(15)
(14)
T1
(29)
(13)
T1
D
(9)
(12)
(8)
(28)
(6)
(29)
(12)
(16)
E
B
(12)
(12)
(18)
(21) (20)
(5)
(22)
(19)
(27)
(12)
(12)
(26)
(23)
(12)
(24)
(2)
T3
(20)
T3
(12)
(25)
(4)
(2)
T2
T2
(1)
(3)
T2
T2
EN1503
FU(w/oOBD)-10
GENERAL DESCRIPTION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Heat shield cover

Fuel tank band
Protector LH
Protector RH
Fuel tank
Fuel pump gasket
Fuel pump ASSY
Fuel meter unit
Fuel cut valve
Evaporation hose A
Clip
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
Evaporation hose B
Joint pipe
Evaporation hose C
Evaporation pipe
Evaporation hose D
Fuel return hose A
Retainer
Quick connector
Evaporation hose E
Fuel pipe ASSY
Evaporation hose F
FU(w/oOBD)-11
(25)
(26)
(27)
(28)
(29)
(30)
Fuel return hose B

Jet pump filter
Fuel sub meter unit
Evaporation hose G
Evaporation hose H

T1: 4.4 (0.45, 3.3)
T2: 7.4 (0.75, 5.4)
T3: 33 (3.4, 24.3)
GENERAL DESCRIPTION
5. FUEL LINE
(19)
B
(24)
(18)
(20)
(17)
(16)
(15)
(24)
(25)
(22)
(21) (13)
T
(23)
(14)
B
C
A
(1)
(1)
C
(12)
(8)
(1) (1) (10)
(9)
(1)
(1)
(1)
(1)
(10)
(11)
(7)
(1)
(6)
(2)
(1)
(5)
(4)
(3)
EN0440
FU(w/oOBD)-12
GENERAL DESCRIPTION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Clip
Fuel filter bracket
Fuel filter holder
Fuel filter cup
Fuel filter
Evaporation hose
Fuel damper
Fuel return hose
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Fuel pipe ASSY

Grommet
Canister hose A
Canister
Cushion
Two-way valve
FU(w/oOBD)-13
(21)
(22)
(23)
(24)
(25)

Connector
Clamp

T: 23 (2.3, 17.0)
GENERAL DESCRIPTION
6. FUEL FILLER PIPE
(9)
(8)
(10)
(11)
T
(1)
(3)
(2)
(5)
T
(3)
T
(6)
T
(4)
(3)
(7)
EN0441
(1)
(2)
(3)
(4)
(5)
(6)

Clip
Clamp
Air vent hose
Air vent pipe
(7)
(8)
(9)
(10)
(11)

Filler pipe packing
Filler ring
Filler cap
FU(w/oOBD)-14

T: 7.5 (0.76, 5.5)
GENERAL DESCRIPTION
C: CAUTION

points.
cable from battery.
D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
24082AA190
(Newly adopted
tool)
DESCRIPTION
CARTRIDGE
REMARKS
SELECT MONITOR KIT

B2M3876
22771AA030
B2M3877
FU(w/oOBD)-15
THROTTLE BODY
2. Throttle Body
6) Disconnect the air by-pass hose from purge control solenoid valve.
A: REMOVAL
H2M2949
G6M0095
(A) Throttle position sensor

(B) Idle air control solenoid valve
(C) Air by-pass hose from purge control solenoid
valve
H2M2947

B2M4255
8) Remove the bolts which install throttle body to

intake manifold.
B: INSTALLATION
NOTE:
B2M4254A
5) Disconnect the connectors from idle air control

solenoid valve and throttle position sensor.
Tightening torque:
Throttle body;
22 Nm (2.2 kgf-m, 16.2 ft-lb)
Air cleaner case;
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
FU(w/oOBD)-16
INTAKE MANIFOLD
3. Intake Manifold
A: REMOVAL
1) Release the fuel pressure. <Ref. to FU(w/
oOBD)-51, RELEASING OF FUEL PRESSURE,
OPERATION, Fuel.>
2) Open the fuel flap lid and remove fuel filler cap.

brackets.
(1) Remove the resonator chamber. <Ref. to
IN-8, REMOVAL, Resonator Chamber.>
(2) Remove the front side V-belt. <Ref. to ME44, REMOVAL, V-belt.>
NOTE:
G6M0095
4) Remove the air intake duct and air cleaner assembly. <Ref. to IN-7, REMOVAL, Air Intake
Duct.> and <Ref. to IN-6, REMOVAL, Air Cleaner
Case.>
B2M4126
B2M3151
B2M4254A
EN0360
FU(w/oOBD)-17
INTAKE MANIFOLD

B2M4259
EN0361

right side wheel apron.
12) Remove the air cleaner case stay RH and engine harness bracket, and then disconnect the engine harness connectors from bulkhead harness
connectors.
EN0208
8) Disconnect the spark plug cords from spark

plugs.
9) Disconnect the PCV hose from intake manifold.
B2M4260
13) Disconnect the connectors from engine coolant

temperature sensor.
B2M4261
B2M4258
10) Disconnect the engine coolant hose from throttle body.
B2M4262
B2M4255
FU(w/oOBD)-18
INTAKE MANIFOLD
15) Disconnect the connector from crankshaft position sensor.
18) Disconnect the fuel hoses from fuel pipes.

WARNING:
Do not spill fuel.
cloth.
B2M1252

switch.
S2M0500F

(B) Return hose
19) Remove the bolts which hold intake manifold

B2M1253
B2M4128
B2M4263
B2M0160
FU(w/oOBD)-19
INTAKE MANIFOLD
B: INSTALLATION
4) Connect the connector to oil pressure switch.

NOTE:
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
B2M1253
5) Connect the connector to crankshaft position

sensor.
B2M4128
2) Connect the fuel hoses.
B2M1252
S2M0500F

(B) Return hose
B2M4262
7) Connect the connectors to engine coolant temperature sensor.
B2M4263
B2M4261
FU(w/oOBD)-20
INTAKE MANIFOLD
8) Install the air cleaner case stay RH and engine

harness bracket, and then connect the engine harness connectors to bulkhead connectors.
13) Install the power steering pump and tank on

brackets.
EN0361
B2M4260
9) Connect the brake booster hose.

pump switch.
B2M4259
10) Connect the engine coolant hose to throttle

body.
EN0360
(3) Tighten the bolts which install power steering pump on bracket.
Tightening torque:
22 Nm (2.2 kgf-m, 16.2 ft-lb)
B2M4255
11) Connect the PCV hose to intake manifold.

B2M3151
(4) Install the power steering pipes onto right

side intake manifold protector.
B2M4258
12) Connect the spark plug cords to spark plugs.
B2M4126
FU(w/oOBD)-21
INTAKE MANIFOLD
(5) Install the front side V-belt. <Ref. to ME-44,

Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
G6M0095
C: DISASSEMBLY
1) Disconnect the engine ground cable from intake
manifold.
B6M1237
14) Connect the accelerator cable (A).

15) Connect the cruise control cable (B). (With
cruise control models)
B2M4265

ignitor assembly.
B2M4254A
16) Install the air intake duct and air cleaner assembly. <Ref. to IN-7, INSTALLATION, Air Intake
Duct.> and <Ref. to IN-6, INSTALLATION, Air
Cleaner Case.>
H2M2957
EN0344
H2M2958
FU(w/oOBD)-22
INTAKE MANIFOLD
B2M4129
H2M2959

sensor from intake manifold.
B2M4130
H2M2960
11) Disconnect the connectors from fuel injectors.
6) Disconnect the connectors from throttle position

sensor and idle air control solenoid valve.
7) Remove the throttle body.
B2M3371

solenoid valve.
H2M2951
8) Disconnect the pressure regulator vacuum hose

B2M3485
H2M2961
FU(w/oOBD)-23
INTAKE MANIFOLD
13) Disconnect the air by-pass hose (A) from purge

(A)

intake manifold.
EN1003
14) Remove the harness bands (A) and harness

bracket (B) which hold engine harness onto intake
manifold.
H2M2966

B2M4272
B2M4271A

20) Remove the fuel injectors.

H2M2969
B2M3487

fuel injector pipe.

intake manifold as shown in the figure.
H2M2970
H2M2965
FU(w/oOBD)-24
INTAKE MANIFOLD

fuel hose to injector pipe, and then remove the pipe
from fuel hose.
25) Remove the fuel pipe assembly (B) and pressure regulator (A) from intake manifold.
H2M2976A
B2M4289
22) Loosen the clamp which holds front right side

fuel hose.
B2M4274
23) Remove the fuel injector pipe.
H2M2975
24) Remove the bolt which installs fuel pipes on intake manifold.
H2M2974
FU(w/oOBD)-25
INTAKE MANIFOLD
D: ASSEMBLY
1) Install the fuel pipe assembly (B) and pressure
regulator (A), etc. to intake manifold.

and then tighten the clamp screw.
B2M4289
H2M2976A
2) Tighten the bolt which installs fuel pipes on intake manifold.
6) Install the fuel injectors.

NOTE:
Tightening torque:
5.0 Nm (0.51 kgf-m, 3.7 ft-lb)
B2M3372A
H2M2974
3) Connect the right side fuel hose to injector pipe,

(A) O-ring
(B) Fuel injector
(C) Intake manifold protector
NOTE:
Do not forget to install the fuel injector securing clip.
B2M4274
4) Install the fuel injector pipe.

H2M2969
H2M2975
FU(w/oOBD)-26
INTAKE MANIFOLD
Tightening torque:
5.0 Nm (0.51 kgf-m, 3.7 ft-lb)
B2M3487

valve.
H2M2965

CAUTION:
Tightening torque:
5.0 Nm (0.51 kgf-m, 3.7 ft-lb)
B2M1893E
A: To fuel pipe
B: To throttle body
B2M4272

Tightening torque:
5.0 Nm (0.51 kgf-m, 3.7 ft-lb)
12) Install the engine harness onto intake manifold.

Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
13) Connect the connectors to fuel injectors and
purge control solenoid valve.
14) Hold the engine harness by harness band (A)
and harness bracket (B).
H2M2966
B2M4271A
NOTE:
Do not use the harness band on harnesses where
they are supposed to be protected by the fuel pipe
protector.
FU(w/oOBD)-27
INTAKE MANIFOLD
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
NOTE:
Tightening torque:
22 Nm (2.2 kgf-m, 16.2 ft-lb)
B2M4130

H2M2951
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
19) Connect the air by-pass hose (A) from purge

control solenoid valve to intake manifold.
B2M4129
17) Connect the pressure regulator vacuum hose

to intake manifold.
H2M2961
FU(w/oOBD)-28
(A)
EN1003
INTAKE MANIFOLD
20) Install the intake air temperature and pressure

sensor.
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
H2M2960
B2M4265
E: INSPECTION
NOTE:
H2M2999
21) Connect the connector to intake air temperature and pressure sensor.
22) Connect the connectors to throttle position sensor and idle air control solenoid valve.
23) Install the ignition coil and ignitor assembly.
H2M2958
24) Connect the connector to ignition coil and ignitor assembly.
FU(w/oOBD)-29


Sensor
B: INSTALLATION
A: REMOVAL
Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
G6M0095
2) Remove the air intake duct and air cleaner assembly. <Ref. to IN-7, REMOVAL, Air Intake
Duct.> and <Ref. to IN-6, REMOVAL, Air Cleaner
Case.>
temperature sensor.
B2M4261
FU(w/oOBD)-30
B2M4275

B: INSTALLATION
A: REMOVAL
Tightening torque:
T: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
G6M0095
G2M0408
3) Remove the crankshaft position sensor, and

then disconnect the connector from it.
G2M0409
FU(w/oOBD)-31
B2M1252B


A: REMOVAL
5) Remove the camshaft position sensor and camshaft position sensor support as a unit.
6) Remove the camshaft position sensor itself.
B2M2322
G6M0095
B: INSTALLATION
Tightening torque:
Camshaft position sensor support;
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
Camshaft position sensor;
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
B2M4263

sensor to camshaft position sensor support.
B2M2375

sensor support to camshaft cap LH.
B2M2321
FU(w/oOBD)-32
KNOCK SENSOR
7. Knock Sensor
B: INSTALLATION
A: REMOVAL
Tightening torque:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
NOTE:
G6M0095

H2M3511C
(A) Front side
H2M2947
B2M4262
3) Install the air cleaner case.
B2M4262
H2M2947
S2M1673
FU(w/oOBD)-33
KNOCK SENSOR
G6M0095
FU(w/oOBD)-34

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

sensor.
H2M2979
B2M3493

H2M2979
FU(w/oOBD)-35

C: ADJUSTMENT
2) Loosen the throttle position sensor holding
screws.
4) When using the Subaru Select Monitor;

(2) Loosen the throttle position sensor holding
screws.
B2M3765
B2M3765
3) When using the voltage meter;

(1) Take out the ECM.
(2) Turn the ignition switch to ON.
(3) Adjust the throttle position sensor to proper
position to allow the voltage signal to ECM to be
in specification.
NOTE:
For detailed operation procedures, refer to the Subaru Select Monitor Operation Manual.
(3) Insert the cartridge to Subaru Select Monitor.
Connector & terminal/Specified voltage

(B136) No. 15 (B136) No. 17/0.45 0.55 V
[Fully closed.]
S2M0286A

link connector.
B2M4131A
(4) Tighten the throttle position sensor holding

screws.
Tightening torque:
1.6 Nm (0.16 kgf-m, 1.2 ft-lb)
B2M3148
B2M3765
5) Turn the ignition switch to ON, and Subaru Select Monitor switch to ON.
Menu.
Menu.
Menu.
FU(w/oOBD)-36

10) Adjust the throttle position sensor to the proper

position to match with the following specifications.
Condition: Throttle fully closed
Throttle opening angle 0.00 %
Throttle sensor voltage 0.50 V
11) Tighten the throttle position sensor holding
screws.
Tightening torque:
1.6 Nm (0.16 kgf-m, 1.2 ft-lb)
B2M3765
FU(w/oOBD)-37
INTAKE AIR TEMPERATURE AND PRESSURE SENSOR

9. Intake Air Temperature and

Pressure Sensor
B: INSTALLATION
A: REMOVAL
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
H2M2982
G6M0095
2) Disconnect the spark plug cord from ignition coil

and ignitor assembly.
NOTE:
B2M3373
H2M2981

sensor.
H2M2982
FU(w/oOBD)-38
H2M2999


Valve
A: REMOVAL
B: INSTALLATION
NOTE:
Tightening torque:
1.6 Nm (0.16 kgf-m, 1.2 ft-lb)
G6M0095

solenoid valve.
H2M2983

throttle body.
H2M2984
FU(w/oOBD)-39
H2M2984
FUEL INJECTOR
11.Fuel Injector
(3) Remove the bolts which install power steering pump to bracket.
A: REMOVAL
1. RH SIDE
<Ref. to FU(w/oOBD)-51, RELEASING OF FUEL
PRESSURE, OPERATION, Fuel.>
cap.
B2M3151
G6M0095

EN0360

B2M4127

brackets.
(1) Remove the front side V-belt. <Ref. to ME44, REMOVAL, V-belt.>
EN0361

the right side wheel apron.
EN0208
B2M4126
FU(w/oOBD)-40
FUEL INJECTOR

B2M4130
H2M2991

fuel injector pipe.
B2M4280
B2M4281
B2M4282
FU(w/oOBD)-41
H2M2992
FUEL INJECTOR
2. LH SIDE
OPERATION, Fuel.>
cap.
8) Move the washer tank, and secure it away from

working area.
B2M3140

G6M0095
4) Remove the two bolts which install washer tank

on body.
B2M4287
B2M3139
5) Disconnect the connector from front window

washer motor.
6) Disconnect the connector from rear gate glass
washer motor.
B2M4129
B6M0562

suitable cap.
FU(w/oOBD)-42
B2M3379
FUEL INJECTOR
12) Remove the bolt which installs injector pipe to

intake manifold.

fuel injector pipe.
B2M4133
H2M3241
B: INSTALLATION
1. RH SIDE
NOTE:
H2M2994
13) Remove the bolt which holds fuel pipe on the

left side intake manifold.
B2M3372A
(A) O-ring
(B) Fuel injector
H2M2995
Tightening torque:
5.0 Nm (0.51 kgf-m, 3.7 ft-lb)

B2M4293
H2M2997
FU(w/oOBD)-43
FUEL INJECTOR
2. LH SIDE
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)

NOTE:
B2M4132
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
B2M3372A
(A) O-ring
(B) Fuel injector
Tightening torque:
5.0 Nm (0.51 kgf-m, 3.7 ft-lb)
B2M4130
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
H2M2994
Tightening torque:
5.0 Nm (0.51 kgf-m, 3.7 ft-lb)
B6M1237
H2M2995
FU(w/oOBD)-44
FUEL INJECTOR
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
B2M4133
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
B2M4129
FU(w/oOBD)-45
OXYGEN SENSOR
12.Oxygen Sensor
B: INSTALLATION
A: REMOVAL
1) Before installing the oxygen sensor, apply antiseize compound only to the threaded portion of oxygen sensor to make the next removal easier.
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to the protector of oxygen sensor.
G6M0095
2) Disconnect the connector from oxygen sensor.
G2M0412
2) Install the oxygen sensor.

Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
B2M3108

threaded portion of oxygen sensor, and leave it for
1 minute or more.
5) Remove the oxygen sensor.
CAUTION:
G2M0411

4) Connect the connector of oxygen sensor.
G2M0411
FU(w/oOBD)-46
B2M3108
OXYGEN SENSOR
G6M0095
FU(w/oOBD)-47

B: INSTALLATION
A: REMOVAL
CAUTION:
G6M0095

EN0532

(A)
(A)
(B)
EN0533

the ECM.
FU(w/oOBD)-48
MAIN RELAY
14.Main Relay
B: INSTALLATION
A: REMOVAL
G6M0095

on body.
EN0534
FU(w/oOBD)-49
FUEL PUMP RELAY

15.Fuel Pump Relay
B: INSTALLATION
A: REMOVAL
G6M0095

bracket on body.
EN0535

bracket.
FU(w/oOBD)-50
FUEL
16.Fuel
A: OPERATION

WARNING:
EN0999
2500 cc MODEL
EN0344

2. DRAINING FUEL
WARNING:
EN0839

Tightening torque:
26 Nm (2.7 kgf-m, 19.2 ft-lb)
G6M0095
cap.
EN0999
2500 cc MODEL
EN0839
FU(w/oOBD)-51
FUEL TANK
17.Fuel Tank

A: REMOVAL
WARNING:
OPERATION, Fuel.>
3) Drain fuel from the fuel tank. <Ref. to FU(w/
oOBD)-51, DRAINING FUEL, OPERATION, Fuel.>
rear harness.
EN0539
10) Move the clips, and then disconnect quick connector. <Ref. to FU(w/oOBD)-68, REMOVAL, Fuel
Delivery, Return and Evaporation Lines.>
(B)
(A)

from canister.
(A)
EN0540
EN0537

WARNING:
(B)
EN0840
FU(w/oOBD)-52
EN0541
FUEL TANK
B: INSTALLATION
grommet.
5) Connect the fuel hoses, and then secure them

with clips and quick connector. <Ref. to FU(w/
oOBD)-69, INSTALLATION, Fuel Delivery, Return
WARNING:
EN0540

Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
EN0541

(A)
(B)
EN0541
EN0840

8) Connect the connectors (A) to fuel tank cord and
plug the service hole with grommet (B).
(B)
(A)
EN0539
FU(w/oOBD)-53
EN0537
FUEL TANK
EN0344
C: INSPECTION
FU(w/oOBD)-54
FUEL FILLER PIPE

18.Fuel Filler Pipe

A: REMOVAL
WARNING:
OPERATION, Fuel.>
cap.
tank.
EN0999
2500 cc MODEL
G6M0095

EN0839
Tightening torque:
26 Nm (2.7 kgf-m, 19.2 ft-lb)
EN0542
6) Remove the rear right side wheel nuts.

EN0999
2500 cc MODEL
B2M1748
EN0839
FU(w/oOBD)-55
FUEL FILLER PIPE

(A)
(B)
EN0548
EN0544

fuel filler pipe.

vehicle.
from body.
EN0545

pipe.
EN0546
14) Remove the bolt which holds fuel filler pipe

bracket on body.
EN0547

FU(w/oOBD)-56
EN0549
FUEL FILLER PIPE

B: INSTALLATION
side of apron.
NOTE:

CAUTION:
(A)
(B)
EN0548

and hold clip.
B2M1196A
L = 27.52.5 mm (1.0830.098 in)
B2M1195A
EN0549
(1) Hose
(2) Clip
(3) Pipe
Tightening torque:
7.5 Nm (0.75 kgf-m, 5.4 ft-lb)
EN0546
EN0547
FU(w/oOBD)-57
FUEL FILLER PIPE


G6M0095
EN0545
EN0544
B2M1748

EN0344
FU(w/oOBD)-58
FUEL PUMP
19.Fuel Pump
A: REMOVAL
Tightening torque:
26 Nm (2.7 kgf-m, 19.2 ft-lb)
WARNING:
NOTE:
level sensor.
OPERATION, Fuel.>
cap.
EN0999

EN0553
G6M0095

tank.
EN0554
EN0999
10) Disconnect the quick connector and then disconnect fuel delivery hose (A). <Ref. to FU(w/
oOBD)-68, REMOVAL, Fuel Delivery, Return and
Evaporation Lines.>
FU(w/oOBD)-59
FUEL PUMP
11) Move the clip and then disconnect the fuel return hose (B).
tank.
(A)
(B)
EN0555
EN0839

Tightening torque:
26 Nm (2.7 kgf-m, 19.2 ft-lb)
EN0556
2500 cc MODEL
OPERATION, Fuel.>
cap.
EN0839

EN0553

G6M0095
S2M0172
FU(w/oOBD)-60
FUEL PUMP
10) Disconnect the quick connector, and then disconnect fuel delivery hose (A). <Ref. to FU(w/
oOBD)-68, REMOVAL, Fuel Delivery, Return and
Evaporation Lines.>
2500 cc MODEL
S2M0063A
C: INSPECTION
S2M0060A

WARNING:
as possible.
S2M0061
3 2 1
6 5 4
B: INSTALLATION
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
(A)
(C)
(E)
(H)
(G)
(F)
(B)
(D)
EN0557
FU(w/oOBD)-61
EN1502
FUEL LEVEL SENSOR

2500 cc MODEL
A: REMOVAL
WARNING:
NOTE:
Fuel level sensor is built in the fuel pump assembly.
1) Remove the fuel pump assembly. <Ref. to FU(w/
oOBD)-59, REMOVAL, Fuel Pump.>
EN0846
B: INSTALLATION
EN0559
2500 cc MODEL
S2M0145

;;;;;
;
EN0560
FU(w/oOBD)-62

A: REMOVAL
NOTE:
Fuel sub level sensor is equipped to only 2500 cc
model.
WARNING:
G2M0863

G6M0095

tank.
S2M0151
9) Remove the bolts which install the fuel sub

meter unit on fuel tank.
EN0839
S2M0152
Tightening torque:
26 Nm (2.7 kgf-m, 19.2 ft-lb)
S2M0153
EN0839
FU(w/oOBD)-63

B: INSTALLATION
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
B2M3178
FU(w/oOBD)-64
FUEL FILTER
22.Fuel Filter
C: INSPECTION
A: REMOVAL

sediment.
from inlet port.
WARNING:
OPERATION, Fuel.>
S2M0195
B: INSTALLATION
CAUTION:
new ones.
Tightening torque:
1.25 Nm (0.13 kgf-m, 0.94 ft-lb)
S2M0195
FU(w/oOBD)-65
FUEL CUT VALVE

23.Fuel Cut Valve
B: INSTALLATION
A: REMOVAL
WARNING:
1) Remove the fuel tank. <Ref. to FU(w/oOBD)-52,
REMOVAL, Fuel Tank.>
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
S2M0177
S2M0176
FU(w/oOBD)-66
FUEL DAMPER VALVE

B: INSTALLATION
A: REMOVAL

OPERATION, Fuel.>
line.
EN0852
FU(w/oOBD)-67


Evaporation Lines
A: REMOVAL
OPERATION, Fuel.>
cap.
EN0564

from canister.
(A)
(B)
S2M0500F
EN0840

(B) Return hose
FU(w/oOBD)-68


and return line.
covered with dust.
down.

NOTE:
NOTE:
S2M0230A
(A) Connector
(B) Retainer
(C) Pipe
S2M0228A
(A) Connector
(B) Retainer
(C) Pipe
B: INSTALLATION
1) Connect the quick connector on fuel delivery
line.
CAUTION:
securely.
NOTE:
S2M0231A
(A) Connector
(B) Retainer
(C) Pipe
S2M0229A
FU(w/oOBD)-69


2: 2.51.5 mm (0.0980.059 in)
C: INSPECTION
L: 22.52.5 mm (0.8860.098 in)
B2M1194B
(1) Fitting
(2) Clamp
(3) Hose

L = 17.52.5 mm (0.6890.098 in)
CAUTION:
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
FU(w/oOBD)-70


A: INSPECTION
1)
Corrective action

2)
3)
4)
5)
6)
7)
1)
2)
3)
4)
5)

1)
filler pipe.
2)
3)
4)
1)
Defective operation of fuel meter unit.
2)
5. Noise
1)
NOTE:
fuel tank.
(2) Drain water condensation from the fuel filter.
the tank.
water condensation.
(3) Cold areas

securely.
Replace.
Retightening.
Replace.
Replace.
Replace.
tube.
Retightening.
Replace.
Replace.
Replace.
Replace.
season, drain water which may have accumulated in the fuel filter and fuel tank in the manner
same as that described under Affected areas
below.
(4) Affected areas
When water condensation is notched in the fuel
filter, drain water from both the fuel filter and fuel
tank or use a water removing agent (or antifreeze solution) in the fuel tank.
FU(w/oOBD)-71

FU(w/oOBD)-72
EMISSION CONTROL
EC(w/oOBD)
1.
2.
3.
4.
5.
6.
Page
Canister.......................................................................................................7
Two-way Valve............................................................................................9
GENERAL DESCRIPTION
A: CAUTION
points.
cable from battery.
EC(w/oOBD)-2


A: REMOVAL


B2M3200
G6M0095
3) Disconnect the front oxygen sensor connector.
8) Remove the front and center exhaust pipe from

hanger bracket.
CAUTION:
Be careful not to pull down the front exhaust
pipe and center exhaust pipe.
B2M3108

B2M3111
9) Separate the front catalytic converter from front

exhaust pipe.
CAUTION:
S2M0923
B2M3109
EC(w/oOBD)-3

B: INSTALLATION
NOTE:
Replace gaskets with new ones.
1) Install the front catalytic converter to front exhaust pipe.

Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
Tightening torque:
30 Nm (3.1 kgf-m, 22.4 ft-lb)
B2M3109
S2M0923
2) Install the front and center exhaust pipe assembly to the vehicle. And temporarily tighten the bolt
which installs center exhaust pipe to hanger bracket.
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
B2M3111
B2M3111

8) Connect the front oxygen sensor connector.

Tightening torque:
30 Nm (3.1 kgf-m, 22.4 ft-lb)
B2M3108
B2M3200
EC(w/oOBD)-4

G6M0095
C: INSPECTION
EC(w/oOBD)-5


A: REMOVAL
the same as the those for the front catalytic converter. <Ref. to EC(w/oOBD)-3, REMOVAL, Front
Catalytic Converter.>
B2M3112A

B: INSTALLATION
the same as the ones described under front catalytic converter. <Ref. to EC(w/oOBD)-4, INSTALLATION, Front Catalytic Converter.>
B2M3112A

C: INSPECTION
EC(w/oOBD)-6
CANISTER
4. Canister
A: REMOVAL
from canister.
EN0898
B2M4166
B: INSTALLATION
Tightening torque:
23 Nm (2.3 kgf-m, 17 ft-lb)
B2M4166
C: INSPECTION
cracked or loose.
EC(w/oOBD)-7

B: INSTALLATION
A: REMOVAL
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
G6M0095
2) Remove the bolt which installs purge control solenoid valve onto intake manifold.
H2M2985
CAUTION:
H2M2985
B2M1893E
3) Take out the purge control solenoid valve

through the bottom of intake manifold.
A: To fuel pipe
B: To throttle body
C: INSPECTION
Make sure hoses are not cracked or loose.
H2M2986
EC(w/oOBD)-8
TWO-WAY VALVE
6. Two-way Valve
A: REMOVAL
2) Remove the canister from body. <Ref. to EC(w/
oOBD)-7, REMOVAL, Canister.>
EN0901
B: INSTALLATION
C: INSPECTION
Make sure that the hoses are not cracked or loose.
EC(w/oOBD)-9
TWO-WAY VALVE
EC(w/oOBD)-10
EXHAUST
EX(w/oOBD)
1.
2.
3.
4.
5.
Page
Center Exhaust Pipe .................................................................................12
Muffler .......................................................................................................14
GENERAL DESCRIPTION
EXHAUST
A: COMPONENT
1. WITH CATALYTIC CONVERTER (1600 CC MODEL)
(16)
(15)
(13)
(14)
T7
(16)
(11)
(10)
(12)
(9)
(16)
T1
T6
T2
(26)
T2
(17)
(22)
(27)
(18)
T4
T2
(23)
(25)
(24)
T2
(8)
(3)
(30)
T3
(1)
(29)
(2)
(3)
T6
(19)
T1
(7)
T5
(28)
(21)
(4)
T2
(20)
T5
(30)
(6)
(5)
T5
EN1374
EX(w/oOBD)-2
GENERAL DESCRIPTION
EXHAUST
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)

CTR
(14)
(15)
(16)
CTR
(17)
Clamp
(18)
Upper front exhaust pipe cover LH (19)
Lower front exhaust pipe cover LH (20)
Front exhaust pipe
(21)
Lower front exhaust pipe cover RH (22)
Upper front exhaust pipe cover RH (23)
Gasket
(24)
Spring
(25)
Chamber
Rear exhaust pipe
(26)
Gasket
Self-locking nut
Muffler
Cushion rubber
Lower clamp
Protector
Gasket
Oxygen sensor
Center exhaust pipe
cover
cover
EX(w/oOBD)-3
(27)

cover
(28)

cover
(29)
(30)

Gasket

T1: 8 (0.8, 5.8)
T2: 13 (1.3, 9.4)
T3: 18 (1.8, 13.0)
T4: 21 (2.1, 15.2)
T5: 30 (3.1, 22.4)
T6: 35 (3.6, 26.0)
T7: 48 (4.9, 35.4)
GENERAL DESCRIPTION
EXHAUST
2. WITH CATALYTIC CONVERTER (2000 CC AND 2500 CC MODEL)
(16)
(15)
(13)
(14)
T2
T7
(16)
(11)
(10)
(17)
(9)
(16)
(12)
T1
T6
T2
(27)
T2
(18)
(23)
(28)
(19)
T4
T2
(24)
(26)
(25)
T2
(8)
(3)
(31)
T3
(1)
(30)
(2)
(3)
T6
(20)
T1
(7)
T5
(29)
(22)
(4)
T2
(21)
T5
(31)
(6)
(5)
T5
EN1375
EX(w/oOBD)-4
GENERAL DESCRIPTION
EXHAUST
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)

CTR
(15)
(16)
(17)
CTR
(18)
Clamp
(19)
Front exhaust pipe
(22)
Gasket
(25)
Spring
(26)
Chamber
(27)
Gasket
Self-locking nut
Muffler
Cushion rubber
Rear exhaust pipe
Lower clamp
Protector
Gasket
Oxygen sensor
Center exhaust pipe
cover
cover
EX(w/oOBD)-5
(28)

cover
(29)

cover
(30)
(31)

Gasket

T1: 8 (0.8, 5.8)
T2: 13 (1.3, 9.4)
T3: 18 (1.8, 13.0)
T4: 21 (2.1, 15.2)
T5: 30 (3.1, 22.4)
T6: 35 (3.6, 26.0)
T7: 48 (4.9, 35.4)
GENERAL DESCRIPTION
EXHAUST
3. WITHOUT CATALYTIC CONVERTER

(16)
(15)
(13)
(14)
T1
T5
(16)
(11)
(10)
(24)
(9)
(16)
(12)
T4
(23)
(17)
(18)
(22)
T1
(21)
T1
(8)
(3)
(25)
(1)
T4
T2
(2)
(3)
T1
(20)
(4)
(7)
(19)
T3
(25)
T3
(6)
(5)
T3
T1
Muffler cutter (Except 1600cc Model)

EN1376
EX(w/oOBD)-6
GENERAL DESCRIPTION
EXHAUST
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)

CTR
(11)
(12)
(13)
CTR
(14)
Clamp
(15)
Front exhaust pipe
(18)
Gasket
(21)
Spring
(22)
Chamber
Gasket
Self-locking nut
Muffler
Cushion rubber
Upper clamp
Lower clamp
Protector
Gasket
Center exhaust pipe
EX(w/oOBD)-7
(23)
(24)
(25)

Rear exhaust pipe
Gasket

T1: 13 (1.3, 9.4)
T2: 18 (1.8, 13.0)
T3: 30 (3.1, 22.4)
T4: 35 (3.6, 26.0)
T5: 48 (4.9, 35.4)
GENERAL DESCRIPTION
EXHAUST
B: CAUTION
points.
cable from battery.
EX(w/oOBD)-8
FRONT EXHAUST PIPE

EXHAUST

A: REMOVAL
CAUTION:
Be careful not to pull down the front and center
exhaust pipe assembly.
G6M0095
2) Disconnect the oxygen sensor connector. (With

B2M3200
7) Remove the bolt which installs front and center

exhaust pipe assembly to hanger bracket.
B2M3108

4) Separate the front and center exhaust pipe assembly from rear exhaust pipe.
WARNING:
B2M3111
8) Remove the front and center exhaust pipe assembly from 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.
9) Separate the front exhaust pipe from center exhaust pipe.
B2M3109
S2M0923
10) Remove the oxygen sensor. (With catalytic

converter) <Ref. to FU(w/oOBD)-46, REMOVAL,
Oxygen Sensor.>
EX(w/oOBD)-9
FRONT EXHAUST PIPE

EXHAUST
B: INSTALLATION
1) Install the oxygen sensor. (With catalytic converter) <Ref. to FU(w/oOBD)-46, INSTALLATION,
Oxygen Sensor.>
2) Install the front exhaust pipe to center exhaust
pipe.

Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
NOTE:
Tightening torque:
30 Nm (3.1 kgf-m, 22.4 ft-lb)
B2M3109
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
S2M0923
3) Install the front and center exhaust pipe assembly to vehicle.

4) Temporarily tighten the bolt which installs front
and center exhaust pipe assembly to hanger bracket.
B2M3111

10) Connect the oxygen sensor connector. (With
B2M3111

Tightening torque:
30 Nm (3.1 kgf-m, 22.4 ft-lb)
B2M3108
B2M3200
EX(w/oOBD)-10
FRONT EXHAUST PIPE

EXHAUST
G6M0095
C: INSPECTION
EX(w/oOBD)-11
CENTER EXHAUST PIPE

EXHAUST

A: REMOVAL
After removing the center and front exhaust pipes
as one unit, separate them. Refer to the procedure
for removing the front exhaust pipe. <Ref. to EX(w/
oOBD)-9, REMOVAL, Front Exhaust Pipe.>
B: INSTALLATION
Install the center exhaust pipe and front exhaust
pipe as one unit. Refer to the procedure for installing the front exhaust pipe. <Ref. to EX(w/oOBD)10, INSTALLATION, Front Exhaust Pipe.>
C: INSPECTION
EX(w/oOBD)-12
REAR EXHAUST PIPE

EXHAUST
2) Install the rear exhaust pipe bracket to cushion

rubber.
A: REMOVAL
CAUTION:
S2M0560
NOTE:
B2M3109
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
CAUTION:
pipe.
G2M0382

pipe.
G2M0382

Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)

4) Remove the rear exhaust pipe bracket from the
cushion rubber.
B2M3109
C: INSPECTION
S2M0560
B: INSTALLATION
cracked.

EX(w/oOBD)-13
MUFFLER
EXHAUST
5. Muffler
B: INSTALLATION
A: REMOVAL

CAUTION:
NOTE:
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
G2M0382

G2M0382
C: INSPECTION
cracked.
G2N0385
3) Remove the front, right and left cushion rubber,

and detach the muffler assembly.
EX(w/oOBD)-14
IGNITION
IG(w/oOBD)
1.
2.
3.
4.
Page
Spark Plug...................................................................................................5
Spark Plug Cord........................................................................................10
GENERAL DESCRIPTION
IGNITION
A: SPECIFICATIONS
Item
Ignition coil and ignitor

assembly
1600 cc
2000 cc
Model
and
2500 cc
1600 cc
2000 cc
Manufacturer
and
2500 cc
1600 cc
2000 cc
Primary coil resistance
and
2500 cc
1600 cc
2000 cc
Secondary coil resistance
and
2500 cc
Insulation resistance between primary terminal
and case
Spark plug
Thread size
Spark gap
FH0137
HITACHI
DIAMOND
0.7 10%
0.73 10%
13.0 k20%
12.8 k15%
More than 100 M
NGK: BKR6E*
CHAMPION: RC8YC4**
NGK: BKR6E-11** (Alternate)
2000 cc
NGK: BKR6E*
and
CHAMPION: RC10YC4**
2500 cc
mm
14, P = 1.25
0.7 0.8 (0.028 0.031)*
mm (in)
1.0 1.1 (0.039 0.043)**
1600 cc
Designation
CM12100C
*: Without catalytic converter

**: With catalytic converter
IG(w/oOBD)-2
GENERAL DESCRIPTION
IGNITION
B: COMPONENT
1. 1600 CC MODEL
T1
(3)
(2)
(2)
(1)
T2
(4)
(4)
T2
EN1039
(1)
(2)
(3)
Spark plug
(4)
IG(w/oOBD)-3

T1: 6.4 (0.65, 4.7)
T2: 21 (2.1, 15.2)
GENERAL DESCRIPTION
IGNITION
2. 2000 CC AND 2500 CC MODEL
S6M0329B
(1)
(2)
(3)
Spark plug
(4)
C: CAUTION

T1: 21 (2.1, 15.2)
T2: 6.4 (0.65, 4.7)

points.
cable from battery.
IG(w/oOBD)-4
SPARK PLUG
IGNITION
2. Spark Plug
4) Remove the spark plugs with the spark plug

sockets.
A: REMOVAL
CAUTION:
1600 cc
2000 cc
and
2500 cc
Spark plug
NGK: BKR6E*
CHAMPION: RC8YC4**
NGK: BKR6E*
CHAMPION: RC10YC4**
B2M4286
2. LH SIDE
*: Without catalytic converter

**: With catalytic converter
1. RH SIDE
G6M0095

G6M0095

the cord itself.
B6M0562

from washer motor, then plug the connection with a
suitable cap.
then take the tank away from working area.
B2M4127
B2M2023
IG(w/oOBD)-5
SPARK PLUG
IGNITION

the cord itself.
2. LH SIDE
21 Nm (2.1 kgf-m, 15.2 ft-lb)
CAUTION:
B2M4287
C: INSPECTION
B2M4288
S6M0420A
B: INSTALLATION
(A)
(B)
(C)
(D)
(E)
1. RH SIDE
21 Nm (2.1 kgf-m, 15.2 ft-lb)
CAUTION:
Electrode gap
Cracks
Damage
Damaged gasket
1) Normal:
G6M0087
IG(w/oOBD)-6
SPARK PLUG
IGNITION
2) Carbon fouled:
cleaner, etc.
heat range.
D: CLEANING
porcelain.
If deposits are too stubborn, replace the plugs.
E: ADJUSTMENT
Correct it if the spark plug gap is measured with a
gap gauge, and it is necessary.
Spark plug gap: L
With catalyst:
1.0 1.1 mm (0.039 0.043 in)
Without catalyst:
0.7 0.8 mm (0.028 0.031 in)
G6M0088
3) Oil fouled:
S6M0412B
NOTE:
worn to ball shape.
G6M0089
4) Overheating:
colder heat range.
G6M0090
IG(w/oOBD)-7

IGNITION

1600 cc MODEL
A: REMOVAL
EN1044

G6M0095
2) Disconnect the spark plug cords from ignition

coil and ignitor assembly.
1600 cc MODEL
B6M0930
B: INSTALLATION
EN1040
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
CAUTION:
Be sure to connect the wires to their proper positions. Failure to do so will damage the unit.
1600 cc MODEL
S6M0373

ignitor assembly.
IG(w/oOBD)-8
EN1044

IGNITION
Specified resistance:(2000 cc and 2500 cc)

[Primary side]
0.73 10%
0.73 10%
B6M0930
C: INSPECTION
Using the accurate tester, inspect the following

items, and replace if defective.
1) Primary resistance
2) Secondary coil resistance
CAUTION:
If the resistance is extremely low, this indicates
the presence of a short-circuit.
Specified resistance:(1600 cc)
[Primary side]
0.7 10%
0.7 10%
EN1041
[Secondary side]
Between (A) and (B)
12.8 k15%
Between (C) and (D)
12.8 k15%
(C)
(A)
(D)
(B)
EN1043
3) Insulation between primary terminal and case:

100 M or more.
EN1041
[Secondary side]
Between (A) and (B)
13.0 k20%
Between (C) and (D)
13.0 k20%
(C)
(D)
(A)
(B)
EN1042
IG(w/oOBD)-9
SPARK PLUG CORD

IGNITION
4. Spark Plug Cord

A: INSPECTION
Check for:
1) Damage to cords, deformation, burning or rust
formation of terminals
2) Resistance values of cords
Resistance value:
#1 cord: 5.6 10.6
#2 cord: 7.3 13.7
#3 cord: 5.9 11.1
#4 cord: 7.3 13.7
S6M0337
IG(w/oOBD)-10
EN(w/oOBD)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Page
Inspection Mode........................................................................................28


A: PROCEDURE
1. WITH SUBARU SELECT MONITOR
Step
1)Ask the customer when and how trouble
to EN(w/oOBD)-4, CHECK, Check List for
Interview.>
2)Start the engine.
Check
No
Inspection using
Diagnostics for
Engine Starting
Failure. <Ref. to
EN(w/oOBD)-42,
Diagnostics for
Engine Starting
Failure.>
Go to step 3.
Inspection using
CHECK ILLUMINATION OF CHECK ENGINE Does the MIL illuminate?
General DiagnosMALFUNCTION INDICATOR LAMP (MIL).
tic Table. <Ref. to
<Ref. to EN(w/oOBD)-32, ACTIVATION OF
CHECK ENGINE MALFUNCTION INDICAEN(w/oOBD)-110,
TOR LAMP (MIL), Engine Malfunction IndicaINSPECTION,
tor Lamp (MIL).>
Does the Subaru Select Moni- Record the DTC. Repair the related
TROUBLE CODE (DTC) ON DISPLAY.
tor indicate DTC? <Ref. to
Repair the trouble parts.
EN(w/oOBD)-63, LIST, List of cause. <Ref. to
NOTE:
2)Connect the Subaru Select Monitor to data Diagnostic Trouble Code
EN(w/oOBD)-66, If a DTC is not
link connector.
(DTC).>
Diagnostic Proce- shown on display
3)Turn the ignition switch to ON and the Subdure with Diagnos- although MIL illuaru Select Monitor switch to ON.
tic Trouble Code minates, perform
4)Read any DTC on Subaru Select Monitor.
(DTC).> Go to
diagnostics of MIL
<Ref. to EN(w/oOBD)-26, WITH SUBARU
step 4.
(CHECK ENGINE
SELECT MONITOR, OPERATION, Read
malfunction indicaDiagnostic Trouble Code (DTC).>
tor lamp) circuit or
combination
meter. <Ref. to
EN(w/oOBD)-32,
Engine Malfunction Indicator Lamp
(MIL).>
Does the Subaru Select Moni- Record the DTC. Complete the
tor indicate DTC? <Ref. to
Repair the trouble diagnosis.
EN(w/oOBD)-30, OPERATION, Clear Memory EN(w/oOBD)-63, LIST, List of cause. <Ref. to
Mode.>
Diagnostic Trouble Code
EN(w/oOBD)-66,
2)Perform the inspection mode. <Ref. to EN(w/ (DTC).>
Diagnostic ProceoOBD)-28, OPERATION, Inspection Mode.>
dure with Diagnostic Trouble Code
(DTC).> Go to
step 4.
EN(w/oOBD)-2
Yes
Go to step 2.

2. WITHOUT SUBARU SELECT MONITOR

CAUTION:
Check the connector while it is connected unless specified otherwise.
Be sure to check again from the beginning in order to prevent secondary trouble caused by repair
work.
Step
occurred using interview check list. <Ref. to
EN(w/oOBD)-4, CHECK, Check List for Interview.>
2)Start the engine.
Check
CHECK ILLUMINATION OF CHECK ENGINE Does the MIL illuminate?

MALFUNCTION INDICATOR LAMP (MIL).
<Ref. to EN(w/oOBD)-32, ACTIVATION OF
CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).>

TROUBLE CODE (DTC) ON MIL.
1)Perform the read DTC (read memory
mode).<Ref. to EN(w/oOBD)-26, WITHOUT
SUBARU SELECT MONITOR, OPERATION,
2)Read any DTC on MIL.
Does the MIL indicate DTC?

<Ref. to EN(w/oOBD)-63,
LIST, List of Diagnostic Trouble Code (DTC).>

EN(w/oOBD)-30, OPERATION, Clear Memory
Mode.>
2)Perform the inspection mode. <Ref. to EN(w/
oOBD)-28, OPERATION, Inspection Mode.>

EN(w/oOBD)-3
Yes
Go to step 2.
No
Inspection using
Diagnostics for
Engine Starting
Failure. <Ref. to
EN(w/oOBD)-42,
Diagnostics for
Engine Starting
Failure.>
Go to step 3.
Inspection using
EN(w/oOBD)-110,
INSPECTION,
Repair the trouble Repair the related
cause. Go to step parts.
4.
NOTE:
If the DTC is not
shown on MIL although MIL illuminates,
perform
diagnostics of MIL
(CHECK ENGINE
malfunction indicator lamp) circuit or
combination
meter.<Ref.
to
EN(w/oOBD)-32,
(MIL).>
Repair the trouble Complete the
cause. Go to step diagnosis.
4.


A: CHECK
1. CHECK LIST NO. 1
NOTE:
Customer's name
Date of sale
Date of repair
Vin No.
Weather
Engine No.
Fuel brand
Odometer reading
Fine
Cloudy
Rainy
Snowy
Various/Others:
F (C)
Outdoor temperature
Place
Engine temperature
Engine speed
Vehicle speed
Driving conditions
Headlight
Blower
A/C compressor
Cooling fan
Front wiper
Rear wiper
km
miles
Hot
Warm
Cool
Cold
Highway
Suburbs
Inner city
Uphill
Downhill
Rough road
Others:
Cold
Warming-up
After warming-up
Any temperature
Others:
rpm
MPH
Not affected
At starting
While idling
At racing
While accelerating
While cruising
While decelerating
ON/ OFF
ON/ OFF
ON/ OFF
ON/ OFF
ON/ OFF
ON/ OFF
Rear defogger
Radio
CD/Cassette
Car phone
CB
EN(w/oOBD)-4
ON/ OFF
ON/ OFF
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
No shift
EN(w/oOBD)-5
GENERAL DESCRIPTION

A: CAUTION
1) Airbag system wiring harness is routed near engine control module (ECM), main relay and fuel
pump relay.
CAUTION:
engine is running.
switch to OFF.
CAUTION:
EN1393
(A) Stud bolt

compartment.
B2M2779

EN1394
(A) Stud bolt

not drop them.
EN(w/oOBD)-6
GENERAL DESCRIPTION

CAUTION:
matching.
complicated, difficult operations. The most important thing in diagnostics is to understand customer's complaint, and distinguish between the three
causes.
16) In AT vehicles, do not continue the stall for
more than 5 seconds at a time (from closed throttle,
fully open throttle to stall engine speed).
B: INSPECTION
1. BATTERY
of electrolyte.

proper grounding.
2. ENGINE GROUNDING
Make sure the engine grounding cable is properly
connected to the engine.
B2M2779
C: NOTE
EN(w/oOBD)-7
GENERAL DESCRIPTION
D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
24082AA190
(Newly adopted tool)
DESCRIPTION
CARTRIDGE
REMARKS
systems.
22771AA030
SELECT MONITOR KIT

systems.
German: 22771AA070
(Without printer)
French: 22771AA080
(Without printer)
Spanish: 22771AA090
(Without printer)
B2M3876
B2M3877
EN(w/oOBD)-8
GENERAL DESCRIPTION
EN(w/oOBD)-9


A: LOCATION
1. MODULE
LHD model
(1)
(3) (4) (2)
(5)
EN0713
RHD model
(3) (4) (2)
(5)
(1)
EN0714
(1)
(2)

(3)
(4)
(5)
Read memory connector

Test mode connector
Data link connector
EN(w/oOBD)-10

(2)
EN0718
S2M0256A
EN1034
EN(w/oOBD)-11
(5)
EN0717

2. SENSOR
(1)
(7) (3)
(2)
(4)
(6)
(5)
EN0928
(1)
(2)
(3)
(4)
(5)
(6)

Knock sensor
EN(w/oOBD)-12
(7)
Vehicle speed sensor

S2M1248A
H2M3255A
H2M3256A
S2M1406B
B2M0213M
B2M0212F
S2M0907C
EN(w/oOBD)-13

(8)
EN0929
(8)
Oxygen sensor (With catalyst

model)
S2M0264B
EN(w/oOBD)-14

EN(w/oOBD)-15

3. SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM

PARTS
(4)
(1)
(3)
(2)
EN0930
(1)
(2)

(3)
EN(w/oOBD)-16
(4)
CO resistor (Without catalyst

model)

H2M3258A
H2M3259A
H2M3261A
S2M1764B
EN(w/oOBD)-17

LHD model
(2)
(3)
(1)
EN1031
RHD model
(1)
(2)
(3)
EN1032
(1)
Fuel pump
(2)
Main relay
EN(w/oOBD)-18
(3)
Fuel pump relay

LHD model
(2)
EN1501
RHD model
(2)
(3)
EN0748
EN(w/oOBD)-19
(3)
EN0744
EN0744


H2M3262A
Content
Crankshaft
position
sensor
Camshaft
position
sensor
Intake air
temperature sensor
Throttle
position
sensor
Connector No.
Terminal
No.
*2
Signal (V)
Ignition SW
Engine ON
(Idling)
ON (Engine OFF)
0
6
0
0
0
0
0
6
0
0
0
0
Note
Signal (+)
Signal ()
Shield
Signal (+)
Signal ()
Shield
B135
B135
B135
B135
B135
B135
Signal
B136
13
Signal
B136
17
Fully closed: 0.50.3

Fully opened: 4.30.3
8
10
*1
2
8
10
2.3 2.5
1.4 1.6
Ambient temperature: 25C (77F)
Power
supply
GND
B136
15
B136
16
Signal
B136
Shield
Engine cool- Signal
ant temperature sensor GND
B136
B136
23
14
0
0.6 1.0
0
0.6 1.0
After warm-up
B136
16
B135
24
0 or 5
0 or 5
Starter switch
B135
28
A/C switch
B135
27
Ignition switch
Neutral position switch
(MT)
Park/Neutral position
switch (AT)
B135
0
ON: 10 13
OFF: 0
10 13
0
ON: 13 14
OFF: 0
13 14
Oxygen
sensor
B135
26
B135
26
Rich mixture: 0.7

Lean mixture: 0
ON: 5
OFF: 0
ON: 0
OFF: 5
EN(w/oOBD)-20
5 and 0 are repeatedly displayed

when vehicle is driven.
Cranking: 10 to 14
Switch is ON when gear is in neutral

position.
Switch is ON when shift lever is in
P or N position.

Content
Connector No.
Terminal
No.
Test mode connector

B135
B135
B136
B136
14
15
9
1
2
25
26
4
13
14
15
Ignition control
Fuel injector
# 1, # 2
# 3, # 4
#1
#2
#3
#4
B134
B134
B134
B134
B134
B134
Signal (V)
Ignition SW
Engine ON
(Idling)
ON (Engine OFF)
5
5
5
5
10 13
13 14
Note
When connected: 0
When connected: 0
10 13
13 14
0
0
10 13
10 13
10 13
10 13
3.4, max.
3.4, max.
13 14
13 14
13 14
13 14
Waveform
Waveform
Waveform
Waveform
*: With immobilizer
EN(w/oOBD)-21

Signal (V)
Ignition SW
Engine ON (Idling)
ON (Engine OFF)
1 13
1 13
1 13
1 13
5
5
5
5
ON: 0
0
OFF: 10 13
ON: 0
ON: 0
OFF: 10 13
OFF: 13 14
ON: 0
ON: 0
OFF: 10 13
OFF: 13 14
ON: 0
ON: 0
OFF: 10 13
OFF: 13 14
10 13
13 14
Connector No.
Terminal
No.
Signal 1
Signal 2
Signal 3
Signal 4
B134
B134
B134
B134
B135
B135
5
6
19
20
16
17
Fuel pump relay control
B134
A/C relay control
B134
17
B134
B134
12
B135
19
B134
11
B134
B136
B136
30
4
25
5
2.8
0
3.4 3.6
0 13, min.
2.8
0
1.2 1.8
Light ON: 1, max.

Light OFF: 10 14
Waveform
B136
15
16
0
ON: 0
OFF: 10 13
0
0
0
0
0
0
ON: 0
OFF: 10 13
8
0 0.3
MT: 0
AT: 5
0
ON: 0
OFF: 13 14
0
0
0
0
0
0
ON: 0
OFF: 10 13
8
0.8 1.2
MT: 0
AT: 5
Content
Radiator fan relay 1 control

Radiator fan relay 2 control
Self-shutoff control
lamp
Engine speed output
Knock sen- Signal
sor
Shield
Signal
Power
Pressure
supply
sensor
GND
valve
GND (sensors)
GND (injectors)
GND (power supply)
29*
16
B134
B136
B134
B134
B134
B136
B136
16
7
27
8
21
22
11
12
Select monitor signal
B135
Power steering switch
B135
13

AT load signal
B134
B136
31
11
MT/AT identification
B135
25
*: With immobilizer
EN(w/oOBD)-22
Note
Waveform
Waveform
Waveform
Waveform

6. Subaru Select Monitor

A: OPERATION
1) Prepare the Subaru Select Monitor kit.
S2M0288E
(A) Power switch
S2M0285

Monitor.
6) Using the Subaru Select Monitor, call up any

DTCs and various data, then record them.

(DTC) FOR ENGINE.
Refer to Read Diagnostic Trouble Code for information about how to indicate the DTC. <Ref. to
EN(w/oOBD)-26, Read Diagnostic Trouble Code
(DTC).>
S2M0286A

connector.
(1) The data link connector is located in lower
portion of instrument panel (on driver's side).
EN0768

connector.
CAUTION:
Do not connect the scan tools except for Subaru Select Monitor.
EN(w/oOBD)-23

3. READ CURRENT DATA SHOWN ON DISPLAY.

1) On the Main Menu display screen, select the {2. Each System Check} and press [YES] key.
key.
3) Press the [YES] key after displayed information of engine type.
4) On the Engine Diagnosis display screen, select the {1. Current Data Display & Save} and press [YES]
key.
5) On the Data Display Menu display screen, select the {1. 12 Data Display} and press [YES] key.
Contents
Battery voltage
Engine speed signal
Pressure sensor signal
ISC valve step
Oxygen sensor output signal*1
Knock correction
CO resistor*2
A/F correction #1
A/F learning #1
Automatic transmission vehicle identification signal
Air conditioning compressor signal
Radiator fan relay signal #1
Knocking signal
Torque control signal #1
Torque permission signal
TCS AET signal
Canister purge control solenoid valve
Oxygen sensor rich signal
Read memory connector signal
P/S switch
Starter switch
Blower fan switch
Light switch
Idle switch signal
Unit of measure
V
km/h or MPH
rpm
C or F
deg
mmHg or kPa or inHg or psi
C or F
V
ms
STEP
V
deg
g/h
%
%
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
*1: With catalyst model only

*2: Without catalyst model only
EN(w/oOBD)-24

NOTE:

Contents
Automatic transmission vehicle identification
signal
Neutral position switch signal*1
Air conditioning compressor signal
Knocking signal
Torque permission signal
TCS AET signal
Canister purge control solenoid valve
Oxygen sensor rich signal*2
Read memory connector signal
P/S switch
Starter switch
Blower fan switch
Light switch
Message
ON or OFF
LED ON requirements
When ignition switch is turned ON.
ON or OFF
When AT identification signal is entered.
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF

When neutral position switch signal is entered.
When air conditioning compressor is in function.
When radiator fan relay #1 is in function.
When fuel pump relay is in function.
When radiator fan relay #2 is in function.
When torque control signal #1 is entered.
When torque control signal #2 is entered.
When torque permission signal is entered.
When TCS AET signal is entered.
When canister purge control solenoid valve is in function.
When oxygen sensor mixture ratio is rich.
When read memory connector is connected.
When steering wheel is turned.
When crankshaft position sensor signal is entered.
When camshaft position sensor signal is entered.
When rear defogger switch signal is entered.
When blower fan switch signal is entered.
When light switch signal is entered.
When throttle sensor sends signal that throttle opening angle
is in idle position.
Idle switch signal
ON or OFF
*1: On MT model, switch is turned ON when gear position is in neutral position.

On AT model, switch is turned ON when shift position is in P or N position.
*2: With catalyst model only
NOTE:
EN(w/oOBD)-25

7. Read Diagnostic Trouble Code (DTC)

A: OPERATION
key.
4) On the Engine Diagnosis display screen, select the {Diagnostic Code(s) Display} and press [YES] key.
5) On the Diagnostic Code(s) Display display screen, select the {Current Diagnostic Code(s)} or {History
Diagnostic Code(s)} and press [YES] key.
NOTE:
For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref.
to EN(w/oOBD)-63, LIST, List of Diagnostic Trouble Code (DTC).>
Step
Check
2)Connect the read memory connector. <Ref.
to EN(w/oOBD)-10, LOCATION, Electrical
Components Location.>

(DTC).
EN(w/oOBD)-26
Yes
Go to step 2.
No
necessary.
NOTE:
Open or short
circuit in engine
control module
power supply or
ground line
Open or short
circuit in CHECK
ENGINE malfunction indicator lamp
Record the DTC. Complete the read
Then turn the igni- DTC. Turn the
tion switch to OFF, ignition switch to
disconnect read
OFF and disconmemory connec- nect read memory
tor.
connector.

The CHECK ENGINE malfunction indicator lamp (MIL) flashes code corresponding to faulty parts. The long
segment (1.3 seconds ON) indicates a ten, and the short segment (0.2 seconds ON) signifies one. And
middle segment (0.5 seconds ON) means OK code.
NOTE:
to EN(w/oOBD)-63, LIST, List of Diagnostic Trouble Code (DTC).>
S2M1768A
EN(w/oOBD)-27
INSPECTION MODE
8. Inspection Mode
A: OPERATION
After performing diagnostics and clearing memory,

check for any remaining unresolved trouble data.
1) Connect the test mode connector (green) at the
lower portion of instrument panel (on the drivers
side).
1. PREPARATIONS FOR THE INSPECTION

MODE
Raise the vehicle using a garage jack and place on
safety stands or drive the vehicle onto free rollers.
WARNING:
Before raising the vehicle, ensure parking
brake is applied.
safety stand.
EN1450
(A) Test mode connector

connector. <Ref. to EN(w/oOBD)-10, LOCATION,
Electrical Components Location.>
S2M0288E
(A) Power switch
B2M2969C
(A) Safety stand

(B) Free rollers

press [YES] key.
7) On the Engine Diagnosis display screen, select the {6. Dealer Check Mode Procedure} and
press [YES] key.
Mode? is shown on the display screen, press
[YES] key.
EN(w/oOBD)-28
INSPECTION MODE

If trouble still remains in the memory, the corresponding diagnostic trouble code (DTC) appears
NOTE:

(DTCs), refer to the DIAGNOSTIC TROUBLE
CODE (DTC) LIST. <Ref. to EN(w/oOBD)-63,
On AWD vehicles, release the parking brake.
wheels may light either ABS warning light, but this
indicates no malfunctions. When the engine control
diagnosis is finished, perform the ABS memory.

Step
Check
1)Start and warm-up the engine.
3)Set the shift lever to neutral position (MT
vehicles), or set selector lever to P position
(AT vehicles).
4)Connect the test mode connector (green) at
lower portion of instrument panel (on drivers
side).
Yes
Go to step 2.

(DTC).
1)Set the selector lever to N position, and
then set selector lever to P position again (AT
vehicles only).
2)Start the engine.

(DTC).
1)Drive the vehicle at speed greater than 11
km/h (7 MPH) for at least 1 minute.
2)Warm-up the engine above 2,000 rpm.
Record the DTC

and inspect using
DTC. <Ref. to
EN(w/oOBD)-66,
(DTC).>
Record the DTC
and inspect using
DTC. <Ref. to
EN(w/oOBD)-66,
(DTC).>
EN(w/oOBD)-29
No
necessary.
NOTE:
Open or short
circuit in engine
control module
power supply or
ground line
Open or short
circuit in CHECK
Go to step 3.
Turn the ignition

switch to OFF.
Disconnect the
test mode connector. Complete the
inspection mode.
NOTE:
When the onboard
diagnosis
system indicates
no trouble, trouble
is in a different
symptom.
CLEAR MEMORY MODE

9. Clear Memory Mode

A: OPERATION
1) On the Main Menu display screen, select the {2. Each System Check} and press [YES] key.
key.
5) When the Done and Turn Ignition Switch OFF are shown on the display screen, turn the Subaru Select
Monitor and ignition switch to OFF.
NOTE:
After the memory has been cleared, the ISC must be initialized. To do this, turn the ignition switch to the
ON position. Wait 3 seconds before starting the engine.
Step
Check
2)Set the shift lever to neutral position (MT
vehicles), or set selector lever to P position
(AT vehicles).
3)Connect the test mode connector and read
memory connectorat at lower portion of instrument panel (on drivers side).

(DTC).
1)Set the selector lever to N position, and
then set selector lever to P position again (AT
vehicles only).
2)Start the engine.
km/h (7 MPH) for at least 1 minute.
4)Warm-up engine above 2,000 rpm.

EN(w/oOBD)-30
Yes
Go to step 2.
No
necessary.
NOTE:
Open or short
circuit in engine
control module
power supply or
ground line
Open or short
circuit in CHECK
Record the DTC. Turn the ignition
Repair the trouble switch to OFF.
cause. <Ref. to
Disconnect the
EN(w/oOBD)-66, read memory conDiagnostic Proce- nector and test
dure with Diagnos- mode connector.
tic Trouble Code Complete the clear
(DTC).>
memory mode.


Check Mode
A: OPERATION
1) Connect the test mode connector at the lower
portion of instrument panel (on the driver's side).
EN1450
(A) Test mode connector
2) Each valve functions when the ignition switch is

turned to ON (engine OFF).
A list of the support portion is shown in the following table.
Contents
EN(w/oOBD)-31


A: PROCEDURE
1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN(w/oOBD)-32, ACTIVATION OF CHECK ENGINE
MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).>
2. Check that engine malfunction indicator lamp (MIL) does not come on. <Ref. to EN(w/oOBD)-34, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).>
3. Check that engine malfunction indicator lamp (MIL) does not go off. <Ref. to EN(w/oOBD)-36, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT GO OFF., Engine Malfunction Indicator Lamp (MIL).>
4. Check that engine malfunction indicator lamp (MIL) does not blink at a cycle of 3 Hz. <Ref. to EN(w/oOBD)-38, CHECK
ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 HZ., Engine Malfunction Indicator
Lamp (MIL).>
5. Check that engine malfunction indicator lamp (MIL) remains blinking at a cycle of 3 Hz. <Ref. to EN(w/oOBD)-40, CHECK
ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 HZ., Engine Malfunction Indicator
Lamp (MIL).>

LAMP (MIL)
off), the CHECK ENGINE malfunction indicator

system is malfunctioning. <Ref. to EN(w/oOBD)-2,
PROCEDURE, Basic Diagnostic Procedure.>
NOTE:
of the CHECK ENGINE light circuit or the combination meter circuit. <Ref. to IDI-15, Combination
Meter Assembly.>
OBD0053A

off) or to START with the test mode connector connected, the MIL blinks at a cycle of 3 Hz.
EN0774
OBD0055A
EN(w/oOBD)-32

EN(w/oOBD)-33


ON.
DIAGNOSIS:
TROUBLE SYMPTOM:
When the ignition switch is turned ON (engine OFF), MIL does not come on.
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
No.13
SBF-4
4
LHD
RHD
B36
B38
i1
i3
B36
4
22
23
MT
AT
i1
MT
AT
LHD
SBF-1
RHD
A7
C6
1 LHD :16
COMBINATION
METER
RHD :13
i2
B37
11
A: i10
C: i12
B134 ECM
A:
B72
B36
B134
i1
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
1 2
3 4
5 6
7 8
9 10 11 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
LHD:
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
RHD:
C:
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
i10
1 2 3 4 5 6 7 8 9 10
i3
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
EN1395
Step
Check
CHECK POOR CONTACT.
EN(w/oOBD)-34
Yes
Go to step 4.
No
Go to step 2.
Repair poor contact in the ECM

connector.
Go to step 3.

Step

combination meter.
(B134) No. 11 (i12) No. 6:
Check
Yes
No
Is the ECM connector correctly Replace the ECM. Repair the conconnected?
nection of ECM
connector.
Go to step 5.
Repair the har?
ness and connector.
Is there poor contact in combiCHECK POOR CONTACT.

nector. <Ref. to IDI-15, Combination Meter
Assembly.>
CHECK HARNESS BETWEEN COMBINAIs the voltage more than 10 V?
TION METER AND IGNITION SWITCH CONNECTOR.
Repair the poor

contact in combination meter connector.
Go to step 7.
CHECK POOR CONTACT.

Is there poor contact in combiCheck poor contact in combination meter con- nation meter connector?
nector. <Ref. to IDI-15, Combination Meter
Assembly.>
Repair the poor

contact in combination meter connector.
EN(w/oOBD)-35
NOTE:
the following:
Open circuit in
harness between
Poor contact in
coupling connector
Go to step 6.

necessary.
NOTE:
Broken down
ignition relay
Blown out fuse
(No. 5)
If replaced fuse
circuit of harness
between fuse (No.
5) and ignition
relay connector.
Open or short
circuit in harness
between fuse (No.
Open circuit in
harness between
fuse (No. 5) and
Poor contact in
Poor contact in
ignition switch
connector
Replace the bulb
or combination
meter.


OFF.
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
No.13
SBF-4
4
LHD
RHD
B36
B38
i1
i3
B36
4
22
23
MT
AT
i1
MT
AT
LHD
SBF-1
RHD
A7
C6
1 LHD :16
COMBINATION
METER
RHD :13
i2
B37
11
A: i10
C: i12
B134 ECM
A:
B72
B36
B134
i1
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
1 2
3 4
5 6
7 8
9 10 11 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
LHD:
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
RHD:
C:
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
i10
1 2 3 4 5 6 7 8 9 10
i3
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
EN1395
Step
Check
EN(w/oOBD)-36
Yes
Repair the short
circuit in harness
ECM connector.
No
Replace the ECM.
<Ref. to FU(w/
oOBD)-48, Engine
Control Module.>

EN(w/oOBD)-37


AT A CYCLE OF 3 HZ.
DIAGNOSIS:
Test mode connector circuit is in open.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
No.13
SBF-4
4
LHD
RHD
B36
B38
i1
i3
B36
4
22
23
MT
AT
i1
1 LHD :16
MT
AT
LHD
SBF-1
RHD :13
RHD
A7
C6
COMBINATION
METER
i2
B75
B76
16
B22
E3
A11
A: i10
B14
B37
C: i12
A: B134
ECM
B: B135
B75
B72
1
2
1 2
3 4
B135
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
A:
i10
C:
1 2 3 4 5 6 7 8 9 10
i1
B22
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
RHD:
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1
5
9
13
2
6
10
14
3
7
11
15
B36
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
i2
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
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
LHD:
i2
1 2 3 4
5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
i3
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
EN1451
EN(w/oOBD)-38

Step
Check
2)Disconnect the test mode connector at lower
portion of instrument panel (on drivers side).
Yes
Go to step 2.

Measure the voltage between test mode connector and chassis ground.
?
ECM and test mode connector.
(B135) No. 14 (B75) No. 1:
Go to step 3.

connector?
CHECK POOR CONTACT.


?
CHECK POOR CONTACT.


connector?
EN(w/oOBD)-39
Go to step 4.
Repair the poor

contact in ECM
connector.
Go to step 6.
Repair the poor

contact in ECM
connector.
No
Repair the MIL circuit. <Ref. to
EN(w/oOBD)-34,
CHECK ENGINE
MALFUNCTION
INDICATOR
LAMP (MIL)
DOES NOT
COME ON.,
Lamp (MIL).>
Go to step 5.

NOTE:
the following:
Open circuit in
harness between
ECM and test
mode connector
Replace the ECM.
<Ref. to FU(w/
oOBD)-48, Engine
Control Module.>
NOTE:
the following:
Open circuit in
harness between
ground
Replace the ECM.
<Ref. to FU(w/
oOBD)-48, Engine
Control Module.>

DIAGNOSIS:
TROUBLE SYMPTOM:
Even though test mode connector is disconnected, MIL blinks at a cycle of 3 Hz when ignition switch is
turned to ON.
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
No.13
SBF-4
4
LHD
RHD
B36
B38
i1
i3
B36
4
22
23
MT
AT
i1
1 LHD :16
MT
AT
LHD
SBF-1
RHD :13
RHD
A7
C6
COMBINATION
METER
i2
B75
B76
16
B22
E3
A11
A: i10
B14
B37
C: i12
A: B134
ECM
B: B135
B75
B72
1
2
1 2
3 4
B135
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
A:
i10
C:
1 2 3 4 5 6 7 8 9 10
i1
B22
i12
RHD:
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1
5
9
13
1 2 3
4 5 6
7 8 9 10 11 12 13 14
2
6
10
14
3
7
11
15
B36
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
i2
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
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
LHD:
i2
1 2 3 4
5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
i3
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
EN1451
EN(w/oOBD)-40

Step
Check
MINAL.
ECM connector and engine ground.
EN(w/oOBD)-41
Yes
Repair the short
circuit in harness
between ECM and
No
Replace the ECM.
<Ref. to FU(w/
oOBD)-48, Engine
Control Module.>


A: PROCEDURE
1. Inspection of starter motor circuit. <Ref. to EN(w/oOBD)-44, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
2. Inspection of ECM power supply and ground line. <Ref. to EN(w/oOBD)-48, CONTROL MODULE POWER SUPPLY AND
GROUND LINE, Diagnostics for Engine Starting Failure.>
3. Inspection of ignition control system. <Ref. to EN(w/oOBD)-52, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.>
4. Inspection of fuel pump circuit. <Ref. to EN(w/oOBD)-56, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
5. Inspection of fuel injector circuit. <Ref. to EN(w/oOBD)-60, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
EN(w/oOBD)-42

EN(w/oOBD)-43


CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref.
to EN(w/oOBD)-30, OPERATION, Clear Memory Mode.> and <Ref. to EN(w/oOBD)-28, OPERATION,
Inspection Mode.>
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-4
IGNITION
SWITCH
B72
INHIBITOR SWITCH
P
12
AT
MT
12
11
7
T3
T7
MT
B12
R N D
B135 ECM
28
AT
B14
STARTER
MOTOR
B72
B12
T7
B135
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
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
EN0862
1
2
Step
Check
(DTC).
<Ref. to EN(w/oOBD)-26, OPERATION, Read LIST, List of Diagnostic TrouDiagnostic Trouble Code (DTC).>
ble Code (DTC).>
EN(w/oOBD)-44
Yes
Go to step 2.
No
Go to step 3.

Repair the trouble
cause. <Ref. to
EN(w/oOBD)-66,
(DTC).>

Step
Check
Yes
CHECK INPUT SIGNAL FOR STARTER MO- Is the voltage more than 10 V? Go to step 4.
TOR.
ground.
NOTE:
On AT vehicles, place the selector lever in the
P or N position.
MOTOR.
ground.
motor and ECM.
1)Ignition the switch to OFF.
switch.
and chassis ground.
No
Go to step 5.

?
Check the starter

motor. <Ref. to
SC-10, INSPECTION, Starter.>
Repair the open

circuit of ground
cable.

?

short circuit.

?
Go to step 7.
Repair the ground

short circuit.
Repair the open

circuit in harness
between ignition
switch and battery.
Is the vehicle AT?
Repair the open

circuit between
ignition switch and
EN(w/oOBD)-45
Go to step 10.

10
11
12
Step
2)Place the selector lever in the P or N position.
3)Separate the transmission harness connector.
4)Measure the resistance between transmission harness connector receptacle's terminals.
(T3) No. 11 No. 12:
CHECK TRANSMISSION HARNESS.
switch.
transmission harness and inhibitor switch connector.
(T3) No. 11 (T7) No. 7:
(T3) No. 12 (T7) No. 12:
CHECK POOR CONTACT.
Check poor contact in inhibitor switch connector.
Check
?
Yes
No
Repair the open
Go to step 11.
circuit in harness
between starter
motor and ignition
switch connector.

?
Go to step 12.
Is there poor contact in inhibitor switch connector?
Repair the poor

Replace the inhibicontact in inhibitor tor switch.
switch connector.
EN(w/oOBD)-46
Repair the open

circuit in harness
between transmission harness and
inhibitor switch
connector.

EN(w/oOBD)-47


CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
RHD
6
4
5
3
2
1
B47
B61
RHD
MAIN RELAY
F44
LHD
B72
IGNITION
SWITCH
BATTERY
SBF-4
No.11
4
B19
C1
C2
C9
B7
SBF-5
LHD
SBF-1
1 AT MODEL (RHD ONLY) : B6

MT MODEL
ECM
: B25
A: B134
B: B135
13
15
14
16
A7
A8
A27
C22
C21
1
C: B136
B22
E3
B72
1 2
3 4
B47
1
3
5
2
4
6
F44
1 2 3 4
5 6 7 8
B: B135
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
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
C: B136
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
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
EN1452
Step
Check
CHECK MAIN RELAY.
?
No. 1 and No. 2.
terminals.
Terminals
No. 3 No. 5:
No. 4 No. 6:
EN(w/oOBD)-48
Yes
Go to step 2.
No
Replace the main
relay.

Step
(B135) No. 25 Chassis ground: (MT
vehicle)
(B135) No. 6 Chassis ground: (AT
vehicle (RHD ONLY))
and chassis ground.
chassis ground.
Check
?
Yes
Go to step 3.
No
Repair the open
circuit in harness
between ECM
connector and
engine grounding
terminal.
Repair the open or

Repair the open or

Go to step 6.
Repair the ground

ECM connector
and main relay
connector, and
then replace the
ECM.
Replace the ECM.

M?

CHECK GROUND CIRCUIT OF MAIN REIs the resistance less than 5
Go to step 9.
LAY.
?
EN(w/oOBD)-49
Repair the open

circuit in harness
between ECM
connector and
Repair the open
circuit between
main relay and
chassis ground.
Repair the open or


10
Step
Check
EN(w/oOBD)-50
Yes
Check the ignition
control system.
<Ref. to EN(w/
oOBD)-52, IGNITION CONTROL
SYSTEM, Diagnostics for Engine
Starting Failure.>
No
Repair the open or
between ECM
connector and

EN(w/oOBD)-51


CAUTION:
After repair or replacement of the faulty parts, conduct the CLEAR MEMORY and INSPECTION
MODES. <Ref. to EN(w/oOBD)-30, OPERATION, Clear Memory Mode.> and <Ref. to EN(w/oOBD)-28,
OPERATION, Inspection Mode.>
WIRING DIAGRAM:
27
26
25
B134 ECM
B72
IGNITION
SWITCH
BATTERY
SBF-4
NO.11
4
SBF-1
14
6
5
4
B22
E3
2.0L AND 2.5L: 1

1.6L: 4
2.0L AND 2.5L: 2

1.6L: 1
E12
3
1
2
3
3
1 2.0L AND 2.5L: 4

1.6L: 2
IGNITOR
&
IGNITION COIL ASSY
E12
B72
1 2 3 4
1 2
3 4
B134
B22
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 32 33
34 35
EN1398
EN(w/oOBD)-52

Step
CHECK IGNITION SYSTEM FOR SPARKS.
1)Remove the plug cord cap from each spark
plug.
2)Install new spark plug on the plug cord cap.
Check
Does spark occur at each cylinder?
Yes
Check the fuel
pump system.
<Ref. to EN(w/
oOBD)-56, FUEL
PUMP CIRCUIT,
Diagnostics for
Engine Starting
Failure.>
CAUTION:
Do not remove the spark plug from engine.
engine.
ignitor assembly.
engine ground.
1.6 L
2.0 L and 2.5 L
than 5 ?
ground.

1)Remove the spark plug cords.
2)Measure the resistance between spark plug
Terminals
1.6 L
No. 4 No. 1:
2.0 L and 2.5 L
No. 1 No. 2:
Measure the resistance between spark plug
Terminals
1.6 L
No. 3 No. 2:
2.0 L and 2.5 L
No. 3 No. 4:

and 15 ?
Go to step 5.

and 15 ?
Go to step 6.
EN(w/oOBD)-53
No
Go to step 2.

NOTE:
the following:
Open circuit or
ground short in
harness between
ignition switch
connector
Poor contact in
coupling connector
(B22)
NOTE:
the following:
Open circuit in
harness between
grounding terminal
assembly.

assembly.

Step
& IGNITOR ASSEMBLY.
1.6 L
2.0 L and 2.5 L
& IGNITOR ASSEMBLY.
1.6 L
2.0 L and 2.5 L
1.6 L
(B134) No. 26 (E12) No. 2:
2.0 L and 2.5 L
(B134) No. 26 (E12) No. 4:
Check
Yes
No
assembly.

assembly.

?
NECTOR.
1.6 L
(B134) No. 25 (E12) No. 4:
2.0 L and 2.5 L
(B134) No. 25 (E12) No. 1:
EN(w/oOBD)-54
Go to step 9.
Go to step 10.
NOTE:
the following:
Open circuit in
harness between
ECM and ignition
coil & ignitor
assembly connector
Poor contact in
a coupling connector (B22)
NOTE:
the following:
Open circuit in
harness between
ECM and ignition
coil & ignitor
assembly connector
Poor contact in

10
11
12
13
Step
Check
NECTOR.
(B134) No. 27 (E12) No. 3:
CHECK POOR CONTACT.
Yes
Go to step 11.

M?
Go to step 12.

M?
Go to step 13.

connector?
Repair the poor

contact in ECM
connector.
EN(w/oOBD)-55
No
NOTE:
the following:
Open circuit in
harness between
ECM and ignition
coil & ignitor
assembly connector
Poor contact in
Repair the ground
ECM and ignition
coil & ignitor
assembly connector.
Repair the ground
ECM and ignition
coil & ignitor
assembly connector.
Check the spark
plug and spark
plug cord. <Ref. to
IG(w/oOBD)-6,
INSPECTION,
Spark Plug.>
<Ref. to IG(w/
oOBD)-10,
INSPECTION,
Spark Plug Cord.>

RHD
RHD
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
LHD
B61
SBF-5
LHD
IGNITION
SWITCH
B72
F44
BATTERY
No.11
SBF-4
4
FUEL PUMP
RELAY
SBF-1
2
1
3
4
B134 ECM
B46
B97
1 LHD :7
R1
RHD :5
2 WITH
IMMOBILIZER :29
WITHOUT
IMMOBILIZER :16
FUEL PUMP
1
4
R58
B46
1 2
3 4
1
3
R57
R15
B72
R58
1 2
3 4
1 2 3
4 5 6
F44
B97
1 2 3 4
5 6 7 8
1 2 3 4
5 6 7 8
R15
B134
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
EN1399
Step
Check
PUMP.
operating sound?
NOTE:
Fuel pump operation check can also be executed using the Subaru Select Monitor. For the
procedure, refer to COMPULSORY VALVE
OPERATION CHECK MODE.<Ref. to EN(w/
oOBD)-31, OPERATION, Compulsory Valve
Operation Check Mode.>
EN(w/oOBD)-56
Yes
No
Check the fuel
Go to step 2.
injector circuit.
<Ref. to EN(w/
oOBD)-60, FUEL
INJECTOR CIRCUIT, Diagnostics

Step
Check
CHECK GROUND CIRCUIT OF FUEL PUMP. Is the resistance less than 5
?
2)Raise the rear seat, and turn floor mat up.
3)Remove the service hole cover.
5)Measure the resistance of harness connector between fuel pump and chassis ground.
Yes
Go to step 3.
CHECK POWER SUPPLY TO FUEL PUMP. Is the voltage more than 10 V? Replace the fuel
pump.
2)Measure the voltage of power supply circuit
between fuel pump connector and chassis
ground.
Go to step 5.
CHECK HARNESS BETWEEN FUEL PUMP Is the resistance less than 1
?
(R58) No. 1 (B46) No. 4:

CHECK FUEL PUMP RELAY.
relay.
2)Remove the fuel pump relay from bracket.
3)Connect the battery to fuel pump relay connector terminals No. 1 and No. 3.
terminals of fuel pump relay.
Terminals
No. 2 No. 4:

M?
Go to step 6.

?
Go to step 7.
EN(w/oOBD)-57
No
NOTE:
the following:
Open circuit in
harness between
grounding terminal
Poor contact in
coupling connector
(R15) and (B97)
Go to step 4.

NOTE:
the following:
Open circuit in
harness between
fuel pump and fuel
pump relay connector
Poor contact in
coupling connectors (R15) and
(B97)
Repair the ground
pump and fuel
pump relay connector.
Replace the fuel
pump relay.

Step
FUEL PUMP RELAY CONNECTOR.
ECM and fuel pump relay connector.
With Immobilizer
(B134) No. 29 (B46) No. 3:
Without Immobilizer
(B134) No. 16 (B46) No. 3:
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(w/
oOBD)-60, FUEL
INJECTOR CIRCUIT, Diagnostics
EN(w/oOBD)-58

EN(w/oOBD)-59


CAUTION:
Check or repair only the faulty parts.
After repair or replacement of the faulty parts, conduct the CLEAR MEMORY and INSPECTION
MODES. <Ref. to EN(w/oOBD)-30, OPERATION, Clear Memory Mode.> and <Ref. to EN(w/oOBD)-28,
OPERATION, Inspection Mode.>
WIRING DIAGRAM:
RHD
4
6
5
3
RHD
MAIN RELAY
LHD
B61
BATTERY
SBF-5
LHD
F44
2
1
C1
A15
A14
11
10
A4
9
C: B136 ECM
A13
A: B134
B22
12
C2
B47
E3
FUEL INJECTOR
No.1
E5
E16
E6
E17
1 2
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
FUEL INJECTOR
No.2
B47
1
3
5
FUEL INJECTOR
No.3
FUEL INJECTOR
No.4
B22
F44
2
4
6
E17
2
E6
E16
E5
1 2 3 4
5 6 7 8
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
A: B134
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
EN0866
Step
Check
TOR.
operating sound?
for this check.
EN(w/oOBD)-60
Yes
No
Check the fuel
Go to step 2.
pressure. <Ref. to
ME-29, INSPECTION, Fuel Pressure.>

Step
Check
Yes
INJECTOR.
fuel injector.

and 20 ?
(B134) No. 4 (B136) No. 2:

(B134) No. 13 (B136) No. 2:


?

and 20 ?

?
EN(w/oOBD)-61
Go to step 4.
No
NOTE:
the following:
Open circuit in
harness between
main relay and fuel
injector connector
Poor contact in
Poor contact in
coupling connector
(B22)
Poor contact in
NOTE:
the following:
Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
coupling connector
(B22)
ECM and fuel
injector connector.
Go to step 6.
NOTE:
the following:
Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
coupling connector
(B22)
ECM and fuel
injector connector.

10
11
12
Step
(B134) No. 14 (B136) No. 2:
Check
and 20 ?

(B134) No. 15 (B136) No. 2:

?

injector terminals.
Terminals
No. 1 No. 2:
CHECK POOR CONTACT.

and 20 ?

?
Yes
Go to step 8.
No
NOTE:
the following:
Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
coupling connector
(B22)
ECM and fuel
injector connector.
Go to step 10.
NOTE:
the following:
Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
coupling connector
(B22)
ECM and fuel
injector connector.

and 20 ?
Go to step 12.
Replace the faulty

fuel injector.

connector?
Repair the poor

contact in ECM
connector.
Inspection using
EN-292, INSPECTION, General
Diagnostic Table.>
EN(w/oOBD)-62


A: LIST
Trouble
code
11
Item
12
Starter switch
13
21
22
Knock sensor
24
Idle air control solenoid

valve
26

sensor
31
32
Oxygen sensor
33
35

valve
Contents of diagnosis
Index
No signal entered from crankshaft

position sensor when starter switch is
ON.
Harness connector between ECM
and crankshaft position sensor is in
short or open.
Starter switch signal is abnormal.
and starter switch is in short or open.
No signal entered from camshaft
position sensor, but signal entered
from crankshaft position sensor.
and camshaft position sensor is in
short or open.
signal is abnormal.
and engine coolant temperature sensor is in short or open.
Knock sensor signal is abnormal.
and knock sensor is in short or open.
Idle air control solenoid valve is not
in function.
and idle air control solenoid valve is in
short or open.
Intake air temperature sensor signal is abnormal.
and intake air temperature sensor is
in short or open.
Throttle position sensor signal is
abnormal.
Throttle position sensor is installed
abnormally.
and throttle position sensor is in short
or open.
Oxygen sensor is not in function.
and oxygen sensor is in short or open.
Vehicle speed signal is abnormal.
and vehicle speed sensor is in short
or open.
Purge control solenoid valve is not
in function.
and purge control solenoid valve is in
short or open.
<Ref. to EN(w/oOBD)-66, DTC 11 CRANKSHAFT

POSITION SENSOR, Diagnostic Procedure with
EN(w/oOBD)-63
<Ref. to EN(w/oOBD)-68, DTC 12 STARTER

SWITCH, Diagnostic Procedure with Diagnostic
<Ref. to EN(w/oOBD)-70, DTC 13 CAMSHAFT
<Ref. to EN(w/oOBD)-72, DTC 21 ENGINE

COOLANT TEMPERATURE SENSOR, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(w/oOBD)-76, DTC 22 KNOCK SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(w/oOBD)-78, DTC 24 IDLE AIR
CONTROL SOLENOID VALVE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(w/oOBD)-82, DTC 26 INTAKE AIR

TEMPERATURE SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(w/oOBD)-86, DTC 31 THROTTLE

<Ref. to EN(w/oOBD)-88, DTC 32 OXYGEN

SENSOR, Diagnostic Procedure with Diagnostic
<Ref. to EN(w/oOBD)-92, DTC 33 VEHICLE
SPEED SIGNAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(w/oOBD)-94, DTC 35 PURGE CONTROL SOLENOID VALVE, Diagnostic Procedure

Trouble
code
38
45
46
51
53*
85
Item
Torque control signal (AT) Abnormal signal is entered from

TCM.
and TCM is in short or open.
Pressure sensor
Pressure sensor signal is abnormal.
and pressure sensor is in short or
open.
CO resistor (General
CO resistor signal is abnormal.
spec. vehicles)
and CO resistor is in short or open.
CO valve is not adjusted to specification.
Neutral position switch signal is
(MT)
abnormal.
and neutral position switch is in short
or open.
Park/Neutral position
Park/neutral position switch signal
switch (AT)
is abnormal.
Shift cable is connected abnormally.
and inhibitor switch is in short or
open.
Immobilizer system
Faulty immobilizer system.
Charge system
Charge system is abnormal.
*: Immobilizer system equipped model only
EN(w/oOBD)-64
Index
<Ref. to EN(w/oOBD)-98, DTC 38 TORQUE
CONTROL SIGNAL, Diagnostic Procedure with
<Ref. to EN(w/oOBD)-100, DTC 45 PRESSURE
<Ref. to EN(w/oOBD)-102, DTC 46 CO RESISTOR (GENERAL SPEC. VEHICLES), Diagnostic

<Ref. to EN(w/oOBD)-104, DTC 51 NEUTRAL

POSITION SWITCH (MT VEHICLE), Diagnostic
<Ref. to EN(w/oOBD)-106, DTC 51 PARK/NEUTRAL POSITION SWITCH (AT VEHICLE), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to IM-2, Basic Diagnostic Procedure.>

<Ref. to EN(w/oOBD)-108, DTC 85 CHARGE
SYSTEM, Diagnostic Procedure with Diagnostic

EN(w/oOBD)-65


A: DTC 11 CRANKSHAFT POSITION SENSOR
DIAGNOSIS:
No signal entered from crankshaft position sensor when ignition switch is ON.
The harness connector between ECM and crankshaft position sensor is open or shorted.
TROUBLE SYMPTOM:
Engine stalls.
Restarting impossible
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
WITH IMMOBILIZER
WITHOUT IMMOBILIZER
CRANKSHAFT
POSITION
SENSOR
:2
:1
E10
2
1
1 2
E10
LHD: B83
1 2 3 4
5 6 7 8
19
17
E2
RHD: B83
B21
1 2 3 4 5 6 7 8 9 10 11 12
LHD
B21
RHD
1
5
7
9
LHD
1 2
3
6 7
9 10
11
13
14 15
17 18
19
5
RHD
B83
8
12
16
20
10
B83
B135
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
B135 ECM
EN1453
EN(w/oOBD)-66

Step
Check
CHECK CONDITION OF CRANKSHAFT PO- Are the crankshaft position
sensor installing bolts tightSITION SENSOR INSTALLATION.
ened securely?
Yes
Go to step 2.

and 4 k?
Go to step 3.

and 5 k?
Go to step 4.
CHECK CRANKSHAFT POSITION SENSOR.

1)Remove the crankshaft position sensor.
terminals of crankshaft position sensor.
Terminals
No. 1 No. 2:
CRANKSHAFT POSITION SENSOR CONNECTOR.
1)Connect the connector to crankshaft position
sensor.
ECM.
With Immobilizer
(B135) No. 8 (B135) No. 2
Without Immobilizer
(B135) No. 8 (B135) No. 1
CRANKSHAFT POSITION SENSOR CONNECTOR.
2)Set the positive (+) probe and ground lead of
oscilloscope at ECM connector terminals.
3)Measure the voltage indicated on oscilloscope while cranking engine.
With Immobilizer
(B135) No. 2 (+) (B135) No. 8 ()
Without Immobilizer
(B135) No. 1 (+) (B135) No. 8 ()
CHECK POOR CONTACT.

?
Is the voltage more than 400

mV?
No
Tighten the crankshaft position sensor installing bolts
securely.
Replace the crankshaft position sensor.
NOTE:
the following:
Open circuit in
harness between
ECM connector
Poor contact in
coupling connector
(B21)
ECM connector.
Go to step 6.
Repair the poor

contact in ECM
connector.
Is the same DTC as in current Replace the gendiagnosis still being output?
erator.
Replace the crankshaft position sensor.

connector?
Go to step 7.
CHECK ECM.
2)Erase the memory. <Ref. to EN(w/oOBD)30, OPERATION, Clear Memory Mode.>
4)Read any DTC on the display. <Ref. to
EN(w/oOBD)-26, OPERATION, Read Diagnostic Trouble Code (DTC).>
CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed?
BLE CODES (DTCs) APPEARANCE.
Go to step 8.
EN(w/oOBD)-67
Proceed with the

DTC.
A temporary poor
contact.

B: DTC 12 STARTER SWITCH

DIAGNOSIS:
The starter switch signal is abnormal.
The harness connector between ECM and starter switch is open or shorted.
TROUBLE SYMPTOM:
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-4
IGNITION
SWITCH
B72
INHIBITOR SWITCH
MT
AT
12
12
11
7
T3
T7
MT
B12
R N D
B135 ECM
28
AT
B14
STARTER
MOTOR
B72
1 2
3 4
B12
1 2 3 4
5 6 7 8
9 10 11 12
T7
B135
1 2 3 4 5 6
7 8 9 10 11 12
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
EN0862
Step
Check
turned to START?
EN(w/oOBD)-68
Yes
Go to step 2.
No
Check the starter
motor circuit.

Step
Check
Yes
CHECK HARNESS BETWEEN ECM AND IG- Is the voltage more than 10 V? Repair the poor
contact in ECM
NITION SWITCH CONNECTOR.
connector.
EN(w/oOBD)-69
No
Repair the open or
between ECM and
ignition switch
connector.

C: DTC 13 CAMSHAFT POSITION SENSOR

DIAGNOSIS:
No signal entered from camshaft position sensor, but signal entered from crankshaft position sensor.
The harness connector between ECM and camshaft position sensor is open or shorted.
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
:1
WITH IMMOBILIZER
WITHOUT IMMOBILIZER : 2
CAMSHAFT
POSITION
SENSOR
E15
2
1
1 2
E15
LHD: B83
1 2 3 4
5 6 7 8
20
18
E2
RHD: B83
B21
1 2 3 4 5 6 7 8 9 10 11 12
LHD
B21
RHD
2
5
8
9
LHD
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
RHD
B83
10
B83
B135
B135 ECM
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
EN1454
Step
CHECK CONDITION OF CAMSHAFT POSITION SENSOR INSTALLATION.
Check
Yes
Are the camshaft position sen- Go to step 2.
sor installing bolts tightened
securely?
EN(w/oOBD)-70
No
Tighten the camshaft position sensor installing bolts
securely.

Step
Terminals
No. 1 No. 2:
CAMSHAFT POSITION SENSOR CONNECTOR.
1)Connect the connector to camshaft position
sensor.
camshaft position sensor connector and ECM.
With Immobilizer
(B135) No. 8 (B135) No. 1:
Without Immobilizer
(B135) No. 8 (B135) No. 2:
CAMSHAFT POSITION SENSOR CONNECTOR.
3)Set the positive (+) probe and ground lead of
oscilloscope at ECM connector terminals.
4)Measure the voltage indicated on oscilloscope while cranking engine.
With Immobilizer
(B135) No. 1 (+) (B135) No. 8 ():
Without Immobilizer
(B135) No. 2 (+) (B135) No. 8 ():
CHECK POOR CONTACT.
Check
and 4 k?
Yes
Go to step 3.
No
Replace the camshaft position sensor.

and 5 k?
Go to step 4.

?
Is the voltage more than 400

mV?
NOTE:
the following:
Open circuit in
harness between
camshaft position
sensor and ECM
connector
Poor contact in
coupling connector
(B21)
camshaft position
sensor and ECM
connector.
Go to step 6.
Repair the poor

contact in ECM
connector.
Is the same DTC as in the cur- Replace the genrent diagnosis still being outerator.
put?
Replace the camshaft position sensor.

connector?
Go to step 7.
CHECK ECM.
2)Erase the memory. <Ref. to EN(w/oOBD)30, OPERATION, Clear Memory Mode.>
Go to step 8.
EN(w/oOBD)-71
Proceed with the

DTC.
A temporary poor
contact.

D: DTC 21 ENGINE COOLANT TEMPERATURE SENSOR

DIAGNOSIS:
The engine coolant temperature sensor signal is abnormal.
The harness connector between ECM and engine coolant temperature sensor is open or shorted.
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
E8
ENGINE
COOLANT
TEMPERATURE
SENSOR
1
2
1 2
3
E8
LHD: B122
1 2 3
4 5 6
13
9
E2
B21
RHD: B83
1 2 3 4 5 6 7 8 9 10 11 12
LHD
RHD
4
1
5
4
LHD
RHD
B83
B122
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
14
16
B136
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
B136 ECM
EN1455
EN(w/oOBD)-72

Step
Check
ECM CONNECTOR.
2)Remove the generator.
ground.
ECM CONNECTOR.
ground.
ECM CONNECTOR.
ground.
EN(w/oOBD)-73
Yes
No
ECM and engine

ECM and engine
Go to step 4.

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
(B21)

Step
Check
ECM CONNECTOR.
and engine ground.
Yes
Go to step 5.

and 3 k at 20C (68F)?
Go to step 6.
CHECK ENGINE COOLANT TEMPERATURE

SENSOR.
Measure the resistance between engine coolant temperature sensor terminals.
Terminals
No. 1 No. 2:
SENSOR.
Terminals
No. 1 No. 2:
SENSOR.
Terminals
No. 1 No. 2:
Is the resistance between 0.35 Go to step 7.

and 0.4 k at 80C (176F)?

and 0.3 k at 90C (194F)?
EN(w/oOBD)-74
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
(B21)
Poor contact in
sensor ground
joint connector
(B83) or (B122)
Replace the
engine coolant
temperature sensor.
Replace the
engine coolant
temperature sensor.
Replace the ECM. Replace the

engine coolant
temperature sensor.

EN(w/oOBD)-75

E: DTC 22 KNOCK SENSOR

DIAGNOSIS:
The knock sensor signal is abnormal.
The harness connector between ECM and knock sensor is open or shorted.
TROUBLE SYMPTOM:
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
KNOCK
SENSOR
E14
1 2
E14
LHD:
B83
1 2 3 4
5 6 7 8
RHD: B83
1 2 3 4 5 6 7 8 9 10 11 12
E2
16
1 LHD : 3
RHD : 2
B21
B21
2 LHD : 7
RHD : 3
1 2
3
6 7
9 10
11
13
14 15
17 18
19
162
4
8
12
16
20
B136
B83
25
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
B136 ECM
EN1456
EN(w/oOBD)-76

Step
Check
CHECK POOR CONTACT.
connector?
Yes
Go to step 2.
No
Go to step 3.
Repair the poor

contact in ECM
connector.
Replace the ECM.

<Ref. to FU(w/
oOBD)-48, Engine
Control Module.>
CHECK KNOCK SENSOR.

1)Disconnect the connector from knock senk and 590 k?
sor.
Terminal
CHECK HARNESS CONNECTOR BETWEEN

ECM AND KNOCK SENSOR.
between ECM and knock sensor.
(E14) No. 2 Chassis ground:
ECM AND KNOCK SENSOR.
Measure the resistance of harness of harness
connector between ECM connector and knock
sensor.
CHECK POOR CONTACT.
NOTE:
the following:
Open circuit in
harness between
knock sensor and
ECM connector
Poor contact in
Poor contact in
coupling connector
(B21)
Replace the knock
sensor. <Ref. to
FU(w/oOBD)-33,
Knock Sensor.>

?
Go to step 5.

M?
Go to step 6.
Repair the ground

short circuit
between ECM and
knock sensor.

connector?
Repair the poor

contact in ECM
connector.
Replace the ECM.

<Ref. to FU(w/
oOBD)-48, Engine
Control Module.>
EN(w/oOBD)-77

F: DTC 24 IDLE AIR CONTROL SOLENOID VALVE

DIAGNOSIS:
The idle air control solenoid valve is not in function.
The harness connector between ECM and idle air control solenoid valve is open or shorted.
TROUBLE SYMPTOM:
Erroneous idling
Hard to start
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
B47
6
4
LHD
5
3
1
3
5
SBF-5
LHD
2
B61
BATTERY
2
4
6
F44
2
1
E7
B47
E22
1
1 2 3
4 5 6
E3
5
2
F44
1 2 3 4
5 6 7 8
IDLE
AIR CONTROL
SOLENOID
VALVE
E7
B22
6
3
4
1
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
E2
3
4
1
2
B21
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
19
20
5
6
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
B134 ECM
EN1457
EN(w/oOBD)-78

Step
Check
Yes

CONNECTOR.
idle air control solenoid valve connector.
#1; (B134) No. 20 (E7) No. 3:
#2; (B134) No. 6 (E7) No. 1:
#3; (B134) No. 19 (E7) No. 6:
#4; (B134) No. 5 (E7) No. 4:

?

CONNECTOR.
#1; (B134) No. 20 Chassis ground:
CHECK POOR CONTACT.
Check poor contact in ECM connector and idle
air control solenoid valve connector.

M?
CHECK IDLE SPEED.

gasket

connector or idle air control
solenoid valve connector?
Go to step 3.
Go to step 4.
No
NOTE:
the following:
Open circuit in
harness between
idle air control
solenoid valve and
Poor contact in
coupling connector
(B22)
NOTE:
the following:
Open circuit in
harness between
ECM and idle air
control solenoid
valve connector
Poor contact in
coupling connector
(B21)
Repair the ground
ECM and idle air
control solenoid
valve connector.
Repair the poor

Go to step 5.
contact in ECM
connector or idle
valve connector.
Is the idling speed higher than Go to step 6.
Go to step 8.
standard?
Is there a fault in the air intake Repair the air suc- Go to step 7.
system?
tion and leaks.
EN(w/oOBD)-79

Step
Check
Are foreign particles in the by1)Turn the ignition switch to OFF.
pass air line?
from throttle body. <Ref. to FU(w/oOBD)-39,
the by-pass air line.
Does air flow out?
from throttle body. <Ref. to FU(w/oOBD)-39,
3)Remove the throttle body from intake manifold. <Ref. to FU(w/oOBD)-16, Throttle Body.>
the throttle body.
control solenoid valve installation area. Confirm that forced air subsequently escapes from
the throttle body interior.
EN(w/oOBD)-80
Yes
No
Remove the forReplace the idle
by-pass air line.
valve. <Ref. to
FU(w/oOBD)-39,
Idle Air Control
Solenoid Valve.>
Replace the idle
valve. <Ref. to
FU(w/oOBD)-39,
Idle Air Control
Solenoid Valve.>

FU(w/oOBD)-16,
Throttle Body.>

EN(w/oOBD)-81

G: DTC 26 INTAKE AIR TEMPERATURE SENSOR

DIAGNOSIS:
The intake air temperature sensor signal is abnormal.
The harness connector between ECM and intake air temperature sensor is open or shorted.
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
E20
1 2 3 4
1
3
2
INTAKE AIR
TEMPERATURE
AND
PRESSURE
SENSOR
E20
B122
1 2 3
4 5 6
LHD:
B21
E20
1 2 3
4 5 6
RHD:
LHD
RHD
B83
1 2 3 4 5 6 7 8 9 10 11 12
4
1
LHD
B83
15
9
12
14
E2
5
4
1
3
RHD
B122
LHD
RHD
4
7
B21
B83
LHD
RHD
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
B136
5
25
16
15
13
B83
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
B136 ECM
EN1458
EN(w/oOBD)-82

Step
CHECK INTAKE AIR TEMPERATURE SENSOR.
temperature sensor.
3)Measure the resistance between intake air
temperature sensor terminals.
Terminals
No. 2 No. 3:
Measure the resistance between intake air
temperature sensor terminals.
Terminals
No. 2 No. 3:
Check
and 3 k at 20C (68F)?
Yes
Go to step 2.
No
Replace the intake
air temperature
sensor. <Ref. to
FU(w/oOBD)-38,
Intake Air Temperature and Pressure Sensor.>

and 1 k at 50C (122F)?
Replace the intake

air temperature
sensor. <Ref. to
FU(w/oOBD)-38,
Intake Air Temperature and Pressure Sensor.>
CHECK HARNESS BETWEEN ECM AND IN- Is the resistance less than 1
TAKE AIR TEMPERATURE SENSOR CON- ?
NECTOR.
2)Measure the resistance of harness connector between ECM and intake air temperature
sensor connector.
(B136) No. 15 (E20) No. 3:
Go to step 4.

?
Go to step 5.

M?
Go to step 6.
Repair the ground

ECM and idle air
control solenoid
valve connector.

M?
Go to step 7.
Repair the ground

ECM and idle air
control solenoid
valve connector.
CHECK HARNESS BETWEEN ECM AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR.
between ECM and intake air temperature sensor connector.
(B136) No. 13 (E20) No. 2:
EN(w/oOBD)-83
NOTE:
the following:
Open circuit in
harness between
ECM and intake
air temperature
and pressure sensor connector
Poor contact in
coupling connector
(B21)

Step
CHECK POOR CONTACT.
Check
connector?
Yes
Repair the poor
contact in ECM
connector.
No
Contact with your
Subaru distributor
service.
NOTE:
Inspection by your
Subaru distributor
service is required,
because probable
parts.
EN(w/oOBD)-84

EN(w/oOBD)-85

H: DTC 31 THROTTLE POSITION SENSOR

DIAGNOSIS:
The throttle position sensor signal is abnormal.
The throttle position sensor is installed abnormally.
The harness connector between ECM and throttle position sensor is open or shorted.
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
THROTTLE
POSITION
SENSOR
E13
1 2 3 4
LHD :
4
3
2
B122
E13
1 2 3
4 5 6
RHD :
B83
1 2 3 4 5 6 7 8 9 10 11 12
12
11
9
E2
B21
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
LHD
RHD
4
1
5
4
LHD
RHD
B83
B122
B136
15
17
16
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
B136 ECM
EN1459
EN(w/oOBD)-86

Step
THROTTLE POSITION SENSOR.
throttle position sensor.
throttle position sensor.
(B136) No. 16 (E13) No. 2:
(B136) No. 17 (E13) No. 3:
(B136) No. 15 (E13) No. 4:
1)Disconnect the connector from TCM. (AT
vehicle)
chassis ground.
1)Connect the connector to ECM and throttle
position sensor.
2)Ignition the switch to ON.
3)Measure the voltage between ECM terminals while throttle valve is fully closed.
(B136) No. 15 (+) No. 17 ():
Measure the voltage between ECM terminals
while throttle valve is fully opened.
(B136) No. 15 (+) No. 17 ():
CHECK POOR CONTACT.
connector.
CHECK CONDITION OF THROTTLE POSITION SENSOR INSTALLATION.
Check
?
Yes
Go to step 2.
No
Repair the open
circuit between
ECM and throttle
position sensor.

M?
Go to step 3.
Repair the ground

short circuit
between ECM and
chassis ground.
Go to step 4.
Go to step 6.

contact in throttle
position sensor
connector.
Are the throttle position sensor Replace the throtinstalling screw tightened
tle position sensor.
securely?
EN(w/oOBD)-87
Adjust the throttle

position sensor
and tighten throttle position sensor
installing screws
securely.

I:
DTC 32 OXYGEN SENSOR
DIAGNOSIS:
The oxygen sensor is not in function.
The harness connector between ECM and oxygen sensor is open or shorted.
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
RHD
MAIN RELAY
6
4
B61
F44
2
LHD
RHD
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
BATTERY
SBF-5
B18
LHD
2 1
4 3
5
3
2
1
B47
1
3
5
2
4
6
B47
F44
OXYGEN SENSOR
1 2 3 4
5 6 7 8
4
1
B18
B22
E3
15
B22
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
23 24 25
26 27
28 29 30
21 22
23
B136
B136 ECM
EN0940
EN(w/oOBD)-88

Step
Check
CHECK FOR OTHER CAUSES AFFECTING Is CO % more than 2 % after
EXHAUST GAS.
the engine warm up?
NOTE:
Check for use of improper fuel.
Check if engine oil or coolant level is
extremely low.
Is there a fault in the exhaust

system?
Yes
Check the fuel
system.
No
Go to step 2.

system.
NOTE:
Loose installation of front portion
of exhaust pipe
onto cylinder
heads
Loose connection between front
exhaust pipe and
front catalytic converter
Damage of
exhaust pipe
resulting in hole
Repair the open
CHECK INPUT VOLTAGE FOR OXYGEN
circuit between
SENSOR.
main relay and
1)Disconnect the connector from oxygen senoxygen sensor.
sor connector.
2)Measure the voltage between main relay and
oxygen sensor.
Repair the open
CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1? Go to step 5.
circuit between
OXYGEN SENSOR AND ENGINE GROUND
oxygen sensor
CABLE.
Measure the resistance between oxygen senand chassis
sor and chassis ground.
ground.
Is the resistance less than 30 Repair poor con- Go to step 6.
CHECK OXYGEN SENSOR.
Measure the resistance between oxygen sen- ?
tact.
sor terminals.
No. 1 No. 2:
CHECK HARNESS BETWEEN ECM AND OX- Is the resistance more than 1 Go to step 7.
Repair the ground
YGEN SENSOR.
M?
short circuit
between ECM and
chassis ground.
chassis ground.
Repair the battery
CHECK HARNESS BETWEEN ECM AND OX- Is the voltage more than 0.2 V? Go to step 8.
short circuit
YGEN SENSOR.
between ECM and
oxygen sensor.
chassis ground.
EN(w/oOBD)-89

Step
CHECK INPUT VOLTAGE FOR ECM.
1)Connect the connector to ECM and oxygen
sensor.
chassis ground.
CHECK POOR CONTACT.
Check
Yes
Do 0.1 and 1 V waveform pat- Go to step 9.
terns alternately appear on the
oscilloscope screen?
No
Replace the oxygen sensor.

connector?
Replace the ECM.

<Ref. to FU(w/
oOBD)-48, Engine
Control Module.>
EN(w/oOBD)-90
Replace the oxygen sensor connector.

EN(w/oOBD)-91

J: DTC 33 VEHICLE SPEED SIGNAL

DIAGNOSIS:
The vehicle speed signal is abnormal.
The harness connector between ECM and vehicle speed sensor is open or shorted.
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
B17
BATTERY
IGNITION SWITCH
B72
SBF-4
SBF-1
1 2 3
1
4
No.18
B72
1 2
3 4
LHD : 9
RHD : 7
i10
1 2 3 4 5 6 7 8 9 10
B22
VEHICLE
SPEED
SENSOR
B56 TCM
1
5
9
13
3
7
11
15
4
8
12
16
1
2
17
B17
2
6
10
14
B56
AT
COMBINATION
METER
5 6
14 15
LHD :
16
i10
1 2 3 4
10 11 12 13
19 20 21
MT
B22
8
17
23
9
18
24
i2
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
E3
i2
7
16
22
B37
B135
24
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
RHD :
B135 ECM
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1460
Step
COMBINATION METER.
Check
Yes
normally?
EN(w/oOBD)-92
No
Check the speedometer and vehicle speed sensor.

Step
Check
1)Lift-up the vehicle.
2)Set the positive (+) terminal and ground lead
of oscilloscope at ECM connector terminals.
1)Start the engine.
2)Shift on the gear position, and put the vehicle
at constant speed.
3)Measure the signal voltage indicated on
oscilloscope.
CHECK POOR CONTACT.
connector?


CHECK POOR CONTACT.

?

connector?
EN(w/oOBD)-93
Yes
Go to step 3.
No
Go to step 4.
Repair the poor

contact in ECM.
Replace the ECM.

<Ref. to FU(w/
oOBD)-48, Engine
Control Module.>
Go to step 5.
NOTE:
the following:
Battery short circuit in harness
between ECM and
combination meter
connector
Repair the poor
contact in ECM.
Replace the ECM.

<Ref. to FU(w/
oOBD)-48, Engine
Control Module.>

K: DTC 35 PURGE CONTROL SOLENOID VALVE

DIAGNOSIS:
The purge control solenoid valve is not in function.
The harness connector between ECM and purge control solenoid valve is open or shorted.
TROUBLE SYMPTOM:
Erroneous idling
RHD
MAIN RELAY
RHD
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
6
4
5
3
LHD
B61
BATTERY
SBF-5
E4
LHD
1 2
F44
2
1
B47
B47
1
3
5
2
4
6
B134 ECM
F44
1 2 3 4
5 6 7 8
B22
1
5
9
13
3
7
11
15
4
8
12
16
3
2
B22
2
6
10
14
E3
B134
1
2
E4
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
PURGE CONTROL
SOLENOID VALVE
EN0942
EN(w/oOBD)-94

Step
CHECK OPERATION SOUND OF PURGE
CONTROL SOLENOID VALVE.
2)Connect the test mode connector at lower
portion of instrument panel (on drivers side).
4)Make sure that the ON/OFF operating sound
of purge control solenoid valve occurs at about
10 Hz.
CHECK POOR CONTACT.
Check
Does the purge control solenoid valve produce operating
sound?
Yes
Go to step 2.

connector?
Repair the poor

contact in ECM.
No
Go to step 3.
Replace the ECM.

<Ref. to FU(w/
oOBD)-48, Engine
Control Module.>
TROL SOLENOID VALVE AND ECM CONshort circuit in harNECTOR.
ness between
ECM and purge
control solenoid
valve connector.
solenoid valve.
After repair,
replace the ECM.
chassis ground.
CHECK HARNESS BETWEEN PURGE CON- Is the resistance less than 1
Go to step 5.
Repair the open
TROL SOLENOID VALVE AND ECM CON?
circuit in harness
NECTOR.
between ECM and
purge control sole2)Disconnect the connector from ECM.
noid valve connec3)Measure the resistance of harness between
tor.
(B134) No. 2 (E4) No. 2:
Replace the purge
and 27 ?
control solenoid
VALVE.
valve. <Ref. to
2)Measure the resistance between purge conEC(w/oOBD)-8,
Purge Control
Terminals
Solenoid Valve.>
No. 1 No. 2:
Repair the harCHECK POWER SUPPLY TO PURGE CON- Is the voltage more than 10 V? Go to step 7.
ness and connecTROL SOLENOID VALVE.
tor.
NOTE:
the following:
Open circuit in
harness between
main relay and
purge control solenoid valve connector
Poor contact in
Poor contact in
coupling connector
(B22)
EN(w/oOBD)-95

Step
CHECK POOR CONTACT.
valve connector.
Check
Yes
tor?
control solenoid
valve connector.
EN(w/oOBD)-96
No
Contact with your
Subaru distributor
service.
NOTE:
Inspection by your
Subaru distributor
service is required,
because probable
parts.

EN(w/oOBD)-97

L: DTC 38 TORQUE CONTROL SIGNAL

DIAGNOSIS:
Abnormal signal entered from TCM
The harness connector between ECM and TCM is shorted.
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
B56
1 2 3 4
10 11 12 13
19 20 21
B56
5 6
14 15
7
16
22
8
17
23
9
18
24
5
14
TCM
B135
16
17
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
B135 ECM
EN1461
EN(w/oOBD)-98

Step
TCM CONNECTOR.
TCM.
TCM CONNECTOR.
Check
?
Yes
No
ECM and TCM
connector.
Is there resistance less than 10 Repair the ground

?
ECM and TCM
connector.
EN(w/oOBD)-99
Replace the TCM.

<Ref. to AT-46,
(TCM).>

M: DTC 45 PRESSURE SENSOR

DIAGNOSIS:
The pressure sensor signal is abnormal.
The harness connector between ECM and pressure sensor is open or shorted.
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
E20
1 2 3 4
1
3
2
INTAKE AIR
TEMPERATURE
AND
PRESSURE
SENSOR
E20
B122
1 2 3
4 5 6
LHD:
B21
E20
1 2 3
4 5 6
RHD:
LHD
RHD
B83
1 2 3 4 5 6 7 8 9 10 11 12
4
1
LHD
B83
15
9
12
14
E2
5
4
1
3
RHD
B122
LHD
RHD
4
7
B21
B83
LHD
RHD
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
B136
5
25
16
15
13
B83
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
B136 ECM
EN1458
EN(w/oOBD)-100

Step
1)Disconnect the connector from pressure
sensor.
3)Measure the voltage between pressure sensor connector and engine ground.
(B136) No. 16 (E20) No. 1:
(B136) No. 5 (E20) No. 4:
2)Connect the connector to ECM and pressure
sensor.
chassis ground.
chassis ground.
CHECK POOR CONTACT.
Check
Yes
5.5 V?
No
Repair the open or
between ECM and
pressure sensor.

?
Go to step 3.
Repair the open

circuit in harness
between ECM and
pressure sensor
connector.

M?
Go to step 4.
Repair the ground

ECM and pressure
sensor connector.

2.5 V?
Replace the pressure sensor. <Ref.

to FU(w/oOBD)38, Intake Air
Temperature and
Pressure Sensor.>

1.8 V?

Temperature and
Pressure Sensor.>
Temperature and
Pressure Sensor.>
EN(w/oOBD)-101
Repair the poor

contact in pressure sensor connector.

N: DTC 46 CO RESISTOR (GENERAL SPEC. VEHICLES)

DIAGNOSIS:
The CO resistor signal is abnormal.
The harness connector between ECM and CO resistor is open or shorted.
The CO value is not adjusted to specifications.
TROUBLE SYMPTOM:
Erroneous idling
Mixture ratio is too rich or too lean.
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
CO RESISTOR
B28
1
2
3
1 2 3
B28
B83
1 2 3 4 5 6 7 8 9 10 11 12
LHD
RHD
5
1
LHD
B122
6
4
B136
B83
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
RHD
B122
15
12
16
1 2 3
4 5 6
B136 ECM
EN1462
EN(w/oOBD)-102

Step
chassis ground.
CHECK POOR CONTACT.
CHECK HARNESS BETWEEN CO RESISTOR AND ECM CONNECTOR.

2)Disconnect the connector from ECM and CO
resistor.
ECM and CO resistor connector.
(B136) No. 15 (B155) No. 1:
(B136) No. 12 (B155) No. 2:
(B136) No. 16 (B155) No. 3:
CHECK HARNESS BETWEEN CO RESISTOR AND ECM CONNECTOR.
CHECK CO RESISTOR.
Measure the resistance between CO resistor
terminals.
Terminals
No. 1 No. 3:
CHECK CO RESISTOR.
Measure the variable resistance between CO
resistor terminals while rotating the screw of
CO resistor.
Terminals
No. 1 No. 2:
Check
Yes
4.5 V?
No
Go to step 2.

connector?
Repair the poor

contact in ECM
connector.

?
Go to step 4.
Replace the ECM.

<Ref. to FU(w/
oOBD)-48, Engine
Control Module.>
Repair the open
circuit in harness
between ECM and
CO resistor connector.

M?
Go to step 5.
Repair the short

circuit in harness
between ECM and
CO resistor connector.

and 6 k?
Go to step 6.
Replace the CO
resistor.

and 6 k?
Replace the ECM. Replace the CO

resistor.
EN(w/oOBD)-103
NOTE:
Ensure resistance
varies in response
to screw rotation.

O: DTC 51 NEUTRAL POSITION SWITCH (MT VEHICLE)

DIAGNOSIS:
The neutral position switch signal is abnormal.
The harness connector between ECM and neutral position switch is open or shorted.
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
B135 ECM
B25
26
1 2
B25
B22
T2
1
5
9
13
NEUTRAL
POSITION
SWITCH
2
6
10
14
3
7
11
15
4
8
12
16
T2
16
B25
B135
B22
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
E3
EN1463
EN(w/oOBD)-104

Step
chassis ground.
CHECK POOR CONTACT.

harness.
3)Measure the resistance between transmission harness and connector terminals.
(T2) No. 1 No. 2:
harness connector terminals.
(T2) No. 1 No. 2:
ECM and transmission harness connector.
(B135) No. 26 (B25) No. 1:
chassis ground.
CHECK POOR CONTACT.
Check
Yes
5.5 V in neutral position?
No
Go to step 2.
Is the voltage less than 1 V in

other positions?
Go to step 3.
Go to step 4.

connector?
Repair the poor

contact in ECM
connector.

M in neutral position?
Go to step 5.
Replace the ECM.

<Ref. to FU(w/
oOBD)-48, Engine
Control Module.>
Repair the short
replace neutral
position switch.

in other positions?
Go to step 6.

?
Go to step 7.

?

connector.

connector?
Repair poor contact in ECM connector.
EN(w/oOBD)-105
Repair the open

replace neutral
position switch.
Repair the open
circuit in harness
between ECM and
transmission harness connector.
Replace the ECM.

<Ref. to FU(w/
oOBD)-48, Engine
Control Module.>

P: DTC 51 PARK/NEUTRAL POSITION SWITCH (AT VEHICLE)

DIAGNOSIS:
The park/neutral position switch signal is abnormal.
The shift cable is connected abnormally.
The harness connector between ECM/TCM and inhibitor switch is open or shorted.
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
EN1464
EN(w/oOBD)-106

Step
positions.
CHECK POOR CONTACT.
Check
Yes
Go to step 2.
No
Go to step 3.

connector?
Repair the poor

contact in ECM
connector.
Go to step 4.
Go to step 3.
?
HIBITOR SWITCH CONNECTOR.
inhibitor switch.
(B135) No. 26 (T7) No. 12:
CHECK INHIBITOR SWITCH GROUND LINE.

CHECK POOR CONTACT.

?
Go to step 5.

?
Repair the ground

connector.
Repair the poor
contact in ECM
connector.

connector?
EN(w/oOBD)-107

NOTE:
the following:
Open circuit in
harness between
ECM and inhibitor
switch connector
Poor contact in
coupling connector
(B12)
Poor contact in
inhibitor switch
connector
Poor contact in
ECM connector
Repair the open
circuit in inhibitor
switch ground line.
Go to step 6.
Replace the ECM.

<Ref. to FU(w/
oOBD)-48, Engine
Control Module.>

Q: DTC 85 CHARGE SYSTEM

DIAGNOSIS:
Power source voltage of the ECM is low or high.
TROUBLE SYMPTOM:
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
GENERATOR
SBF-1
MAIN RELAY
5
3
RHD
RHD
6
4
LHD
LHD
2
B61
BATTERY
SBF-5
F44
2
1
1
2
B47
B136 ECM
B47
1
3
5
2
4
6
F44
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
23 24 25
26 27
28 29 30
21 22
EN1465
EN(w/oOBD)-108

Step
CHECK GENERATOR.
1)Start the engine.
Terminal
ground ():
CHECK GENERATOR.
Terminal
ground ():
Check
Is the voltage between 10.8 V
and 16.2 V?
Yes
Go to step 2.
No
Repair the generator. <Ref. to SC14, Generator.>

and 16.2 V?
Go to step 3.

clamped?
and 16.2 V?
Go to step 4.
Tighten the clamp

of terminal.
Go to step 5.

between battery,
main relay and
ECM.
Go to step 6.
Go to step 7.
Proceed with the

DTC.
A temporary poor
contact.

CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in the
connectors between generator,
battery and ECM?
CHECK ECM.
Is the same DTC as in the cur1)Connect all connectors.
rent diagnosis still being out2)Erase the memory. <Ref. to EN(w/oOBD)put?
30, OPERATION, Clear Memory Mode.>
EN(w/oOBD)-109


A: INSPECTION
NOTE:
Malfunction of parts other than those listed is also possible.
The right-hand priority column indicates inspection priority of probable causes of the symptom. Carry out
the check starting from A.
Symptom
1. Engine does not start. (Internal combustion does
not occur.)
2. Engine does not start. (Internal combustion

occurs.)
3. Engine does not start. (Engine stalls after internal

combustion.)
4. Engine stalls.
Problem parts
1) ECM power supply
2) Engine ground cable
3) Crankshaft position sensor
4) Camshaft position sensor
5) Fuel pump
6) Pressure regulator
7) Ignition coil & ignitor
8) Spark plug
9) Fuel injector
1) ECM power supply
2) Spark plug
5) Pressure sensor
6) Fuel pump
7) Fuel injector
1) ECM power supply
2) Pressure sensor
4) Spark plug
5) Ignition coil
6) Fuel pump
8) Fuel injector
2) Pressure sensor
3) Spark plug
4) Accelerator cable is out of adjustment
5) ECM power supply
8) Vehicle speed sensor
9) Ignition coil
10) Fuel pump
EN(w/oOBD)-110
Priority
A
A
B
B
B
B
C
C
C
A
A
B
B
C
C
C
C
C
C
A
A
B
B
C
C
C
C
C
A
B
B
B
C
C
C
C
C
C

Symptom
5. Rough idling
6. Hard to drive at constant speed
7. Poor acceleration/deceleration
8. Poor return to idling
9. Back fire
10. Knocking
11. Excessive fuel consumption

12. Shocks while driving
Problem parts
1) Spark plug
2) Pressure sensor
6) Air leak in air intake system
7) ECM power supply
11) Oxygen sensor
12) Fuel pump
13) Fuel injector
14) Test mode or read memory connectors are connected
2) Fuel injector
3) Pressure sensor
6) Fuel pump
1) Spark plug
3) Ignition coil
4) Fuel pump
6) Fuel injector
7) Pressure sensor
10) Knock sensor
1) Accelerator cable is out of adjustment
4) Pressure sensor
1) Spark plug
2) Fuel injector
3) Ignition coil and ignitor
4) Fuel pump
1) Pressure sensor
2) Fuel pump
3) Knock sensor
1) Pressure sensor
2) ECM power supply
EN(w/oOBD)-111
Priority
A
B
B
B
B
B
C
C
C
C
C
C
C
C
C
A
B
C
C
C
C
A
B
B
B
B
B
C
C
C
C
A
B
B
C
C
A
B
C
C
C
A
B
B
B
C
A
B
A
B
B

Symptom
13. Poor engine revving
14. Remarks
Problem parts
2) Pressure sensor
4) Throttle sensor
5) Fuel pump
1) ECM power supply
2) Pressure sensor
5) Air leak in air intake system
A*: Including ECM ground circuit

B*: Check hoses.
EN(w/oOBD)-112
Priority
A
B
B
B
B
A*
B*
B*
B*
B*
FU(TURBO)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Page
Throttle Body.............................................................................................14
Intake Manifold..........................................................................................15
Knock Sensor............................................................................................32
Mass Air Flow and Intake Air Temperature Sensor ..................................34
Pressure Sensor .......................................................................................35
Fuel Injector ..............................................................................................37
Tumble Generator Valve Assembly ..........................................................41
Tumble Generator Valve Actuator.............................................................42
Wastegate Control Solenoid Valve ...........................................................43
Front Oxygen (A/F) Sensor .......................................................................44
Rear Oxygen Sensor.................................................................................46
Exhaust Temperature Sensor ...................................................................48
Main Relay ................................................................................................50
Fuel Pump Relay.......................................................................................51
Fuel Pump Controller ................................................................................52
Fuel ...........................................................................................................53
Fuel Tank ..................................................................................................54
Fuel Filler Pipe ..........................................................................................56
Fuel Pump.................................................................................................60
Fuel Filter ..................................................................................................65
Fuel Cut Valve...........................................................................................66
GENERAL DESCRIPTION
A: SPECIFICATIONS
Fuel tank
Fuel pump

Discharge flow
Fuel filter
60 2 (15.9 US gal, 13.2 Imp gal)

Under rear seat
Impeller
Capacity
Location
Type
450 677 kPa (4.59 6.9 kg/cm2, 65.27 98.2 psi)

[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
Cartridge type
FU(TURBO)-2
GENERAL DESCRIPTION
FU(TURBO)-3
GENERAL DESCRIPTION
B: COMPONENT
1. INTAKE MANIFOLD
T6
T2
(19)
(18)
T6
(22)
(17)
T6
T3
T6
T3
(20)
(16)
(24)
T3
T6
(23)
(21)
T6
(14)
T5
(15)
(26)
T5
(26)
(12)
(13)
T7
(25)
T7
T1
T6
(12)
(11)
(27)
(8)
(27)
T1
(10)
(8)
(9)
(11)
(7)
(6)
T6
T4
(16)
(5)
(4)
(2)
(9)
(3)
(1)
T1
(10)
(14)
(15)
(3)
(2)
T1
(3)
(2)
EN1389
FU(TURBO)-4
GENERAL DESCRIPTION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Fuel pipe ASSY

Fuel hose
Clip
Vacuum hose
Vacuum control hose
Purge valve
Purge hose
Intake manifold gasket
Guide pin
Tumble generator valve ASSY
Tumble generator valve gasket
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)

Fuel injector
Insulator
Fuel injector pipe
Pressure regulator
Pressure regulator hose
Blow-by hose stay
Intake manifold
Solenoid valve cover
Solenoid valve cover stay
Wastegate control solenoid valve
ASSY
FU(TURBO)-5
(25)
(26)
(27)

Nipple
Tumble generator valve actuator

T1: 4.9 (0.5, 3.6)
T2: 6.4 (0.65, 4.7)
T3: 8.25 (0.84, 6.1)
T4: 16 (1.6, 11.8)
T5: 17 (1.7, 12.5)
T6: 19 (1.9, 14.0)
T7: 25 (2.5, 18.4)
GENERAL DESCRIPTION
T1
(3)
T2
(5)
(7)
(6)
T3
(1)
(2)
(4)
T1
EN1134
(1)
(2)
(3)
(4)
Gasket
Throttle body
(5)
(6)
(7)
Pressure sensor
Gasket
O-ring
FU(TURBO)-6

T1: 1.6 (0.16, 1.2)
T2: 2.8 (0.29, 2.1)
T3: 22 (2.2, 16.2)
GENERAL DESCRIPTION
T2
(3)
T1
T1
(1)
(2)
EN0780
(1)
(2)

Knock sensor
(3)
FU(TURBO)-7

T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)
GENERAL DESCRIPTION
4. FUEL TANK
T1
T1
E
(10)
(30)
(17)
(11)
(9)
(7)
(12)
(12)
D
(12)
C
(15)
(14)
(8)
(29)
T1
T1
(13)
(29)
(12)
D
(9)
(28)
(6)
(16)
(12)
(12)
(22)
(19)
(5)
(18)
(21) (20)
(27)
(12)
(8)
(12)
(12)
(23)
(12)
(24)
(2)
T3
(20)
T3
(12)
(25)
(4)
(2)
T2
T2
(1)
(3)
T2
T2
EN0998
FU(TURBO)-8
GENERAL DESCRIPTION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Heat shield cover

Fuel tank band
Protector LH
Protector RH
Fuel tank
Fuel pump gasket
Fuel pump ASSY
Fuel meter unit
Fuel cut valve
Evaporation hose A
Clip
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
Evaporation hose B
Joint pipe
Evaporation hose C
Evaporation pipe
Evaporation hose D
Fuel return hose A
Retainer
Quick connector
Evaporation hose E
Fuel pipe ASSY
Evaporation hose F
FU(TURBO)-9
(25)
(26)
(27)
(28)
(29)
(30)
Fuel return hose B

Jet pump filter
Fuel sub meter unit
Evaporation hose G
Evaporation hose H

T1: 4.4 (0.45, 3.3)
T2: 7.4 (0.75, 5.4)
T3: 33 (3.4, 24.3)
GENERAL DESCRIPTION
5. FUEL LINE
(19)
B
(24)
(18)
(20)
(17)
(16)
(15)
(24)
(25)
(22)
(21) (13)
T
(23)
(14)
B
C
A
(1)
(1)
C
(12)
(8)
(1) (1) (10)
(9)
(1)
(1)
(1)
(1)
(10)
(11)
(7)
(1)
(6)
(2)
(1)
(5)
(4)
(3)
EN0440
FU(TURBO)-10
GENERAL DESCRIPTION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Clip
Fuel filter bracket
Fuel filter holder
Fuel filter cup
Fuel filter
Evaporation hose
Fuel damper
Fuel return hose
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Fuel pipe ASSY

Grommet
Canister hose A
Canister
Cushion
Two-way valve
FU(TURBO)-11
(21)
(22)
(23)
(24)
(25)

Connector
Clamp

T: 23 (2.3, 17.0)
GENERAL DESCRIPTION
6. FUEL FILLER PIPE
(9)
(8)
(10)
(11)
T
(1)
(3)
(2)
(5)
T
(3)
T
(6)
T
(4)
(3)
(7)
EN0441
(1)
(2)
(3)
(4)
(5)

Clip
Clamp
Air vent hose
(6)
(7)
(8)
(9)
(10)
Air vent pipe

Filler pipe packing
Filler ring
Filler cap
FU(TURBO)-12
(11)

T: 7.5 (0.76, 5.5)
GENERAL DESCRIPTION
C: CAUTION

points.
cable from battery.
D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
24082AA190
(Newly adopted
tool)
DESCRIPTION
CARTRIDGE
REMARKS
SELECT MONITOR KIT

B2M3876
22771AA030
B2M3877
FU(TURBO)-13
THROTTLE BODY
2. Throttle Body
A: REMOVAL
EN0784
G6M0095
2) Remove the intercooler. <Ref. to IN(TURBO)10, REMOVAL, Intercooler.>

3) Disconnect the connector from the throttle position sensor (A) and idle air control solenoid valve
(B) and pressure sensor (C).
6) Remove the bolts which secure throttle body to

intake manifold.
B: INSTALLATION
NOTE:
Tightening torque:
22 Nm (2.2 kgf-m, 16.2 ft-lb)
(B)
(C)
(A)
EN0782
4) Disconnect the accelerator cable.

EN0785
H2M1890
FU(TURBO)-14
INTAKE MANIFOLD
3. Intake Manifold
A: REMOVAL
1) Release the fuel pressure. <Ref. to FU(TURBO)-53, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>
cap.
12) Remove the power steering pump.

<Ref. to ME(TURBO)-44, REMOVAL, V-belt.>
(2) Disconnect the power steering switch connector.
EN0360
(3) Remove the bolts which secure power

steering pipe brackets to intake manifold.
G6M0095

6) Drain the coolant about 3.0 2 (3.2 US qt, 2.6
Imp qt).
NOTE:
S2M2248
(4) Remove the bolts which secure power

steering pump bracket.
EN0073
7) Remove the air cleaner upper cover and air intake boot. <Ref. to IN(TURBO)-7, REMOVAL, Air
Cleaner.>
10) Disconnect the accelerator cable.
H2M1954
H2M1890
11) Remove the coolant filler tank. <Ref. to CO-53,

REMOVAL, Coolant Filler Tank.>
FU(TURBO)-15
INTAKE MANIFOLD

EN0204
EN0361
16) Disconnect the pressure hose from intake duct.

wheel apron.
EN0787
EN0208
17) Disconnect the engine harness connectors

from bulkhead harness connectors.
13) Disconnect the emission hose from PCV valve.
EN0788
EN0789
14) Disconnect the engine coolant hoses from

throttle body.
S2M2260
EN0784
FU(TURBO)-16
INTAKE MANIFOLD
18) Disconnect the connectors from the engine

coolant temperature sensor (A), oil pressure switch
(B) and crankshaft position sensor (C).
22) Disconnect the engine harness fixed by clip (A)

from the bracket.
(A)
(B)
(C)
S2M2256A
EN0790

WARNING:
Do not spill fuel.
cloth.
S2M1613

EN0214
24) Remove the bolts which secure intake manifold

to the cylinder heads.
B2M1251
21) Disconnect the connector from ignition coil.

EN0792
EN0854
FU(TURBO)-17
INTAKE MANIFOLD
B: INSTALLATION
4) Connect the connector to knock sensor.

NOTE:
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
S2M1613
EN0792
2) Connect the fuel delivery hose, return hose, and

evaporation hose.
B2M1251
6) Connect the connector to ignition coil.
EN0214
3) Connect the connector to the oil pressure switch

(B), crankshaft position sensor (C) and engine
coolant temperature sensor (A).
EN0854
(A)
7) Connect the engine harness with clip (A) to the

bracket.
(B)
(C)
EN0790
S2M2256A
FU(TURBO)-18
INTAKE MANIFOLD
8) Connect the engine harness connector to bulkhead harness connectors.
11) Connect the emission hose to PCV valve.
EN0789
EN0788
12) Connect the pressure hose to intake duct.
EN0787
S2M2260
9) Connect the brake booster vacuum hose.
13) Install the power steering pump.

EN0204
10) Connect the engine coolant hoses to throttle

body.
EN0361

pump switch.
EN0784
EN0360
FU(TURBO)-19
INTAKE MANIFOLD
(3) Install the power steering pump, and then

tighten the bolts.
Tightening torque:
22 Nm (2.2 kgf-m, 16.2 ft-lb)
EN0344

H2M1954
(4) Install the power steering pipe brackets on

right side intake manifold.
G6M0095
EN0206

23) Fill the coolant. <Ref. to CO-26, FILLING OF
ENGINE COOLANT, Engine Coolant.>
(5) Install the front side V-belt.

<Ref. to ME(TURBO)-44, REMOVAL, V-belt.>
14) Install the cooler filler tank. <Ref. to CO-53, INSTALLATION, Coolant Filler Tank.>
15) Connect the accelerator cable.
H2M1890
16) Install the intercooler. <Ref. to IN(TURBO)-11,

INSTALLATION, Intercooler.>
17) Install the air cleaner element.
18) Install the air cleaner upper cover and air intake
duct as a unit. <Ref. to IN(TURBO)-7, INSTALLATION, Air Cleaner.>
FU(TURBO)-20
INTAKE MANIFOLD
C: DISASSEMBLY
4) Disconnect the connector from the throttle position sensor (A), idle air control solenoid valve (B)
and pressure sensor (C).
5) Disconnect the engine harness fixed by clip (D)
from the intake manifold.
EN0793

S2M2249A
6) Remove the throttle body from intake manifold.
EN0794
3) Remove the engine ground cable from intake

manifold.
EN0785
EN0795
EN0798
8) Disconnect the connector from tumble generator

valve actuator.
EN0796
EN0799
FU(TURBO)-21
INTAKE MANIFOLD

valve sensor.
13) Disconnect the evaporation hoses from purge

valve.
EN0800

solenoid valve.
EN0804

EN0801
EN0802
12) Disconnect the evaporation hose from intake

manifold.
EN0803
FU(TURBO)-22
EN0805
INTAKE MANIFOLD
15) Remove the bolts which hold fuel injector pipe

onto intake manifold.
LH SIDE
16) Remove the fuel injector.
EN0810
EN0806
17) Remove the harness bracket which holds engine harness onto intake manifold.
EN0811
EN0807
RH SIDE

clamp.
EN0808
EN0812
20) Remove the fuel injector pipe LH.

21) Remove the bolts which install fuel pipe on intake manifold.
EN0809
EN0813
FU(TURBO)-23
INTAKE MANIFOLD
22) Remove the fuel pipe assembly and pressure

regulator from intake manifold.
23) Remove the intake duct from intake manifold.
2) Install the air intake duct to intake manifold.

Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
EN1115
EN1115
24) Remove the tumble generator valve assembly

3) Install the fuel pipe assembly and pressure regulator to intake manifold.
Tightening torque:
4.9 Nm (0.5 kgf-m, 3.6 ft-lb)
EN0815
D: ASSEMBLY
NOTE:
1) Install the tumble generator valve assembly to
intake manifold.
EN0813
4) Install the fuel injector pipe LH.

Tightening torque:
8.25 Nm (0.84 kgf-m, 6.1 ft-lb)
EN0812
EN0815
6) Install the engine harness to intake manifold.
FU(TURBO)-24
INTAKE MANIFOLD
7) Install the harness bracket which holds engine

harness onto intake manifold.
9) Tighten the bolts which install fuel injector pipe

onto intake manifold.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
LH SIDE
EN0811
EN0806
8) Install the fuel injector.
EN0807
EN0810
RH SIDE
EN0808
EN0809
FU(TURBO)-25
INTAKE MANIFOLD

12) Connect the evaporation hose to intake manifold.
Tightening torque:
4.9 Nm (0.5 kgf-m, 3.6 ft-lb)
EN0803

EN0805
11) Connect the evaporation hoses to purge valve.
Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
CAUTION:
(B)
(A)
EN0802

valve.
CAUTION:
(C)
(D)
(A)
EN0816
(A)
(B)
(C)
(D)
To fuel pipe ASSY

To intake duct
To purge control solenoid valve
To intake manifold
(B)
(A) To intake manifold

(B) To purge valve
FU(TURBO)-26
EN0817
INTAKE MANIFOLD
15) Connect the connector to purge control solenoid valve.

NOTE:
Tightening torque:
22 Nm (2.2 kgf-m, 16.2 ft-lb)
EN0801
16) Connect the connector to tumble generator

valve sensor.
EN0785
20) Connect the connector to the throttle position

sensor (A), idle air control solenoid valve (B) and
pressure sensor (C).
21) Connect the engine harness with clip (D) to the
intake manifold.
EN0800
17) Connect the connector to tumble generator

valve actuator.
S2M2249A
EN0799
18) Connect the connector to fuel injector.
EN0798
FU(TURBO)-27
INTAKE MANIFOLD

Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)

Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
EN0793
EN0795
E: INSPECTION
EN0796

Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
EN0794
FU(TURBO)-28


Sensor
B: INSTALLATION
A: REMOVAL
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
G6M0095
2) Remove the generator <Ref. to SC-14, REMOVAL, Generator.>

temperature sensor.
EN0851
FU(TURBO)-29

B: INSTALLATION
A: REMOVAL
Tightening torque:
T: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
G6M0095
G2M0408
3) Remove the crankshaft position sensor, and disconnect the connector from it.
G2M0409
FU(TURBO)-30
B2M1252B

B: INSTALLATION
A: REMOVAL
Tightening torque:
T: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
G6M0095
G2M0416
3) Remove the camshaft position sensor from camshaft support LH.
G2M0417
FU(TURBO)-31
G2M0417
KNOCK SENSOR
7. Knock Sensor
B: INSTALLATION
A: REMOVAL
Tightening torque:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
NOTE:
G6M0095

H2M3511C
(A) Front side
B2M4262
B2M4262

S2M1673
G6M0095
FU(TURBO)-32

B: INSTALLATION
A: REMOVAL
Tightening torque:
1.6 Nm (0.16 kgf-m, 1.2 ft-lb)
G6M0095

sensor.
EN0819

EN0820
FU(TURBO)-33
EN0820
MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR

9. Mass Air Flow and Intake Air

Temperature Sensor
B: INSTALLATION
A: REMOVAL
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
G6M0095
2) Disconnect the connector mass air flow and intake air temperature sensor.
3) Remove the mass air flow and intake air temperature sensor.
EN1045
FU(TURBO)-34
PRESSURE SENSOR
10.Pressure Sensor
B: INSTALLATION
A: REMOVAL
NOTE:
Replace the O-ring for the pressure sensor with
new ones.
Tightening torque:
1.6 Nm (0.16 kgf-m, 1.2 ft-lb)
G6M0095
2) Remove the idle air control solenoid valve. <Ref.

to FU(TURBO)-36, REMOVAL, Idle Air Control Solenoid Valve.>
3) Disconnect the connectors from pressure sensor.
EN0821
4) Remove the pressure sensor from throttle body.
FU(TURBO)-35


Valve
B: INSTALLATION
A: REMOVAL
NOTE:
Tightening torque:
2.8 Nm (0.29 kgf-m, 2.1 ft-lb)
G6M0095

solenoid valve.
EN0822

throttle body.
EN0823
4) Remove the gasket from throttle body.
EN1122
FU(TURBO)-36
EN0823
FUEL INJECTOR
12.Fuel Injector
A: REMOVAL
1. RH SIDE
cap.
EN0808
G6M0095
4) Remove the intake manifold. <Ref. to FU(TURBO)-15, REMOVAL, Intake Manifold.>

EN0809
8) Remove the fuel injector while lifting up the fuel

injector pipe.
EN0794
EN0798
FU(TURBO)-37
EN0810
FUEL INJECTOR
2. LH SIDE
cap.
EN0805
G6M0095

EN0807
EN0793

EN0806
8) Remove the fuel injector while lifting up the fuel

injector pipe.
EN0798
EN0824
FU(TURBO)-38
FUEL INJECTOR
B: INSTALLATION
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
1. RH SIDE
NOTE:
Replace the O-ring and insulators with new ones.
EN0794
2. LH SIDE
S2M2250A
NOTE:
Replace the O-ring and insulators with new ones.
(A) O-ring
(B) Fuel injector
(C) Insulator
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
S2M2250A
(A) O-ring
(B) Fuel injector
(C) Insulator
EN0808
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
Tightening torque:
4.9 Nm (0.5 kgf-m, 3.6 ft-lb)
EN0805
EN0809
FU(TURBO)-39
FUEL INJECTOR
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
EN0806
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
EN0807
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
EN0793
FU(TURBO)-40
TUMBLE GENERATOR VALVE ASSEMBLY

13.Tumble Generator Valve Assembly
8) Remove the tumble generator valve body from

intake manifold.
A: REMOVAL
cap.
EN0815
B: INSTALLATION
NOTE:
Tightening torque:
8.25 Nm (0.84 kgf-m, 6.1 ft-lb)
G6M0095

valve sensor.
EN0815
EN0800

valve actuator.
EN0799
7) Remove the fuel injector. <Ref. to FU(TURBO)37, REMOVAL, Fuel Injector.>
FU(TURBO)-41
TUMBLE GENERATOR VALVE ACTUATOR

14.Tumble Generator Valve Actuator
3) Remove the tumble generator valve actuator LH.
A: REMOVAL
1. RH SIDE
cap.
EN1391
B: INSTALLATION
1. RH SIDE
2. LH SIDE
G6M0095

valve actuator RH.
6) Remove the tumble generator valve RH.
EN1390
2. LH SIDE
G6M0095

valve LH.
FU(TURBO)-42
WASTEGATE CONTROL SOLENOID VALVE

15.Wastegate Control Solenoid

Valve
5) Remove the wastegate control solenoid valve

from bracket
A: REMOVAL
EN0830
B: INSTALLATION
G6M0095

Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
2) Remove the solenoid valve cover.
EN0828
3) Disconnect the connector (A) from wastegate

4) Disconnect the pressure hoses (B) from wastegate control solenoid valve.
(A)
(B)
EN0829
FU(TURBO)-43
EN0830

16.Front Oxygen (A/F) Sensor
A: REMOVAL
EN0832
G6M0095

threaded portion of front oxygen (A/F) sensor, and
leave it for 1 minute or more.
9) Remove the front oxygen (A/F) sensor.
CAUTION:
When removing the oxygen (A/F) sensor, wait
until the exhaust pipe cools, otherwise it will
damage exhaust pipe.
EN0828
3) Disconnect the connector from front oxygen

(A/F) sensor.
EN0833
EN0831
4) Disconnect the engine harness fixed by clip (A)

from the bracket (B).
S2M2253A
5) Remove the front right side wheel.

FU(TURBO)-44

B: INSTALLATION
1) Before installing the 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.
7) Connect the connector of front oxygen (A/F)

sensor.
SS-30 by 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.
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
EN0831
8) Install the solenoid valve cover.
EN0828
EN0833
3) Install the service hole cover.
EN0832

5) Install the front right side wheel.
6) Connect the engine harness with clip (A) to the
bracket (B).
S2M2253A
FU(TURBO)-45
G6M0095
REAR OXYGEN SENSOR

17.Rear Oxygen Sensor
6) Remove the rear oxygen sensor.
A: REMOVAL
CAUTION:
G6M0095

3) Disconnect the connector from rear oxygen sensor.
EN0835
B: INSTALLATION
1) Before installing the rear oxygen sensor, apply
anti-seize compound only to the threaded portion of
rear oxygen sensor to make the next removal easier.
CAUTION:
Never apply anti-seize compound to the protector of rear oxygen sensor.
EN0834
4) Remove the clip by pulling out from the upper

side of crossmember.
SS-30 by JET LUBE
2) Install the rear oxygen sensor.
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
EN0835
S2M2254

threaded portion of rear oxygen sensor, and leave
it for 1 minute or more.
EN0834
FU(TURBO)-46
REAR OXYGEN SENSOR

4) Connect the clip to crossmember.
S2M2254

G6M0095
FU(TURBO)-47
EXHAUST TEMPERATURE SENSOR

18.Exhaust Temperature Sensor
B: INSTALLATION
A: REMOVAL
1) Before installing the exhaust temperature sensor, apply anti-seize compound only to the threaded portion of rear oxygen sensor to make the next
removal easier.
CAUTION:
Never apply anti-seize compound to the protector of exhaust temperature sensor.
SS-30 by JET LUBE
2) Install the exhaust temperature sensor.
G6M0095
2) Remove the joint pipe. <Ref. to EX(TURBO)-12,

REMOVAL, Joint Pipe.>
threaded portion of exhaust temperature sensor,
and leave it for 1 minute or more.
NOTE:
Align the marking (A) of exhaust temperature sensor to the marking (B) of joint pipe, and tighten the
screws.
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)

4) Remove the exhaust temperature sensor.
CAUTION:
When removing the exhaust temperature sensor, wait until the exhaust pipe cools, otherwise
it will damage exhaust pipe.
S2M2255A
3) Install the joint pipe <Ref. to EX(TURBO)-12, INSTALLATION, Joint Pipe.>.

EN0836
G6M0095
FU(TURBO)-48

B: INSTALLATION
A: REMOVAL
CAUTION:
G6M0095

EN1188

(A)
(A)
(B)
EN1189

the ECM.
FU(TURBO)-49
MAIN RELAY
20.Main Relay
B: INSTALLATION
A: REMOVAL
G6M0095

on body.
EN0534
FU(TURBO)-50
FUEL PUMP RELAY

21.Fuel Pump Relay
B: INSTALLATION
A: REMOVAL
G6M0095

bracket on body.
EN0535

bracket.
FU(TURBO)-51
FUEL PUMP CONTROLLER

22.Fuel Pump Controller
B: INSTALLATION
A: REMOVAL
G6M0095
2) Remove the rear quarter trim. <Ref. to EI-46,

REMOVAL, Rear Quarter Trim.>
3) Disconnect the connector from fuel pump control
unit.
EN0837
4) Remove the fuel pump control unit.
EN0838
FU(TURBO)-52
FUEL
23.Fuel

A: OPERATION
WARNING:
EN0839

Tightening torque:
26 Nm (2.7 kgf-m, 19.2 ft-lb)
EN0344

2. DRAINING FUEL
WARNING:
G6M0095
cap.
FU(TURBO)-53
EN0839
FUEL TANK
24.Fuel Tank

A: REMOVAL
WARNING:
3) Drain fuel from the fuel tank. <Ref. to FU(TURBO)-53, DRAINING FUEL, OPERATION, Fuel.>
rear harness.
EN0539
10) Move the clips, and disconnect quick connector. <Ref. to FU(TURBO)-68, REMOVAL, Fuel Delivery, Return and Evaporation Lines.>
(B)
(A)

from canister.
(A)
EN0540
EN0537

WARNING:
(B)
EN0840
EN0541
B: INSTALLATION
grommet.
FU(TURBO)-54
FUEL TANK

WARNING:

Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
EN0541
EN0541

(A)

8) Connect the connector (A) to fuel tank cord and
plug the service hole with grommet (B).
(B)
(B)
EN0840
(A)
EN0537

EN0539
5) Connect the fuel hoses, and secure them with

clips and quick connector. <Ref. to FU(TURBO)69, INSTALLATION, Fuel Delivery, Return and
Evaporation Lines.>
EN0344
C: INSPECTION
EN0540
FU(TURBO)-55
FUEL FILLER PIPE

25.Fuel Filler Pipe
tank.
A: REMOVAL
WARNING:
cap.
EN0839
Tightening torque:
26 Nm (2.7 kgf-m, 19.2 ft-lb)
G6M0095
EN0839
EN0542
6) Loosen the rear right side wheel nuts.

EN0544

fuel filler pipe.
B2M1748
EN0545
FU(TURBO)-56
FUEL FILLER PIPE


pipe.
B: INSTALLATION
side of apron.
NOTE:
EN0546
14) Remove the bolts which hold fuel filler pipe

bracket on body.
B2M1196A
EN0547

(A)
EN0549
(B)
EN0548

vehicle.
from body.
EN0546
EN0549
FU(TURBO)-57
FUEL FILLER PIPE



CAUTION:
(A)
(B)
EN0545
EN0548

and hold clip.
L = 27.52.5 mm (1.0830.098 in)
EN0544
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
B2M1748
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)

EN0344
EN0547
FU(TURBO)-58
FUEL FILLER PIPE

G6M0095
FU(TURBO)-59
FUEL PUMP
26.Fuel Pump
A: REMOVAL
Tightening torque:
26 Nm (2.7 kgf-m, 19.2 ft-lb)
WARNING:
NOTE:
level sensor.
cap.
EN0839

G6M0095

tank.
EN0553
S2M0172
EN0839
10) Disconnect the quick connector and then disconnect fuel delivery hose (A). <Ref. to FU(TURBO)-68, Fuel Delivery, Return and Evaporation
Lines.>
FU(TURBO)-60
FUEL PUMP
B: INSTALLATION
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
S2M0060A
S2M0063A
C: INSPECTION
S2M0061

WARNING:
as possible.
G2M0366
FU(TURBO)-61
FUEL LEVEL SENSOR

B: INSTALLATION
A: REMOVAL
WARNING:
NOTE:
Fuel level sensor is built in fuel pump assembly.
1) Remove the fuel pump assembly. <Ref. to
FU(TURBO)-60, REMOVAL, Fuel Pump.>
S2M0145

EN0846
FU(TURBO)-62

A: REMOVAL
WARNING:
G2M0863

G6M0095

tank.
S2M0151
9) Remove the bolts which install fuel sub meter

unit on fuel tank.
EN0839

Tightening torque:
26 Nm (2.7 kgf-m, 19.2 ft-lb)
S2M0152
EN0839

S2M0153
FU(TURBO)-63

B: INSTALLATION
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
B2M3178
FU(TURBO)-64
FUEL FILTER
29.Fuel Filter
C: INSPECTION
A: REMOVAL

sediment.
from inlet port.
WARNING:
EN1117
B: INSTALLATION
CAUTION:
new ones.
Tightening torque:
1.25 Nm (0.13 kgf-m, 0.94 ft-lb)
EN1117
FU(TURBO)-65
FUEL CUT VALVE

30.Fuel Cut Valve
B: INSTALLATION
A: REMOVAL
WARNING:
1) Remove the fuel tank. <Ref. to FU(TURBO)-54,
REMOVAL, Fuel Tank.>
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
S2M0177
S2M0176
FU(TURBO)-66
FUEL DAMPER VALVE

B: INSTALLATION
A: REMOVAL
line.
EN0852
FU(TURBO)-67


Evaporation Lines
A: REMOVAL
cap.
EN1392

from canister.
(A)
(B)
S2M0500
EN0840
FU(TURBO)-68


and return line.
covered with dust.
down.

NOTE:
NOTE:
S2M0230A
(A) Connector
(B) Retainer
(C) Pipe
S2M0228A
(A) Connector
(B) Retainer
(C) Pipe
B: INSTALLATION
1) Connect the quick connector on fuel delivery and
return line.
CAUTION:
securely.
NOTE:
S2M0231A
(A) Connector
(B) Retainer
(C) Pipe
S2M0229A
FU(TURBO)-69


2 : 2.51.5 mm (0.0980.059 in)
C: INSPECTION
L: 22.52.5 mm (0.8860.098 in)
B2M1194B
(1) Fitting
(2) Clamp
(3) Hose

L = 17.52.5 mm (0.6890.098 in)
CAUTION:
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
FU(TURBO)-70


A: INSPECTION
1)
Corrective action

2)
3)
4)
5)
6)
7)
1)
2)
3)
4)
5)

1)
filler pipe.
2)
3)
4)
1)
Defective operation of fuel level sensor.
2)
5. Noise
1)
NOTE:
fuel tank.
(2) Drain the water condensation from the fuel
filter.
the tank.
water condensation.
(3) Cold areas:

securely.
Replace.
Retightening.
Replace.
Replace.
Replace.
tube.
Retightening.
Replace.
Replace.
Replace.
Replace.

season, drain the water which may have accumulated in the fuel filter and fuel tank in the manner same as that described under Affected
areas below.
(4) Affected areas:
When the water condensation is notched in the
fuel filter, drain the water from both the fuel filter
and fuel tank or use a water removing agent (or
anti-freeze solution) in the fuel tank.
FU(TURBO)-71

FU(TURBO)-72
EMISSION CONTROL
EC(TURBO)
1.
2.
3.
4.
5.
6.
7.
Page
Precatalytic Converter.................................................................................5
Canister.......................................................................................................6
Two-way Valve............................................................................................8
GENERAL DESCRIPTION
A: CAUTION
points.
cable from battery.
EC(TURBO)-2


A: REMOVAL
1) Remove the center exhaust pipe. <Ref. to
EX(TURBO)-8, REMOVAL, Center Exhaust Pipe.>
2) Separate the front catalytic converter (A) from
rear catalytic converter (B).
(A)
(B)
EN0993
B: INSTALLATION
NOTE:
C: INSPECTION
EC(TURBO)-3


A: REMOVAL
2) Separate the rear catalytic converter (B) from
front catalytic converter (A).
(A)
(B)
EN0993
B: INSTALLATION
NOTE:
C: INSPECTION
EC(TURBO)-4
PRECATALYTIC CONVERTER
4. Precatalytic Converter
A: REMOVAL
Precatalytic converter (A) is built in the joint pipe.
Refer to the removal of joint pipe for removal
procedure. <Ref. to EX(TURBO)-12, REMOVAL,
Joint Pipe.>
(A)
EN0994
B: INSTALLATION
Precatalytic converter is built in the joint pipe. Refer
to the installation of joint pipe for installation procedure. <Ref. to EX(TURBO)-12, INSTALLATION,
Joint Pipe.>
C: INSPECTION
EC(TURBO)-5
CANISTER
5. Canister
A: REMOVAL
from canister.
EN0898
B2M4166
B: INSTALLATION
Tightening torque:
23 Nm (2.3 kgf-m, 17 ft-lb)
B2M4166
C: INSPECTION
cracked or loose.
EC(TURBO)-6

B: INSTALLATION
A: REMOVAL
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
G6M0095

3) Remove the bolt which installs the purge control
solenoid valve onto intake manifold.
EN0899
CAUTION:
(A)
(B)
EN0817
EN0899
(A) To intake manifold

(B) To purge valve
C: INSPECTION
Make sure the hoses are not cracked or loose.
EC(TURBO)-7
TWO-WAY VALVE
7. Two-way Valve
A: REMOVAL
2) Remove the canister from body. <Ref. to
EC(TURBO)-6, REMOVAL, Canister.>
EN0901
B: INSTALLATION
C: INSPECTION
Make sure that the hoses are not cracked or loose.
EC(TURBO)-8
INTAKE (INDUCTION)
IN(TURBO)
1.
2.
3.
4.
5.
6.
7.
8.
Page
Air Cleaner ..................................................................................................7
Air Intake Duct.............................................................................................8
Intake Duct ..................................................................................................9
Intercooler .................................................................................................10
Turbocharger.............................................................................................12
Air By-pass Valve......................................................................................14
Resonator Chamber..................................................................................15
GENERAL DESCRIPTION
INTAKE (INDUCTION)
A: COMPONENT
1. AIR CLEANER
T4
(1)
(2)
T1
(3)
T3
(12)
(8)
T3
T1
(14)
T1
(13)
(11)
(6)
(12)
T2
(7)
(4)
(6)
(10)
(5)
(9)
T1
EN1178
(1)
Mass air flow and intake air temperature sensor
(2)
(3)
(4)
(5)
(6)
(7)
Air cleaner upper cover

Air cleaner element
Spacer
Bush
Clip
Air cleaner lower case
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Cushion rubber
Air intake duct
Resonator chamber ASSY
Cushion rubber
Clamp
Air intake boot
Cushion
IN(TURBO)-2

T1: 7.5 (0.76, 5.5)
T2: 33 (3.4, 24.6)
T3: 2.5 (0.25, 1.8)
T4: 1.7 (0.17, 1.2)
GENERAL DESCRIPTION
INTAKE (INDUCTION)
2. INTAKE DUCT
(4)
(3)
(5)
(1)
(2)
T1
(7)
(6)
EN1114
(1)
(2)
(3)
(4)
Clamp
PCV hose ASSY
Air by-pass hose A
Air by-pass hose B
(5)
(6)
(7)
Air by-pass hose C

Intake duct
Clamp
IN(TURBO)-3

T1: 16 (1.6, 11.7)
GENERAL DESCRIPTION
INTAKE (INDUCTION)
3. INTERCOOLER
T2
(2)
(1)
(4)
(5)
(4)
T1
T2
(6)
(7)
T2
(8)
(3)
(9)
(11)
(10)
T2
EN1508
(1)
(2)
(3)
(4)
(5)
(6)
Intercooler
Intercooler bracket RH
Intercooler bracket LH
Clamp
Air intake duct
Air by-pass valve
(7)
(8)
(9)
(10)
(11)
Gasket
Clamp
Air by-pass hose A
Intercooler duct
Clamp
IN(TURBO)-4

T1: 3 (0.3, 2.2)
T2: 16 (1.6, 11.6)
GENERAL DESCRIPTION
INTAKE (INDUCTION)
4. TURBOCHARGER
EN1116
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Oil inlet pipe

Metal gasket
Turbocharger
Water pipe
Clamp
Engine coolant hose
Gasket
(8)
(9)
(10)
(11)
(12)
Oil outlet pipe

Clip
Oil outlet hose
Turbocharger bracket RH
Turbocharger bracket LH
IN(TURBO)-5

T1: 4.4 (0.45, 3.3)
T2: 4.9 (0.50, 3.6)
T3: 29 (3.0, 21.7)
T4: 30 (3.1, 22.4)
T5: 33 (3.4, 24.6)
T6: 16 (1.6, 11.6)
GENERAL DESCRIPTION
INTAKE (INDUCTION)
B: CAUTION
points.
sensor or units, be sure to disconnect the ground
cable from battery.
IN(TURBO)-6
AIR CLEANER
INTAKE (INDUCTION)
2. Air Cleaner
7) Remove the air cleaner lower case.
A: REMOVAL
EN0905
B: INSTALLATION
G6M0095
2) Disconnect the connector from mass air flow

sensor.

Tightening torque:
33 Nm (3.4 kgf-m, 24.6 ft-lb)
EN0905
EN0031
3) Loosen the clamp (A) which connects air intake

boot to intake duct.
4) Remove the two clips (B) from air cleaner upper
cover.
CAUTION:
Before installing the air cleaner upper cover,
align the holes with protruding portions of air
cleaner lower case, then secure the upper cover to lower case.
(B)
(A)
EN0992
5) Remove the air cleaner upper cover.

EN0906
C: INSPECTION
Replace if excessively damaged or dirty.
IN(TURBO)-7
AIR INTAKE DUCT

INTAKE (INDUCTION)
3. Air Intake Duct

A: REMOVAL
1) Remove the bolts which install air intake duct on
the front side of body.
EN0108
B: INSTALLATION
C: INSPECTION
1) Inspect for cracks and loose connections.
2) Inspect that no foreign objects are mixed in the
air intake duct.
IN(TURBO)-8
INTAKE DUCT
INTAKE (INDUCTION)
4. Intake Duct
A: REMOVAL
G6M0095

3) Remove the sensor, engine harness, and fuel
pipe attached to intake manifold. <Ref. to FU(TURBO)-21, DISASSEMBLY, Intake Manifold.>
4) Remove the intake duct from intake manifold.
EN1115
B: INSTALLATION
IN(TURBO)-9
INTERCOOLER
INTAKE (INDUCTION)
5. Intercooler
5) Separate the intercooler from throttle body.
A: REMOVAL
1) Disconnect the air by-pass hoses from intercooler.
EN0916
EN0907
2) Separate the air by-pass valve from intercooler.
EN0908
3) Remove the bolts which secure intercooler to

bracket.
EN0915
EN0909
4) Separate the intercooler air duct from turbocharger.
IN(TURBO)-10
INTERCOOLER
INTAKE (INDUCTION)
B: INSTALLATION
C: DISASSEMBLY
1) Remove the intercooler ducts from intercooler.
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
H2M1886
D: ASSEMBLY
EN0915

Tightening torque:
16 Nm (1.6 kgf-m, 11.7 ft-lb)
EN0909
H2M1886
EN0908
IN(TURBO)-11
TURBOCHARGER
INTAKE (INDUCTION)
6. Turbocharger
7) Loosen the clamp which secures turbocharger to

air inlet duct.
A: REMOVAL
H2M1936
G6M0095
8) Remove the bolt which secures bracket of oil

pipe to turbocharger.
9) Remove the oil pipe from turbocharger.

5) Separate the turbocharger joint pipe from turbocharger.
EN0913
10) Remove the turbocharger bracket.
EN0911
6) Disconnect the engine coolant hose which is

connected to coolant filler tank.
H2M1940
11) Disconnect the oil outlet hose from pipe.
EN0912
H2M1941
12) Take out the turbocharger from engine compartment.
IN(TURBO)-12
TURBOCHARGER
INTAKE (INDUCTION)
B: INSTALLATION
5) Install the turbocharger bracket.
1) Connect the oil outlet hose to outlet pipe.
H2M1940
H2M1941
2) Install the turbocharger to air intake duct.
6) Connect the engine coolant hose which is connected to coolant filler tank.
EN0912
H2M1936

8) Install the center exhaust pipe. <Ref. to EX(TURBO)-9, INSTALLATION, Center Exhaust Pipe.>
3) Install the oil pipe to turbocharger.
EN0913
4) Install the joint pipe to turbocharger.

NOTE:
Tightening torque:
30 Nm (3.1 kgf-m, 22.4 ft-lb)
EN0911
IN(TURBO)-13
AIR BY-PASS VALVE

INTAKE (INDUCTION)
7. Air By-pass Valve
B: INSTALLATION
A: REMOVAL
1) Remove the air by-pass valve from intercooler.
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
EN0908
EN0908
2) Disconnect the air by-pass hoses from air bypass valve.
IN(TURBO)-14
RESONATOR CHAMBER
INTAKE (INDUCTION)
8. Resonator Chamber
A: REMOVAL
2) Remove the air intake duct. <Ref. to IN(TURBO)-8, Removal.>
3) Remove the air cleaner lower case. <Ref. to
IN(TURBO)-7, Removal.>
4) Remove the resonator chamber mounting bolt
on the right of engine compartment.
B2M4556
5) Remove the front right tire, and lift the vehicle.

6) Remove the front mudguard RH.
7) Remove the resonator chamber (A) from the inside front fender.
(A)
EN1377
B: INSTALLATION
C: INSPECTION
Inspect for cracks and loose connections. Check
that no foreign objects are mixed in the resonator
chamber.
IN(TURBO)-15
RESONATOR CHAMBER
INTAKE (INDUCTION)
IN(TURBO)-16
MECHANICAL
ME(TURBO)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
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 ......................................................................................33
Engine Mounting .......................................................................................42
V-belt.........................................................................................................44
Crankshaft Pulley ......................................................................................46
Belt Cover .................................................................................................47
Timing Belt Assembly................................................................................48
Camshaft Sprocket....................................................................................57
Crankshaft Sprocket..................................................................................58
Camshaft...................................................................................................59
Cylinder Head Assembly...........................................................................64
Cylinder Block ...........................................................................................71
Engine Trouble in General ........................................................................91
Engine Noise.............................................................................................96
GENERAL DESCRIPTION
MECHANICAL
A: SPECIFICATIONS
Type
Valve arrangement
Bore x Stroke
Piston displacement
Engine
Compression ratio
Compression pressure (at 200 300
rpm)
Number of piston rings
Opening
Intake valve timing
Closing
Opening
Exhaust valve timing
Closing
Intake
Valve clearance
Exhaust
mm (in)
Horizontally opposed, liquid cooled, 4-cylinder,

4-stroke gasoline engine
Belt driven, double overhead camshaft, 4-valve/cylinder
92 x 75 (3.62 x 2.95)
1,994 (121.67)
cm (cu in)
8.0
kPa (kgf/cm2, psi)
981 1,177 (10 12, 142 171)
mm (in)
mm (in)
MT
Idling speed [At neutral position]
rpm
AT
Firing order
Ignition timing
BTDC/rpm
ME(TURBO)-2
Pressure ring: 2, Oil ring: 1

10 BTDC
50 ABDC
53 BBDC
7 ATDC
0.200.02 (0.00790.0008)
0.250.02 (0.00980.0008)
750100 (No load)
750100 (No load)
1324
123/750 rpm
GENERAL DESCRIPTION
MECHANICAL
NOTE:
STD: Standard
Belt
tension
adjuster
I.D.: Inner Diameter
OS: Oversize
Protrusion of adjuster rod
5.2 6.2 mm (0.205 0.244 in)
Spacer O.D.
Tensioner bush I.D.
Belt
tensioner
Clearance between spacer and bush

Side clearance of spacer
17.955 17.975 mm (0.7069 0.7077 in)

18.0 18.08 mm (0.7087 0.7118 in)
0.025 0.125 mm (0.0010 0.0049 in)
0.175 mm (0.0069 in)
0.2 0.55 mm (0.0079 0.0217 in)
0.81 mm (0.0319 in)
0.020 mm (0.0079 in)
0.015 0.070 mm (0.0006 0.0028 in)
0.10 mm (0.0039 in)
46.25 46.35 mm (1.821 1.825 in)
46.15 mm (1.817 in)
46.15 46.25 mm (1.817 1.821 in)
46.05 mm (1.813 in)
37.946 37.963 mm (1.4939 1.4946 in)
STD
Limit
STD
Limit
Bend limit
Thrust clearance
Intake
Cam lobe height
Camshaft
Exhaust
Jounal O.D.
STD
Oil clearance
Cylinder
head
Valve seat
Intake
Contacting width
Head edge thickness

Exhaust
Stem diameter
Stem oil clearance
STD
Limit
Overall length
Free length
Squareness
Valve
spring
STD
Limit
STD
Limit
Inner diameter
Protrusion above head
Intake
Valve
STD
Limit
STD
Limit
STD
Limit
Front
Center
rear
STD
Limit
Surface warpage limit

Standard height
Refacing angle
Exhaust
Valve guide
Tension/spring height
US: Undersize
STD
Limit
STD
Limit
Intake
Exhaust
Intake
Exhaust
Intake
Exhaust
29.946 29.963 mm (1.1790 1.1796 in)

0.037 0.072 mm (0.0015 0.0028 in)
0.10 mm (0.0039 in)
0.05 mm (0.0020 in)
0.3 mm (0.012 in)
127.5 mm (5.02 in)
90
1.0 mm (0.039 in)
1.7 mm (0.067 in)
1.5 mm (0.059 in)
2.2 mm (0.087 in)
6.000 6.012 mm (0.2362 0.2367 in)
12.0 12.4 mm (0.472 0.488 in)
1.2 mm (0.047 in)
0.8 mm (0.031 in)
1.5 mm (0.059 in)
0.8 mm (0.031 in)
5.950 5.965 mm (0.2343 0.2348 in)
5.945 5.960 mm(0.2341 0.2346 in)
0.035 0.062 mm (0.0014 0.0024 in)
0.040 0.067 mm (0.0016 0.0026 in)
0.15 mm (0.0059 in)
104.4 mm (4.110 in)
104.7 mm (4.122 in)
44.67 mm (1.7587 in)
2.5, 2.0 mm (0.079 in)
205.0 236.4 N (20.9 24.1 kgf, 46.1 53.1 lb)
/36.0 mm (1.417 in)
485.4 536.4 N (49.5 54.7 kgf, 109.2 120.6 lb)
/26.6 mm (1.047 in)
ME(TURBO)-3
GENERAL DESCRIPTION
MECHANICAL
Cylinder
block
Piston
Piston pin
Surface warpage limit (mating with cylinder head)

A
Cylinder bore
STD
B
STD
Taper
Limit
STD
Out-of-roundness
Limit
STD
Piston clearance
Limit
Enlarging (boring) limit
A
STD
B
0.25
mm
(0.0098
in)
Outer diameter
OS
0.50 mm (0.0197 in)
OS
STD
Standard clearance between piston
pin and hole in piston
Limit
Piston ring gap
Oil ring
Piston ring
Clearance between piston ring and piston ring
groove
Connecting
rod
Second
ring
Top ring
Second
ring
Bend twist per 100 mm (3.94 in) in

length
Side clearance
Oil clearance
Connecting
rod bearing
Connecting
rod bushing
Thickness at center portion
Clearance between piston pin and

bushing
92.225 92.235 mm (3.6309 3.6313 in)

92.475 92.485 mm (3.6407 3.6411 in)
STD
Limit
STD
Limit
STD
Limit
STD
Limit
STD
Limit
0.004 0.008 mm (0.0002 0.0003 in)

0.020 mm (0.0008 in)
Piston pin must be fitted into position with thumb at 20C
(68F).
0.20 0.25 mm (0.0079 0.0098 in)
1.0 mm (0.039 in)
0.35 0.50 mm (0.0138 0.0197 in)
1.0 mm (0.039 in)
0.20 0.50 mm (0.0079 0.0197 in)
1.5 mm (0.059 in)
0.055 0.090 mm (0.0022 0.0035 in)
0.15 mm (0.0059 in)
0.030 0.070 mm (0.0012 0.0028 in)
0.15 mm (0.0059 in)
Limit
0.10 mm (0.0039 in)
Degree of fit
Top ring
0.05 mm (0.0020 in)

0.1 mm (0.004 in)
92.005 92.015 mm (3.6222 3.6226 in)
91.995 92.005 mm (3.6218 3.6222 in)
0.015 mm (0.0006 in)
0.050 mm (0.0020 in)
0.010 mm (0.0004 in)
0.050 mm (0.0020 in)
0.010 0.030 mm (0.0004 0.0012 in)
0.050 mm (0.0020 in)
0.5 mm (0.020 in)
91.985 91.995 mm (3.6214 3.6218 in)
91.975 91.985 mm (3.6211 3.6214 in)
STD
Limit
STD
Limit
STD
0.03 mm
(0.0012
in) US
0.05 mm
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
Limit
ME(TURBO)-4
0.070 0.330 mm (0.0028 0.0130 in)

0.4 mm (0.016 in)
0.020 0.046 mm (0.0008 0.0018 in)
0.05 mm (0.0020 in)
1.486 1.498 mm (0.0585 0.0590 in)
1.504 1.512 mm (0.0592 0.0595 in)
1.514 1.522 mm (0.0596 0.0599 in)
1.614 1.622 mm (0.0635 0.0639 in)

0 0.022 mm (0 0.0009 in)
0.030 mm (0.0012 in)
GENERAL DESCRIPTION
MECHANICAL
Bend limit
Crank pin and crank journal
Crank pin outer diameter
Crankshaft
Crank journal outer diameter
Thrust clearance
Oil clearance
Crankshaft
bearing
Crankshaft bearing thickness
Out-of-roundness
Grinding limit
STD
0.03 mm
(0.0012
in) US
0.05 mm
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
0.03 mm
(0.0012
in) US
0.05
mm
#1, #3, #5
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
0.03 mm
(0.0012
in) US
0.05 mm
#2, #4
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
Limit
STD
Limit
STD
0.03 mm
(0.0012
in) US
0.05 mm
#1, #3
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
0.03 mm
(0.0012
in) US
0.05 mm
#2, #4, #5
(0.0020
in) US
0.25 mm
(0.0098
in) US
ME(TURBO)-5
0.035 mm (0.0014 in)

0.020 mm (0.0008 in) or less
0.25 mm (0.0098 in)
51.984 52.000 mm (2.0466 2.0472)
51.954 51.970 mm (2.0454 2.0461)
51.934 51.950 mm (2.0447 2.0453)
51.734 51.750 mm (2.0368 2.0374)

59.992 60.008 mm (2.3619 2.3625 in)
59.962 59.978 mm (2.3607 2.3613 in)
59.942 59.958 mm (2.3599 2.3605 in)
59.742 59.758 mm (2.3520 2.3527 in)

59.992 60.008 mm (2.3619 2.3625 in)
59.962 59.978 mm (2.3607 2.3613 in)
59.942 59.958 mm (2.3599 2.3605 in)
59.742 59.758 mm (2.3520 2.3527 in)

0.030 0.115 mm (0.0012 0.0045 in)
0.25 mm (0.0098 in)
0.010 0.030 mm (0.0004 0.0012 in)
0.040 mm (0.0016 in)
1.998 2.011 mm (0.0787 0.0792 in)
2.017 2.020 mm (0.0794 0.0795 in)
2.027 2.030 mm (0.0798 0.0799 in)
2.127 2.130 mm (0.0837 0.0839 in)

2.000 2.013 mm (0.0787 0.0793 in)
2.019 2.022 mm (0.0795 0.0796 in)
2.029 2.032 mm (0.0799 0.0800 in)
2.129 2.132 mm (0.0838 0.0839 in)
GENERAL DESCRIPTION
MECHANICAL
B: COMPONENT
1. TIMING BELT
(2)
(1)
(2)
T2
T2
(3)
T1
(2)
(4)
T2
(5)
T1
T3
(6)
(12)
(9)
(7)
(8)
T1
(14)
T5
T3
T4
T1
T4
(2)
(10)
(14)
T2
(11)
T4
(17)
(13)
T5
T1
(15)
(16)
T6
(18)
T1
EN1136
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Belt cover No. 2 (RH)

Timing belt guide (MT vehicles
only)
Crankshaft sprocket
Belt cover No. 2 (LH)
Tensioner bracket
Automatic belt tension adjuster
ASSY
Belt idler
Exhaust camshaft sprocket (RH)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Intake camshaft sprocket (RH)

Intake camshaft sprocket (LH)
Exhaust camshaft sprocket (LH)
Timing belt
Belt idler No. 2
Belt idler
Belt cover (LH)
Front belt cover
Belt cover (RH)
Crankshaft pulley
ME(TURBO)-6

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: 98 (10, 72.4)
T6: <Ref. to ME(TURBO)-46,
INSTALLATION, Crankshaft
Pulley.>
GENERAL DESCRIPTION
MECHANICAL
ME(TURBO)-7
GENERAL DESCRIPTION
MECHANICAL
2. CYLINDER HEAD AND CAMSHAFT
EN1480
ME(TURBO)-8
GENERAL DESCRIPTION
MECHANICAL
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Rocker cover (RH)

Rocker cover gasket (RH)
Oil separator cover
Gasket
Intake camshaft cap (Front RH)
Intake camshaft cap (Center RH)
Intake camshaft cap (Rear RH)
Intake camshaft (RH)
Exhaust camshaft cap (Front RH)
Exhaust camshaft cap (Center RH)
Exhaust camshaft cap (Rear RH)
Exhaust camshaft (RH)
Cylinder head bolt
Oil seal
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
Cylinder head (RH)

Cylinder head gasket (RH)
Cylinder head (LH)
Intake camshaft (LH)
Exhaust camshaft (LH)
Intake camshaft cap (Front LH)
Intake camshaft cap (Center LH)
Intake camshaft cap (Rear LH)
Exhaust camshaft (Front LH)
Exhaust camshaft cap (Center LH)
Exhaust camshaft cap (Rear LH)
Rocker cover gasket (LH)
Rocker cover (LH)
Oil filler cap
ME(TURBO)-9
(29)
(30)
(31)
(32)
Gasket
Oil filler duct
O-ring
Stud bolt

T1: <Ref. to ME(TURBO)-64,
INSTALLATION, Cylinder Head
Assembly.>
T2: 5 (0.5, 3.6)
T3: 10 (1.0, 7.2)
T4: 6.4 (0.65, 4.7)
GENERAL DESCRIPTION
MECHANICAL
3. CYLINDER HEAD AND VALVE ASSEMBLY
S2M1197A
(1)
(2)
(3)
(4)
(5)
Exhaust valve
Intake valve
Cylinder head
Valve spring seat
(6)
(7)
(8)
(9)
(10)
Valve spring
Retainer
Retainer key
Valve lifter
Shim
ME(TURBO)-10
(11)
(12)
(13)

Intake valve guide
Exhaust valve guide
GENERAL DESCRIPTION
MECHANICAL
4. CYLINDER BLOCK
EN0144
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Oil pressure switch

Cylinder block (RH)
Service hole plug
Gasket
Oil separator cover
Water by-pass pipe
Oil pump
Front oil seal
Rear oil seal
O-ring
Service hole cover
Cylinder block (LH)
Water pump
Baffle plate
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
Oil cooler
Waster by-pass pipe
Connector
Oil strainer
Gasket
Oil pan
Drain plug
Metal gasket
Oil filter
Gasket
Water pump hose
Plug
ME(TURBO)-11

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: 47 (4.8, 34.7)
T6: 69 (7.0, 50.6)
T7: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
T8:
T9:
T10:
T11:
16 (1.6, 11.6)
44 (4.5, 33)
25 (2.5, 18.1)
55 (5.5, 40)
GENERAL DESCRIPTION
MECHANICAL
5. CRANKSHAFT AND PISTON
EN0415
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Flywheel (MT vehicles only)

Ball bearing (MT vehicles only)
Reinforcement (AT vehicles only)
Drive plate (AT vehicles only)
Top ring
Second ring
Oil ring
Piston
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Piston pin
Circlip
Connecting rod bolt
Connecting rod
Connecting rod cap
Crankshaft
Woodruff key
ME(TURBO)-12
(17)
(18)
(19)

Crankshaft bearing #5

T1: 44.6 (4.55, 32.9)
T2: 72 (7.3, 52.8)
GENERAL DESCRIPTION
MECHANICAL
6. ENGINE MOUNTING
S2M1783A
(1)
(2)
Heat shield cover

Front cushion rubber
(3)
Front engine mounting bracket
ME(TURBO)-13

T1: 34 (3.5, 25.3)
T2: 42 (4.3, 30.9)
T3: 85 (8.7, 62.7)
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 stain seats and windows with
coolant or oil. Place a cover over fenders, as required, for protection.
Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission
jacks, etc.
Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
498267600
DESCRIPTION
CYLINDER
HEAD TABLE
REMARKS
Used for replacing valve guides.
Used for removing and installing valve springs.
498457000
ENGINE STAND
ADAPTER RH
EN0147
B2M3851
ME(TURBO)-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 and tightening crankshaft pulley bolt, etc.
398744300
PISTON GUIDE
Used for installing piston in cylinder for 2000 cc

engine.
498857100
VALVE OIL
SEAL GUIDE
Used for press-fitting of intake and exhaust valve

guide oil seals.
B2M3852
B2M3853
B2M3854
B2M3855
ME(TURBO)-15
GENERAL DESCRIPTION
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499017100
DESCRIPTION
PISTON PIN
GUIDE
REMARKS
Used for installing piston pin, piston and connecting rod.
499037100
CONNECTING
ROD BUSHING
REMOVER &
INSTALLER
Used for removing and installing connecting rod

bushing.
499097700
PISTON PIN
REMOVER
ASSY
Used for removing piston pin.
499207400
CAMSHAFT
SPROCKET
WRENCH

sprocket. (Except intake camshaft sprocket
sprocket LH)
B2M3856
B2M3857
B2M3858
B2M4158
ME(TURBO)-16
GENERAL DESCRIPTION
MECHANICAL
ILLUSTRATION
TOOL NUMBER
18231AA010
(Newly adopted
tool)
DESCRIPTION
CAMSHAFT
SPROCKET
WRENCH
REMARKS
sprocket. (Intake camshaft sprocket LH)
499587700
CAMSHAFT OIL
SEAL
INSTALLER
Used for installing cylinder head plug for DOHC

engine.
499587200
CRANKSHAFT
OIL SEAL
INSTALLER

Used with CRANKSHAFT OIL SEAL GUIDE
(499597100).
499597100
CRANKSHAFT
OIL SEAL GUIDE Used with CRANKSHAFT OIL SEAL
B2M3859
B2M3860
B2M3861
B2M3863
ME(TURBO)-17
GENERAL DESCRIPTION
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499718000
DESCRIPTION
VALVE SPRING
REMOVER
REMARKS
Used for removing and installing valve spring.
498267700
VALVE GUIDE
ADJUSTER
Used for installing intake and exhaust valve

guides.
499767200
VALVE GUIDE
REMOVER
Used for removing valve guides.
499767400
VALVE GUIDE
REAMER
Used for reaming valve guides.
B2M3864
B2M3865
B2M3867
B2M3868
ME(TURBO)-18
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).
499977300
CRANK PULLEY
WRENCH

bolts.
499987500
CRANKSHAFT
SOCKET
Used for rotating crankshaft.
498547000
OIL FILTER
WRENCH
B2M3869
B2M4157
B2M3871
B2M3872
ME(TURBO)-19
GENERAL DESCRIPTION
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499587100
DESCRIPTION
OIL SEAL
INSTALLER
REMARKS
B2M3875
499587600
OIL SEAL GUIDE Used for installing camshaft oil seal for DOHC
engine.
499597200
OIL SEAL GUIDE Used for installing camshaft oil seal for DOHC
engine.
Used with OIL SEAL GUIDE (499587600).
498187200
SHIM
REPLACER
S1H0136
EN0168
EN0169
ME(TURBO)-20
Used for correct valve clearance.
GENERAL DESCRIPTION
MECHANICAL
ILLUSTRATION
TOOL NUMBER
498277200
DESCRIPTION
STOPPER SET
REMARKS
Used for installing automatic transmission assembly to engine.
24082AA190
(Newly adopted
tool)
CARTRIDGE
SELECT MONITOR KIT

H1H0492
B2M3876
22771AA030
B2M3877

TOOL NAME
REMARKS
Used for measuring compression.
Used for measuring ignition timing.
Compression Gauge
Timing Light
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
Camshaft
Cylinder Head
ME(TURBO)-21
COMPRESSION
MECHANICAL
2. Compression
A: INSPECTION
CAUTION:
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(TURBO)-4, 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 spark
plug hole.
CAUTION:
When using a screw-in type compression
gauge, the screw (put into cylinder head spark
plug hole) should be less than 18 mm (0.71 in)
long.
8) Crank the engine by means of starter motor, and
then read the maximum value on the gauge when
the pointer is steady.
EN0172
9) Perform at least two measurements per cylinder,

and make sure that the values are correct.
Compression (350 rpm and fully open throttle):
Standard;
951 1,147 kPa (9.7 11.7 kgf/cm2, 138
166 psi)
Limit;
834 kPa (8.5 kgf/cm2, 121 psi)
Difference between cylinders;
49 kPa (0.5 kgf/cm2, 7 psi)
ME(TURBO)-22
IDLE SPEED
MECHANICAL
3. Idle Speed
A: INSPECTION
1) Before checking the idle speed, check the following:
clogging, ignition timing is correct, spark plugs
are in good condition, and that the hoses are
connected properly.
3) Stop the engine, and then turn the ignition switch
to OFF.
4) Insert the cartridge to SUBARU SELECT MONITOR.
5) Connect the SUBARU SELECT MONITOR to
data link connector.
6) Turn the ignition switch to ON, and SUBARU
SELECT MONITOR switch to ON.
Menu.
Menu.
Menu.
11) Start the engine, and then 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]:
750100 rpm
13) Check the idle speed when loaded. (Turn the
air conditioning switch to ON and operate the
compressor for at least 1 minute before measurement.)
Idle speed [A/C ON, no load and gears in neutral]:
800150 rpm (MT models)
825150 rpm (AT models)
CAUTION:
Never rotate the idle adjusting screw. If the idle
speed is out of specifications, refer to General
On-board Diagnosis Table under Engine Control System. <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.>
ME(TURBO)-23
IGNITION TIMING
MECHANICAL
4. Ignition Timing
A: INSPECTION
1) Before checking the ignition timing speed, check
the following:
clogging, spark plugs are in good condition, and
that hoses are connected properly.
3) Stop the engine, and then turn the ignition switch
to OFF.
4) Insert the cartridge to SUBARU SELECT MONITOR.
5) Connect the SUBARU SELECT MONITOR to
6) Turn the ignition switch to ON, and SUBARU
SELECT MONITOR switch to ON.
Menu.
Menu.
Menu.
11) Start the engine, at idle speed and check the ignition timing.
Ignition timing [BTDC/rpm]:
123/750
If the timing is not correct, check the ignition control
system. Refer to Engine Control System. <Ref. to
EN(TURBO)-2, Basic Diagnostic Procedure.>
ME(TURBO)-24
INTAKE MANIFOLD VACUUM

MECHANICAL
5. Intake Manifold Vacuum

A: INSPECTION
2) Disconnect the brake vacuum hose, and then install the vacuum gauge to hose fitting on manifold.
3) Keep the engine at the idle speed, and then read

the vacuum gauge indication.
By observing the gauge needle movement, the internal condition of engine can be diagnosed as described below.
H2M1767
Vacuum pressure (at idling, A/C OFF):

Less than 60.0 kPa (450 mmHg, 17.72
inHg)
Diagnosis of engine condition by measurement of manifold vacuum
Vacuum gauge indication
Possible engine condition
1. Needle is steady but lower than normal position. This tenLeakage around intake manifold gasket or disconnection or
dency becomes more evident as engine temperature rises.
damaged vacuum hose
2. When engine speed is reduced slowly from higher speed,
Back pressure too high, or exhaust system clogged
needle stops temporarily when it is lowering or becomes steady
above normal position.
3. Needle intermittently drops to position lower than normal
Leakage around cylinder
position.
4. Needle drops suddenly and intermittently from normal posiSticky valves
tion.
5. When engine speed is gradually increased, needle begins to Weak or broken valve springs
vibrate rapidly at certain speed, and then vibration increases as
engine speed increases.
6. Needle vibrates above and below normal position in narrow
Defective ignition system or throttle chamber idle adjustment
range.
ME(TURBO)-25
ENGINE OIL PRESSURE

MECHANICAL
6. Engine Oil Pressure
5) After measuring the oil pressure, install the oil

pressure switch. <Ref. to LU-21, INSTALLATION,
Oil Pressure Switch.>
A: INSPECTION
1) Remove the oil pressure switch from engine cylinder block. <Ref. to LU-21, REMOVAL, Oil Pressure Switch.>
2) Connect the oil pressure gauge hose to cylinder
block.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
G6M0095
4) Start the engine, and then measure the oil pressure.
S2M0242
Oil pressure:
98 kPa (1.0 kg/cm2, 14 psi) or more at 800 rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000
rpm
CAUTION:
If the oil pressure is out of specification,
check oil pump, oil filter and lubrication line.
<Ref. to LU-25, INSPECTION, Engine Lubrication System Trouble in General.>
If the oil pressure warning light is turned ON
and oil pressure is in specification, replace the
oil pressure switch. <Ref. to LU-25, INSPECTION, Engine Lubrication System Trouble in
General.>
NOTE:
The specified data is based on an engine oil temperature of 80C (176F).
ME(TURBO)-26
FUEL PRESSURE
MECHANICAL
7. Fuel Pressure
A: INSPECTION
6) Measure the fuel pressure while disconnecting

the pressure regulator vacuum hose from intake
manifold.
WARNING:
Before removing the fuel pressure gauge, release the fuel pressure.
Fuel pressure:
Standard; 284 314 kPa (2.9 3.2 kgf/cm2,
41 46 psi)
NOTE:
If out of specification, check or replace the pressure
regulator and pressure regulator vacuum hose.
2) Open the fuel flap lid, and then remove the fuel
filler cap.
3) Disconnect the fuel delivery hoses from fuel filter, and then connect the fuel pressure gauge.
S2M0554
7) After connecting the pressure regulator vacuum

hose, measure the fuel pressure.
Fuel pressure:
Standard; 230 260 kPa (2.35 2.65
kgf/cm2, 33 38 psi)
EN1117
4) Connect the connector of fuel pump relay.
S2M0554
NOTE:
The fuel pressure gauge registers 10 to 20 kPa (0.1
to 0.2 kgf/cm2, 1 to 3 psi) higher than standard values during high-altitude operations.
EN0344
ME(TURBO)-27
VALVE CLEARANCE
MECHANICAL
8. Valve Clearance
10) When inspecting the #2 and #4 cylinders:

(1) Disconnect the battery cable, and then remove the battery and battery carrier.
A: INSPECTION
CAUTION:
Inspection and adjustment of the valve clearance should be performed while engine is cold.
H6M0426
(2) Remove the bolt which secures engine harness bracket onto body.
G6M0095
3) Remove the air intake duct. <Ref. to IN(TURBO)-8, REMOVAL, Air Intake Duct.>
4) Remove the bolt which secures belt cover (RH).
7) Loosen the remaining bolts which secure belt
cover (RH), and then remove the belt cover.
9) When inspecting the #1 and #3 cylinders:
(1) Pull out the engine harness connector with
bracket from air cleaner upper cover.
H6M0429
(3) Disconnect the washer motor connectors.
H6M0430
(4) Remove the washer tank mounting bolts.

H2M1958
(2) Remove the air cleaner case. <Ref. to

IN(TURBO)-7, REMOVAL, Air Cleaner.>
plugs (#1 and #3 cylinders).
(4) Place a suitable container under the vehicle.
(RH).
rocker cover (RH).
ME(TURBO)-28
B6M0561
VALVE CLEARANCE
MECHANICAL
12) Measure the #1 cylinder intake valve and #3

cylinder exhaust valve clearance by using thickness gauge (A).
(5) Move the washer tank upward.
CAUTION:
Insert the thickness gauge in as horizontal a
direction as possible with respect to the shim.
Measure the exhaust valve clearances while
lifting-up the vehicle.
H6M0431

plugs (#2 and #4 cylinders).
(7) Place a suitable container under the vehicle.
(LH).
rocker cover (LH).
11) Turn the crankshaft pulley clockwise until arrow
mark on the camshaft sprocket is set to position
Valve clearance:
Intake: 0.200.02 mm (0.00790.0008 in)
Exhaust: 0.250.02 mm (0.00980.0008 in)
NOTE:
If the measured value is not within specification,
take notes of the value in order to adjust the valve
clearance later on.
NOTE:
Turn the crankshaft using ST.
ST 499987500
CRANKSHAFT SOCKET
B2M1234B
S2M1192B
13) If necessary, adjust the valve clearance. <Ref.

to ME(TURBO)-30, ADJUSTMENT, Valve Clearance.>
14) Further turn the crankshaft pulley clockwise.
Using the same procedures described previously,
and then measure the valve clearances again.
(1) Set the arrow mark on camshaft sprocket to
position shown in the figure, and then measure
the #2 cylinder exhaust valve and #3 cylinder intake valve clearances.
S2M1194B
ME(TURBO)-29
VALVE CLEARANCE
MECHANICAL

the #2 cylinder intake valve and #4 cylinder exhaust valve clearances.
B: ADJUSTMENT
CAUTION:
Adjustment of the valve clearance should be
performed while engine is cold.
1) Measure all valve clearances. <Ref. to ME(TURBO)-28, INSPECTION, Valve Clearance.>
NOTE:
Record each valve clearance after it has been
measured.
S2M1195B

the #1 cylinder exhaust valve and #4 cylinder intake valve clearances.
B2M1234
2) Remove the shim from valve lifter.

(1) Prepare the ST.
ST 498187200
SHIM REPLACER
S2M1196B

Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
H2M3622
(2) Rotate the notch of the valve lifter outward

by 45.
EN0191
H2M1777A
ME(TURBO)-30
VALVE CLEARANCE
MECHANICAL
(3) Adjust the SHIM REPLACER notch to valve

lifter and set it.
(6) Insert tweezers into the notch of valve lifter,

and then take the shim out.
H2M3628
NOTE:
When setting, be careful the SHIM REPLACER
edge does not touch shim.
(4) Tighten the bolt (A), and then install it to the
cylinder head.
(5) Tighten the bolt (B), and then insert the
valve lifter.
H2M3629
NOTE:
By using a magnet (A), the shim (B) can be taken
out without dropping it.
H2M3624A
3) Measure the thickness of shim with a micrometer.

H2M3623A
B2M1240
4) Select a shim of suitable thickness using measured valve clearance and shim thickness, by referring to the following table.
5) Set the suitable shim selected in step 4) to valve
lifter.
Unit: mm
Intake valve: S =(V + T) - 0.20
Exhaust valve: S =(V + T) - 0.25
S: Shim thickness to be used
V: Measured valve clearance
T: Shim thickness required
ME(TURBO)-31
VALVE CLEARANCE
MECHANICAL
Part No.
13218 AK010
13218 AK020
13218 AK030
13218 AK040
13218 AK050
13218 AK060
13218 AK070
13218 AK080
13218 AK090
13218 AK100
13218 AK110
13218 AE710
13218 AE720
13218 AE730
13218 AE740
13218 AE750
13218 AE760
13218 AE770
13218 AE780
13218 AE790
13218 AE800
13218 AE810
13218 AE820
13218 AE830
13218 AE840
13218 AE850
13218 AE860
13218 AE870
13218 AE880
13218 AE890
13218 AE910
13218 AE920
13218 AE930
13218 AE940
13218 AE950
13218 AE960
13218 AE970
13218 AE980
13218 AE990
13218 AF000
13218 AF010
13218 AF020
13218 AF030
13218 AF040
13218 AF050
13218 AF060
13218 AF070
13218 AF080
13218 AF090
13218 AF100
13218 AF110
Thickness mm (in)
2.00 (0.0787)
2.02 (0.0795)
2.04 (0.0803)
2.06 (0.0811)
2.08 (0.0819)
2.10 (0.0827)
2.12 (0.0835)
2.14 (0.0843)
2.16 (0.0850)
2.18 (0.0858)
2.20 (0.0866)
2.22 (0.0874)
2.23 (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)
2.42 (0.0953)
2.43 (0.0957)
2.44 (0.0961)
2.45 (0.0965)
2.46 (0.0969)
2.47 (0.0972)
2.48 (0.0976)
2.49 (0.0980)
2.50 (0.0984)
2.51 (0.0988)
2.52 (0.0992)
2.53 (0.0996)
2.54 (0.1000)
2.55 (0.1004)
2.56 (0.1008)
2.57 (0.1012)
2.58 (0.1016)
2.59 (0.1020)
2.60 (0.1024)
2.61 (0.1028)
2.62 (0.1031)
Part No.
13218 AF120
13218 AF130
13218 AF140
13218 AF150
13218 AF160
13218 AF170
13218 AF180
13218 AF190
13218 AF200
13218 AF210
13218 AF220
13218 AF230
13218 AF240
13218 AF250
13218 AF260
13218 AF270
13218 AF280
13218 AF290
13218 AF300
13218 AK010
13218 AK020
13218 AK030
13218 AK040
13218 AK050
13218 AK060
13218 AK070
13218 AK080
13218 AK090
13218 AK100
13218 AK110
Thickness mm (in)
2.63 (0.1035)
2.64 (0.1039)
2.65 (0.1043)
2.66 (0.1047)
2.67 (0.1051)
2.68 (0.1055)
2.69 (0.1059)
2.70 (0.1063)
2.71 (0.1067)
2.72 (0.1071)
2.73 (0.1075)
2.74 (0.1079)
2.75 (0.1083)
2.76 (0.1087)
2.77 (0.1091)
2.78 (0.1094)
2.79 (0.1098)
2.80 (0.1102)
2.81 (0.1106)
2.00 (0.0787)
2.02 (0.0795)
2.04 (0.0803)
2.06 (0.0811)
2.08 (0.0819)
2.10 (0.0827)
2.12 (0.0835)
2.14 (0.0843)
2.16 (0.0850)
2.18 (0.0858)
2.20 (0.0866)
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(TURBO)-32
ENGINE ASSEMBLY
MECHANICAL
9. Engine Assembly
A: REMOVAL
2) Open the front hood fully, and then support with
the hood stay.
3) Raise the rear seat, and then turn the floor mat
up.
(1) Disconnect the fuel pump relay connector.
9) Collect refrigerant, and then remove the pressure hoses.

(1) Place and connect the attachment hose to
the refrigerant recycle system.
(2) Collect the refrigerant from A/C system.
(3) Disconnect the A/C pressure hoses from
A/C compressor.
S2M1584
EN0344
(2) Start the engine, and run until stalls.

(3) After the engine stalls, crank it for 5 seconds
more.
5) Remove the filler cap.

11) Disconnect the following connectors and cable.
(1) Engine harness connector
S2M2260
(2) Engine ground terminal
G6M0095
7) Remove the radiator from vehicle. <Ref. to CO39, REMOVAL, Radiator.>

8) Remove the coolant filler tank. <Ref. to CO-53,
REMOVAL, Coolant Filler Tank.>
S2M0731
ME(TURBO)-33
ENGINE ASSEMBLY
MECHANICAL
(3) Engine harness connector
12) Disconnect the following hoses.

S2M1930
(4) Generator connector, terminal and A/C

compressor connectors
EN0204
(2) Heater inlet outlet hose
EN0205
B2M1291I
13) Remove the power steering pump from bracket.

(1) Loosen the lock bolt and slider bolt, and
then remove the front side V-belt. <Ref. to
ME(TURBO)-44, FRONT SIDE BELT, REMOVAL, V-belt.>
(2) Disconnect the power steering switch connector.
(A) A/C compressor connector

(B) Generator connector and terminal
S2M1931
(6) Clutch release spring

EN0360
S2M1932
ME(TURBO)-34
ENGINE ASSEMBLY
MECHANICAL
(3) Remove the pipe with bracket from intake

manifold.

EN0206
(4) Remove the power steering pump from engine.
B3M2047

H2M1954
(5) Remove the power steering tank from

S2M1927

20) Separate the clutch release fork from release
bearing. (MT vehicles)
(1) Remove the clutch operating cylinder from
transmission.
(2) Remove the plug using a 10 mm hexagon
wrench.
EN0361

wheel apron.
S2M1935
EN0208

15) Remove the ATF cooler pipe from frame. (AT
vehicles)
ME(TURBO)-35
ENGINE ASSEMBLY
MECHANICAL
(3) Screw the 6 mm dia. bolt into release fork

shaft, and remove it.
H3M1839

CAUTION:
Catch fuel from the hose into container.
Disconnect the hose with its end wrapped
with cloth to prevent fuel from splashing.
S2M1936A
(A) Shaft
(B) Bolt
(4) Raise the release fork, and then unfasten

the release bearing tabs to free release fork.
CAUTION:
Step (4) is required to prevent interference with
engine when removing the engine from transmission.
plate. (AT vehicles)
(1) Lower the vehicle.
(4) Remove the other bolts while rotating the
engine using ST.
ST 499977300
CRANK PULLEY WRENCH
EN0214
24) Remove the fuel filter and bracket.
G2M0818

wire ropes.
S2M0207
G2M0297
ME(TURBO)-36
ENGINE ASSEMBLY
MECHANICAL
26) Support the transmission with a garage jack.

CAUTION:
Before moving the engine away from transmission, check to be sure no work has been overlooked. Doing this is very important in order to
facilitate re-installation and because transmission lowers under its own weight.
28) Remove the engine from vehicle.

(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
(3) Move the engine horizontally until the mainshaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.
CAUTION:
Be careful not to damage adjacent parts or
body panels with crank pulley, oil pressure
gauge, etc.
29) Remove the front cushion rubbers.
S2M1928
27) Separation of the engine and transmission.

(1) Remove the starter. <Ref. to SC-5, REMOVAL, Starter.>
(2) Install the ST to torque converter clutch
case. (AT vehicles)
ST 498277200
STOPPER SET
H2M1961A
(3) Remove the bolts which hold right upper

side of transmission to engine.
B3M2044
ME(TURBO)-37
ENGINE ASSEMBLY
MECHANICAL
B: INSTALLATION
1) Install the clutch release fork and bearing onto
transmission. (MT vehicles)
(1) Remove the release bearing from clutch
cover with flat type screw driver.
(4) Apply grease to the specified points.

Spline FX2200
Shaft SUNLIGHT 2
S2M1843
(2) Install the release bearing on transmission.

(3) Install the release fork into release bearing
tab.
S2M1938A
(A) Spline (FX2200)

(B) Shaft (SUNLIGHT 2)
S2M1937A
(A) Release fork

(B) Release bearing
(5) Insert the release fork shaft into release

fork.
CAUTION:
Make sure the cutout portion of release fork
shaft contacts spring pin.
S2M1845A
(A) Release fork

(B) Release shaft
(C) Spring pin
ME(TURBO)-38
ENGINE ASSEMBLY
MECHANICAL
(6) Tighten the plug.
6) Remove the garage jack.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
G2M0297

S2M1846
2) Install the front cushion rubbers to engine.

Tightening torque:
34 Nm (3.5 kgf-m, 25.3 ft-lb)
3) Install the engine onto transmission.
(1) Position the engine in engine compartment,
and then align it with the transmission.
CAUTION:
body panels with crank pulley, oil pressure
gauge, etc.
(2) Apply a small amount of grease to the
splines of mainshaft. (MT vehicles)
4) Tighten the bolts which hold right upper side of
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)
H3M1839A
8) Remove the ST from torque converter clutch

case. (AT vehicles)
NOTE:
clutch case when removing ST.
ST 498277200
STOPPER SET
9) Install the starter. <Ref. to SC-6, INSTALLATION, Starter.>
B2M2791
5) Remove the lifting device and wire ropes.
ME(TURBO)-39
ENGINE ASSEMBLY
MECHANICAL
10) Install the torque converter clutch onto drive

plate. (AT vehicles)
(2) Tighten other bolts while rotating the engine
by using ST.
(2) Install the power steering pump.

Tightening torque:
20.1 Nm (2.05 kgf-m, 14.8 ft-lb)
CAUTION:
Be careful not to drop bolts into the torque converter clutch housing.
ST 499977300
CRANK PULLEY WRENCH
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
H2M1954
(3) Install the power steering pipe bracket on

right side intake manifold, and then install the
spark plug cords.
S2M0207
(3) Clog the service hole with plug.

11) Install the fuel filter and bracket.
EN0206
(4) Connect the power steering switch connector.
G2M0818
12) Install the power steering pump on bracket.

EN0360
(5) Install the front side V-belt, and adjust it.

<Ref. to ME(TURBO)-45, FRONT SIDE BELT,
EN0361
ME(TURBO)-40
ENGINE ASSEMBLY
MECHANICAL
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
21) Connect the following cables:

(2) Clutch release spring
CAUTION:
After connecting each cable, adjust them.
22) Install the air intake system.
(1) Install the intercooler. <Ref. to IN(TURBO)11, INSTALLATION, Intercooler.>
(2) Install the air cleaner element and air cleaner upper cover.
(3) Install the engine harness connector bracket.
(4) Install the filler hose to air cleaner case.
23) Install the A/C pressure hoses.
B2M2790
15) Tighten the nuts which install front cushion rubber onto crossmember.
Tightening torque:
83 Nm (8.5 kgf-m, 61 ft-lb)
CAUTION:
Use new O-rings.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
CAUTION:
Make sure the front cushion rubber mounting
bolts (A) and locator (B) are securely installed.
S2M1584
B2M3880A
16) Install the ATF cooler pipe to frame. (AT vehicles)

17) Install the center exhaust pipe.
<Ref. to EX(TURBO)-9, INSTALLATION, Center
Exhaust Pipe.>
19) Connect the following hoses:
(1) Fuel delivery hose, return hose and evaporation hose
(2) Heater inlet and outlet hoses
20) Connect the following connectors and terminals:
(1) Engine ground terminal
(3) Generator connector and terminal
(4) A/C compressor connectors
24) Install the radiator. <Ref. to CO-42, INSTALLATION, Radiator.>

25) Install the coolant filler tank. <Ref. to CO-53,
INSTALLATION, Coolant Filler Tank.>
26) Install the window washer tank.
27) Install the battery in the vehicle, and connect
cables.
28) Fill coolant.
<Ref. to CO-26, FILLING OF ENGINE COOLANT,
REPLACEMENT, Engine Coolant.>
29) Charge the A/C system with refrigerant.
<Ref. to AC-22, OPERATION, Refrigerant Charging Procedure.>
30) Remove the front hood stay, and close the front
hood.
ME(TURBO)-41
ENGINE MOUNTING
MECHANICAL
10.Engine Mounting
A: REMOVAL
1) Remove the engine assembly. <Ref. to
ME(TURBO)-33, REMOVAL, Engine Assembly.>
2) Remove the engine mounting from engine assembly.
B: INSTALLATION
Tightening torque:
Engine mounting;
34 Nm (3.5 kgf-m, 25.3 ft-lb)
C: INSPECTION
Make sure there are no cracks or other damage.
ME(TURBO)-42

MECHANICAL
11.Preparation for Overhaul

A: PROCEDURE
1) After removing the engine from body, secure it in
the ST shown below.
RH
LH
ST3 499817000 ENGINE STAND
S2M1876A
2) In this section the procedures described under

each index are all connected and stated in order. It
will be the complete procedure for overhauling of
the engine itself when you go through all steps in
the process.
Therefore, in this section, to conduct the particular
procedure within the flow of a section, you need to
go back and conduct the procedure described previously in order to do that particular procedure.
ME(TURBO)-43
V-BELT
MECHANICAL
12.V-belt
4) Remove the A/C belt tensioner.
A: REMOVAL
1. FRONT SIDE BELT
NOTE:
Perform the following procedures 1) to 4) with the
engine installed to body.
S2M0113
EN0048

(B)
(C)
(A)
EN0225
2. REAR SIDE BELT

(B)
(A)
EN0226
3) Remove the A/C belt.
ME(TURBO)-44
V-BELT
MECHANICAL
B: INSTALLATION
C: INSPECTION
1. FRONT SIDE BELT

CAUTION:
1) Install the belt (C), and tighten the slider bolt so
as to obtain the specified belt tension <Ref. to
2) Tighten the lock bolt (A)
Tightening torque:
Lock bolt through bolt:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
Slider bolt:
8 Nm (0.8 kgf-m, 5.5 ft-lb)

found.
2) Check the drive belt tension and adjust it if necessary by changing generator installing position
Belt tension
(A)
replaced: 7 9 mm (0.276 0.354 in)
reused: 9 11 mm (0.354 0.433 in)
(B)*
replaced: 7.5 8.5 mm (0.295 0.335 in)
reused: 9.0 10.0 mm (0.354 0.394 in)
*: with air conditioner
(B)
(C)
(A)
EN1179
EN0225
2. REAR SIDE BELT

1) Install the belt, and tighten the slider bolt (B) so
as to obtain the specified belt tension. <Ref. to
C/P
GEN
P/S
A/C
I/P
Tightening torque:
Lock nut (A);
22.6 Nm (2.3 kgf-m, 16.6 ft-lb)
(B)
(A)
EN0226
ME(TURBO)-45
Crankshaft pulley
Generator
Idler pulley
CRANKSHAFT PULLEY
MECHANICAL
13.Crankshaft Pulley
A: REMOVAL

following procedures (1) through (4).
1) Remove the V-belt. <Ref. to ME(TURBO)-44,

REMOVAL, V-belt.>
2) Remove the crankshaft pulley bolt. To lock the
crankshaft, use ST.
ST 499977300
CRANKSHAFT PULLEY WRENCH
CAUTION:
If the tightening angle of crankshaft pulley bolt
is less than 45 degrees, the bolt should be damaged. In this case, the bolt must be replaced.
clean them.
12369AA011
gun.
degrees.
H2M2393C
B: INSTALLATION
1) Install the crankshaft pulley.
2) Install the pulley bolt.
ST 499977300
CRANKSHAFT PULLEY
WRENCH
air gun.
seat and thread.
Tightening torque:
127 Nm (13 kgf-m, 94.0 ft-lb)
CAUTION:
Conduct the tightening procedures by confirming the turning angle of the crankshaft pulley
bolt referring to the gauge indicated on the belt
cover.
4) Install the A/C belt tensioner.
S2M0113
5) Install the V-belt. <Ref. to ME(TURBO)-45, 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(TURBO)-45, INSPECTION, V-belt.>
H2M2393A
ME(TURBO)-46
BELT COVER
MECHANICAL
14.Belt Cover
A: REMOVAL
REMOVAL, V-belt.>
2) Remove the crankshaft pulley. <Ref. to
ME(TURBO)-46, REMOVAL, Crankshaft Pulley.>
3) Remove the belt cover (LH) (A).
4) Remove the belt cover (RH) (B).
5) Remove the front belt cover (C).
S2M1221A
B: INSTALLATION
1) Install the front belt cover (C).
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
2) Install the belt cover (RH) (B).
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
3) Install the belt cover (LH) (A).
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
S2M1221A
4) Install the crankshaft pulley. <Ref. to ME(TURBO)-46, INSTALLATION, Crankshaft Pulley.>

C: INSPECTION
Make sure the cover is not damaged.
ME(TURBO)-47

MECHANICAL
15.Timing Belt Assembly

A: REMOVAL
1. TIMING BELT
REMOVAL, V-belt.>
3) Remove the belt cover. <Ref. to ME(TURBO)47, REMOVAL, Belt Cover.>
4) Remove the timing belt guides. (MT vehicles)
S2M0294
EN0259
5) If the alignment mark and/or arrow mark (which

indicates rotation direction) on timing belt fade
away, put new marks before removing the timing
belt as follows:
(1) Turn the crankshaft using ST, and align the
alignment marks on crankshaft sprocket, intake
camshaft sprocket (LH), exhaust camshaft
sprocket (LH), intake camshaft sprocket (RH)
and exhaust camshaft sprocket (RH) with notches of belt cover and cylinder block.
ST 499987500
CRANKSHAFT SOCKET
S2M1878A
EN0257
EN0258
ME(TURBO)-48

MECHANICAL
(2) Using white paint, put alignment and/or arrow marks on the timing belts in relation to the
sprockets.

CAUTION:
After the timing belt has been removed, never
rotate the intake and exhaust, camshaft sprocket. If the camshaft sprocket is rotated, the intake and exhaust valve heads strike together
and valve stems are bent.
2. BELT IDLER AND AUTOMATIC BELT

TENSION ADJUSTER ASSEMBLY
1) Remove the belt idler (B) and (C).
EN0233
S2M1226A

S2M1225

Z2: 51 tooth length
Z3: 28 tooth length
S2M0411

S2M1223A
6) Remove the belt idler (A).
S2M0412
S2M1226A
ME(TURBO)-49

MECHANICAL
B: INSTALLATION
1. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER
1) Preparation for installation of automatic belt tension adjuster assembly:
CAUTION:
Be sure to slowly move the adjuster rod down
applying a pressure of 294 N (30 kgf, 66 lb).
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 the cylinder. Doing so may damage the cylinder.
Do not release the press pressure until stopper pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to the vertical pressing tool.
(2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kgf, 66 lb) until the adjuster rod is aligned with the stopper pin hole in the
cylinder.
2) Install the automatic belt tension adjuster assembly.

Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
S2M0416

Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
S2M0411
4) Install the belt idler.

Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
H2M2382
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2

mm (0.08 in) (nominal) dia. hex bar wrench inserted into the stopper pin hole in the cylinder,
secure the adjuster rod.
H2M2383
ME(TURBO)-50
S2M0410

MECHANICAL
2. TIMING BELT
1) Preparation for installation of automatic belt tension adjuster assembly. <Ref. to ME(TURBO)-50,
AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, Timing Belt Assembly.>
2) Crankshaft and camshaft sprocket alignment.
(1) Align mark (A) on the crankshaft sprocket
with mark on the oil pump cover at cylinder
block.
(4) Align single line mark (A) on exhaust camshaft sprocket (LH) with notch (B) on belt cover
by turning the sprocket counterclockwise (as
viewed from front of engine).
(A)
S2M1229B
EN0243
(5) Align the single line mark (A) on intake camshaft sprocket (LH) with notch (B) on belt cover
by turning the sprocket clockwise (as viewed
from front of engine).
Ensure the double lines (C) on intake and exhaust camshaft sprockets are aligned.
(2) Align single line mark (A) on the exhaust

camshaft sprocket (RH) with notch (B) on belt
cover.
S2M1230B
S2M1227B
(3) Align single line mark (A) on the intake camshaft sprocket (RH) with notch (B) on belt cover.
(Make sure double lines (C) on intake camshaft
and exhaust camshaft sprockets are aligned.)
S2M1228B
ME(TURBO)-51

MECHANICAL
(6) Ensure the camshaft and crankshaft 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.
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
left-hand camshafts are held to push their corresponding valves down. (Under this condition,
these valves are held lifted.) Right-side camshafts are held so that their cams do not push
valves down.
Left-hand camshafts must be rotated from
the zero-lift position to the position where the
timing belt is to be installed at as small an angle
as possible, in order to prevent mutual interference of intake and exhaust valve heads.
Do not allow 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.
B2M1392B
(A) Intake camshaft

(B) Exhaust camshaft
S2M1231A
ME(TURBO)-52

MECHANICAL
3) Installation of timing belt:
S2M0418
Align the alignment mark on timing belt with marks on sprockets in alphabetical order shown in the figure.
While aligning marks, position the timing belt properly.
CAUTION:
Disengagement of more than three timing belt teeth may result in interference between the valve
and piston.
Ensure the belts rotating direction is correct.
S2M1232A
ME(TURBO)-53

MECHANICAL
4) Install the belt idlers.

Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
CAUTION:
Make sure that the marks on the timing belt and
sprockets are aligned.
EN0255
H2M2398
5) After ensuring that the marks on the timing belt

and sprockets are aligned, remove the stopper pin
from tensioner adjuster.
6) Install the timing belt guide. (MT vehicles)
(1) Temporarily tighten the remaining bolts.
(2) Check and adjust the clearance between
timing belt and timing belt guide.
Clearance:
1.00.5 mm (0.0390.020 in)
EN0256
(3) Tighten the remaining bolts.

Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
S2M0294
S2M0297
EN0257
EN0254
ME(TURBO)-54

MECHANICAL
C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks,
and wear. If any fault is found, replace the belt.
2) Check the condition of back side of belt; if any
crack is found, replace the belt.
EN0258
CAUTION:
Be careful not to let oil, grease or coolant
contact the belt. Remove quickly and thoroughly if this happens.
Do not bend the belt sharply.
Bending radius: h
EN0259
7) Install the belt cover. <Ref. to ME(TURBO)-47,

INSTALLATION, Belt Cover.>
8) Install the crankshaft pulley. <Ref. to ME(TURBO)-46, REMOVAL, Crankshaft Pulley.>
G2M0115
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 automatic belt tension adjuster assembly.
CAUTION:
Slight traces of oil at rod's oil seal does not indicate a problem.
2) Check that the adjuster rod does not move when
a pressure of 294 N (30 kgf, 66 lb) is applied to it.
This is to check adjuster rod stiffness.
ME(TURBO)-55

MECHANICAL
3) If the adjuster rod is not stiff and moves freely

when applying 294 N (30 kgf, 66 lb), check it using
the following procedures:
(1) Slowly press the adjuster rod down to the
end surface of the cylinder. Repeat this motion 2
or 3 times.
(2) With the adjuster rod moved all the way up,
apply a pressure of 294 N (30 kgf, 66 lb) to it.
Check the adjuster rod stiffness.
(3) If the the adjuster rod is not stiff and moves
down, replace the automatic belt tension adjuster assembly with a new one.
4. BELT IDLER
1) Check the idler for smooth rotation. Replace if
noise or excessive play is noted.
2) Check the outer contacting surfaces of idler pulley for abnormal wear and scratches.
3) Check the idler for grease leakage.
CAUTION:
N (1,000 kgf, 2,205 lb).
Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster
rod into the cylinder. Doing so may damage the
cylinder.
4) Measure the extension of rod beyond the body.
If it is not within specifications, replace with a new
one.
Rod extension: H
5.70.5 mm (0.2240.020 in)
H2M2381A
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 is noted.
3) Check the belt tension pulley for grease leakage.
ME(TURBO)-56
CAMSHAFT SPROCKET
MECHANICAL
16.Camshaft Sprocket
B: INSTALLATION
A: REMOVAL
1) Install the camshaft sprocket No. 1. and No. 2.

To lock the camshaft, use ST.
WRENCH (Intake LH)
ST 499207400
CAMSHAFT SPROCKET
WRENCH (Except Intake LH)

REMOVAL, V-belt.>
4) Remove the timing belt assembly. <Ref. to
ME(TURBO)-48, REMOVAL, Timing Belt Assembly.>
FU(TURBO)-31, REMOVAL, Camshaft Position
Sensor.>
6) Remove the camshaft sprockets. To lock the
camshaft, use ST.
WRENCH (Intake LH)
ST 499207400
CAMSHAFT SPROCKET
WRENCH (Except Intake LH)
Tightening torque:
98 Nm (10 kgf-m, 72.4 ft-lb)
CAUTION:
Do not confuse the right and left side camshaft
sprockets during installation. The camshaft
sprocket No. 2 is identified by a projection used
to monitor camshaft position sensor.
ST
EN1320
ST
EN1320

FU(TURBO)-31, INSTALLATION, Camshaft Position Sensor.>
3) Install the timing belt assembly. <Ref. to
ME(TURBO)-50, INSTALLATION, Timing Belt Assembly.>
C: INSPECTION
scratches.
3) Check the crankshaft sprocket notch used for
sensor for damage and contamination of foreign
matter.
ME(TURBO)-57
CRANKSHAFT SPROCKET
MECHANICAL
17.Crankshaft Sprocket
B: INSTALLATION
A: REMOVAL
1) Install the crankshaft sprocket.

REMOVAL, V-belt.>
5) Remove the camshaft sprocket. <Ref. to
ME(TURBO)-57, REMOVAL, Camshaft Sprocket.>
EN0263
EN0263
2) Install the camshaft sprocket. <Ref. to ME(TURBO)-57, INSTALLATION, Camshaft Sprocket.>

C: INSPECTION
scratches.
3) Check the crankshaft sprocket notch used for
sensor for damage and contamination of foreign
matter.
ME(TURBO)-58
CAMSHAFT
MECHANICAL
18.Camshaft
A: REMOVAL
6) Remove the crankshaft sprocket. <Ref. to
ME(TURBO)-58, REMOVAL, Crankshaft Sprocket.>
7) Remove the belt cover No.2 (RH).
11) Remove the spark plug cord.

12) Remove the rocker cover and gasket.
13) Loosen the intake camshaft cap bolts equally, a
little at a time in alphabetical sequence shown in
the figure.
S2M1233A
14) Remove the camshaft caps and intake camshaft.

15) Loosen the exhaust camshaft cap bolts equally, a little at a time in alphabetical sequence shown
in the figure.
B2M0738

S2M1234A
16) Remove the camshaft caps and exhaust camshaft.

CAUTION:
Arrange the camshaft caps in order so that they
can be installed in their original positions.
17) Similarly, remove the camshafts (RH) and related parts.
S2M1163
S2M1162
10) Remove the oil level gauge guide. (LH side

only)
ME(TURBO)-59
CAMSHAFT
MECHANICAL
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 valves is close to or
in contact with base circle of cam lobe.
CAUTION:
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.
Exhaust camshaft (LH): Rotate 45 counterclockwise.
2) Camshaft cap installation:

(1) Apply fluid packing sparingly to the cap mating surface.
CAUTION:
Do not apply fluid packing excessively. Failure
to do so may cause excess packing to come out
and flow toward oil seal, resulting in oil leaks.
Fluid packing:
S2M1839A
(2) Apply engine oil to cap bearing surface and

install the cap on camshaft as shown by identification mark (A).
(3) Gradually tighten the cap in at least two
stages in alphabetical sequence shown in the
figure, and then tighten to 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)
(A)
T2
(E)
(C)
(F)
(D)
T1
(B)
B2M1200B
A
B
(a)
(b)
Left side cylinder head

Right side cylinder head
Intake camshaft
Exhaust camshaft
EN1321
(4) Similarly, tighten the cap on exhaust side.

After tightening the cap, ensure the camshaft rotates only slightly while holding it at base circle.
Tightening torque:
T1: 10 Nm (1.0 kgf-m, 7.2 ft-lb)
T2: 20 Nm (2.0 kgf-m, 14.5 ft-lb)
ME(TURBO)-60
CAMSHAFT
MECHANICAL
3) 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.
CAUTION:
Use a new oil seal.
7) Install the belt cover No. 2 (RH).

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
B2M0738

S2M1880A
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
4) Rocker cover installation:

(1) Install the gasket on rocker cover.
Install the peripheral gasket and ignition coil
gasket.
(2) Apply fluid packing to the four front open
edges of peripheral gasket.
Fluid packing:
S2M1163

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
S2M0300B
(3) Install the rocker cover on cylinder head.

Ensure the gasket is properly positioned during
installation.
5) Install the spark plug cord.
6) Similarly, install the parts on right-hand side.
S2M1162
10) Install the crankshaft sprocket. <Ref. to

ME(TURBO)-58, INSTALLATION, Crankshaft
Sprocket.>
11) Install the camshaft sprockets. <Ref. to
ME(TURBO)-57,
INSTALLATION,
Camshaft
Sprocket.>
ME(TURBO)-61
CAMSHAFT
MECHANICAL
C: INSPECTION
1) Measure the bend, and repair or replace if necessary.
Limit:
0.020 mm (0.0008 in)
G2M0746
2) Check the journal for damage and wear. Replace if faulty.

3) Measure the outside diameter of camshaft journal. If the jounal diameter is not as specified, check
the oil clearance.
Standard
Camshaft journal
Front
Center, rear
37.946 37.9635 mm 29.946 29.963 mm
(1.4939 1.4946 in)
(1.1790 1.1796 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 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)
(A)
T2
(E)
(C)
(F)
(D)
T1
(B)
EN1321
CAUTION:
Do not turn the camshaft.
ME(TURBO)-62
CAMSHAFT
MECHANICAL
(5) Remove the bearing caps.

(6) Measure the widest point of plastigauge on
each journal.
If the oil clearance exceeds the limit, replace the
camshaft. If necessary, replace the camshaft
caps and cylinder head as a set.
Standard:
0.037 0.072 mm (0.0015 0.0028 in)
6) Measure the thrust clearance of camshaft with

dial gauge. If the clearance exceeds the limit, replace the caps and cylinder head as a set. If necessary replace the camshaft.
Standard:
0.015 0.070 mm (0.0006 0.0028 in)
Limit:
0.1 mm (0.004 in)
Limit:
0.10 mm (0.0039 in)
B2M1217
B2M1216
(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; replace if the limit has been exceeded.
Cam height: H
Standard:
Intake:
46.25 46.35 mm (1.821 1.825 in)
Exhaust:
46.15 46.25 mm (1.817 1.821 in)
Limit:
Intake:
46.15 mm (1.817 in)
Exhaust:
46.05 mm (1.813 in)
Cam base circle diameter A:
37.0 mm (1.457 in)
B2M1209A
ME(TURBO)-63

MECHANICAL
19.Cylinder Head Assembly

A: REMOVAL
REMOVAL, V-belt.>
7) Remove the bolt which installs A/C compressor
bracket on cylinder head.
8) Remove the camshaft. <Ref. to ME(TURBO)-59,
REMOVAL, Camshaft.>
CAUTION:
Leave bolts (A) and (D) engaged by three or
four threads to prevent the cylinder head from
falling.
B2M1397C

Remove the bolts (A) and (D) to remove cylinder
head.
B2M1397C

CAUTION:
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 head and cylinder block.
bolt threads.
by 180 again.
(4) Tighten the bolts (A) and (B) to 34 Nm (3.5
kgf-m, 25 ft-lb).
B2M1397D
ME(TURBO)-64

MECHANICAL
(5) Tighten the bolts (C), (D), (E) and (F) to 15

B2M1397D

sequence.
C: DISASSEMBLY
1) Remove the valve shims and valve lifters.
2) Compress the valve spring and remove the
valve spring retainer key. Remove each valve and
valve spring.
ST2 499718000 VALVE SPRING REMOVER
CAUTION:
Keep the removed parts in order for re-installing in their original positions.
Mark each valve to prevent confusion.
Use extreme care not to damage the lips of
the intake valve oil seals and exhaust valve oil
seals.
CAUTION:
Do not tighten the bolts more than 90.
(7) Further tighten all bolts by 80 to 90 in alphabetical sequence.
CAUTION:
Ensure the total re-tightening angle [in the
two previous steps] do not exceed 180.
3) Install the camshaft. <Ref. to ME(TURBO)-60,
INSTALLATION, Camshaft.>
4) Install the A/C compressor bracket on cylinder
head.
5) Install the intake manifold. <Ref. to FU(TURBO)18, INSTALLATION, Intake Manifold.>
6) Install the camshaft sprocket. <Ref. to ME(TURBO)-57, INSTALLATION, Camshaft Sprocket.>
ME(TURBO)-65
S2M1881A

MECHANICAL
D: ASSEMBLY
S2M1197A
(1)
(2)
(3)
(4)
(5)
Exhaust valve
Intake valve
Cylinder head
Valve spring seat
(6)
(7)
(8)
(9)
(10)
Valve spring
Retainer
Retainer key
Valve lifter
Shim
ME(TURBO)-66
(11)
(12)
(13)

Intake valve guide
Exhaust valve guide

MECHANICAL
1) Installation of valve spring and valve:

(1) Coat the stem of each valve with engine oil
and insert the valve into valve guide.
CAUTION:
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
CAUTION:
Uneven torque for the cylinder head nuts can
cause warping. When reassembling, pay special attention to the torque so as to tighten
evenly.
CAUTION:
Be sure to install the valve springs with their
close-coiled end facing the seat on the cylinder
head.
S2M1840A
2. VALVE SEAT
Inspect the intake and exhaust valve seats, and
then correct the contact surfaces with valve seat
cutter if they are defective or when valve guides are
replaced.
S2M1881A
(4) Compress the valve spring, and then fit the

valve spring retainer key.
(5) After installing, tap the valve spring retainers
lightly with wooden hammer for better seating.
2) Apply oil to the surface of the valve lifter and
valve shim.
3) Install the valve lifter and valve shim.
Valve seat width: W

Intake
Standard
1.0 mm (0.039 in)
Limit
1.7 mm (0.067 in)
Exhaust
Standard
1.5 mm (0.059 in)
Limit
2.2 mm (0.087 in)
E: INSPECTION
1. CYLINDER HEAD
1) Make sure that no crack or other damage exists.
In addition to visual inspection, inspect the important areas by means of red check.
2) Measure the warping of the cylinder head surface that mates with crankcase by using a straight
edge (A) and thickness gauge (B).
If the warping exceeds 0.05 mm (0.0020 in), regrind the surface with a surface grinder.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.3 mm (0.012 in)
Standard height of cylinder head:
127.5 mm (5.02 in)
ME(TURBO)-67
G2M0761

MECHANICAL
3. VALVE GUIDE
1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring
the outside diameter of valve stem and the inside
diameter of valve guide with outside and inside micrometers respectively.
Clearance between the valve guide and valve
stem:
Standard
Intake
0.035 0.062 mm (0.0014 0.0024 in)
Exhaust
0.040 0.067 mm (0.0016 0.0026 in)
Limit
0.15 mm (0.0059 in)
2) If the clearance between valve guide and stem
exceeds the limit, replace the valve guide or valve
itself whichever shows greater amount of wear.
See the following procedure for valve guide 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 the ST2 into valve guide and press it
down to remove the valve guide.
(3) Turn the cylinder head upside down and

place ST as shown in the figure.
ST 498767700
G2M0763
(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 ST1 into valve guide.
Press in until the valve guide upper end is flush
with the upper surface of ST2.
S2M1883A
(6) Check the valve guide protrusion.

Valve guide protrusion: L
12.0 12.4 mm (0.472 0.488 in)
(7) Ream the inside of valve guide with ST.
Gently rotate the reamer clockwise while pressing it lightly into the valve guide, and return it
also rotating clockwise. After reaming, clean the
valve guide to remove chips.
ST 499767400
VALVE GUIDE REAMER
S2M1882A
CAUTION:
Apply engine oil to the reamer when reaming.
If the inner surface of the valve guide is torn,
the edge of the reamer should be slightly
ground with an oil stone.
If the inner surface of the valve guide becomes lustrous and the reamer does not chips,
use a new reamer or remedy the reamer.
ME(TURBO)-68

MECHANICAL
(8) Recheck the contact condition between

valve and valve seat after replacing the valve
guide.
4. INTAKE AND EXHAUST VALVE

1) Inspect the flange and stem of valve, and replace if damaged, worn, or deformed, or if H is
less than the specified limit.
H:
5. VALVE SPRINGS
1) Check the valve springs for damage, free length,
and tension. Replace the valve spring if it is not
within specifications presented in the table.
2) To measure the squareness of valve spring,
stand the spring on a surface plate and measure its
deflection at the top using a try square.
Free length
Intake
Standard
1.2 mm (0.047 in)
Limit
0.8 mm (0.031 in)
Exhaust
Standard
1.5 mm (0.059 in)
Limit
0.8 mm (0.031 in)
Tension/spring
height
Squareness
Valve spring
44.67 mm (1.7587 in)
205.0 236.4 N
(20.9 24.1 kgf, 46.1 53.1 lb)
/36.0 mm (1.417 in)
485.4 536.4 N
(49.5 54.7 kgf, 109.2 120.6 lb)
/26.6 mm (1.047 in)
2.5, 2.0 mm (0.079 in)
Valve overall length:

Intake
104.4 mm (4.110 in)
Exhaust
104.7 mm (4.122 in)
G2M0154
G2M0153
2) Put a small amount of grinding compound on the

seat surface and lap the valve and seat surface. Install a new intake valve oil seal after lapping.
ME(TURBO)-69

MECHANICAL
6. INTAKE AND EXHAUST VALVE OIL

SEAL
3) Measure the inner diameter of valve lifter mating

part on cylinder head.
Replace the oil seal with a new one, if the lip is

damaged or spring out of place, or when the surfaces of intake valve and valve seat are reconditioned
or intake valve guide is replaced.
1) Place the cylinder head on ST1.
2) Press in the oil seal to the specified dimension
indicated in the figure by using ST2.
Inner diameter:
34.994 35.016 mm (1.3777 1.3786 in)
CAUTION:
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 [Black]
Exhaust [Brown]
B2M1400
CAUTION:
If difference between outer diameter of valve
lifter and inner diameter of valve lifter mating
part is over the limit, replace the cylinder head.
Standard:
0.019 0.057 mm (0.0007 0.0022 in)
Color of spring part:

Intake [Silver]
Exhaust [Silver]
Limit:
0.100 mm (0.0039 in)
S2M1924A
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)
B2M1222
ME(TURBO)-70
CYLINDER BLOCK
MECHANICAL
20.Cylinder Block
16) Remove the oil cooler.
A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely if applicable.
REMOVAL, V-belt.>
7) Remove the crankshaft sprocket. <Ref. to
ME(TURBO)-58, REMOVAL, Crankshaft Sprocket.>
8) Remove the generator and A/C compressor with
their brackets.
9) Remove the cylinder head assembly. <Ref. to
ME(TURBO)-64, REMOVAL, Cylinder Head Assembly.>
10) Remove the clutch disc and cover. (MT vehicles) <Ref. to CL-20, REMOVAL, Clutch Disc and
Cover.>
11) Remove the flywheel. (MT vehicles) <Ref. to
CL-24, REMOVAL, Flywheel.>
12) Remove the drive plate. (AT vehicles)
Using the ST, lock crankshaft.
ST 498497100
CRANKSHAFT STOPPER
S2M1835B
(a) Gasket
(b) Oil cooler
(c) Connector
17) Removal of oil pan:

(1) Turn the cylinder block with #2 and #4 piston
sides facing 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 then remove
the oil pan.
CAUTION:
of oil pan cutter.
ST
EN1118
13) Remove the oil separator cover.

14) Remove the water by-pass pipe for heater.
15) Remove the oil filter.
S2M1820
18) Remove the oil strainer stay.

21) Remove the water pipes.
ME(TURBO)-71
CYLINDER BLOCK
MECHANICAL
23) Remove the oil pump from cylinder block.

Use a flat-bladed screwdriver as shown in the figure when removing the oil pump.
CAUTION:
Be careful not to scratch the mating surface of
S2M1819
EN0294
(1)
(2)
Service hole plug

Gasket
(3)
(4)
Circlip
Piston pin
24) Remove the service hole cover and service

hole plugs using hexagon wrench [14 mm (0.55
in)].
(5)
(6)
Service hole cover

O-ring
25) Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, and then remove the piston circlip through service hole of #1
and #2 cylinders.
B2M2620
G2M0165
ME(TURBO)-72
CYLINDER BLOCK
MECHANICAL
26) Draw out the piston pin from #1 and #2 pistons

using ST.
ST 499097700
PISTON PIN REMOVER
CAUTION:
Be careful not to confuse the original combination of piston, piston pin and cylinder.
27) Similarly remove the piston pins from #3 and #4

pistons.
28) Remove the bolts which connect cylinder block
on the side of #2 and #4 cylinders.
29) Back off the bolts which connect cylinder block
on the side of #1 and #3 cylinders two or three
turns.
30) Set up the cylinder block so that #1 and #3 cylinders are on the upper side, then remove the cylinder block connecting bolts.
31) Separate the cylinder blocks (LH) and (RH).
CAUTION:
When separating the cylinder block, do not allow the connecting rod to fall and damage the
cylinder block.
G2M0166
B2M2408A
(1)
(2)
Cylinder block
Rear oil seal
(3)
(4)
Crankshaft
Crankshaft bearing
32) Remove the rear oil seal.

33) Remove the crankshaft together with connecting rod.
34) Remove the crankshaft bearings from cylinder
block using a hammer handle.
CAUTION:
Do not confuse the combination of crankshaft
bearings.
Press the bearing at the end opposite to locking
(5)
Piston
lip.
35) Draw out each piston from cylinder block using
a wooden bar or hammer handle.
CAUTION:
Do not confuse the combination of piston and
cylinder.
ME(TURBO)-73
CYLINDER BLOCK
MECHANICAL
B: INSTALLATION
B2M2407A
(1)
(2)
(3)
Crankshaft bearing
Crankshaft
Cylinder block
(4)
Rear oil seal

T1: 25 (2.5, 18.1)
T2: 47 (4.8, 34.7)
CAUTION:
Remove oil in the mating surface of bearing and
cylinder block before installation. Also apply a
coat of engine oil to crankshaft pins.
1) Position the crankshaft on #2 and #4 cylinder
block.
2) Apply fluid packing to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.
Fluid packing:
S2M1826A
CAUTION:
Do not allow fluid packing to jut into O-ring
grooves, oil passages, bearing grooves, etc.
ME(TURBO)-74
CYLINDER BLOCK
MECHANICAL
3) Temporarily tighten the 10 mm cylinder block

connecting bolts in alphabetical sequence shown in
the figure.
6) Install the rear oil seal using ST1 and ST2.

B2M0088D
4) Tighten the 10 mm cylinder block connecting

bolts in alphabetical sequence.
Tightening torque:
47 Nm (4.8 kgf-m, 34.7 ft-lb)
S2M1827A
(A) Rear oil seal

(B) Flywheel attaching bolt
7) Position the top ring gap at (A) or (B) in the figure.

8) Position the second ring gap at 180 on the reverse side for the top ring gap.
(A)
(B)
B2M0088D
5) Tighten the 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown in the
figure.
Tightening torque:
(A) (G): 25 Nm (2.5 kgf-m, 18.1 ft-lb)
(H): 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
EN1509
9) Position the expander gap at (C) in the figure.
(C)
B2M0089F
ME(TURBO)-75
EN1510
CYLINDER BLOCK
MECHANICAL
10) Position the lower rail gap at (D) in the figure.
12) Install the circlip.

Install the circlips in piston holes located opposite
of service holes in cylinder block, when positioning
all pistons in the corresponding cylinders.
NOTE:
Use new circlips.
(D)
EN1511
NOTE:
Align lower rail spin stopper (F) with piston side surface hole (E).
B2M1403A
CAUTION:
Piston front mark faces towards the front of the
engine.
B2M4601A
11) Position the upper rail gap at (G) in the figure.
(A)
EN1513
(A) Front mark
(G)
EN1512
CAUTION:
Ensure ring gaps do not face the same direction.
Ensure ring gaps are not within the piston
skirt area.
ME(TURBO)-76
CYLINDER BLOCK
MECHANICAL
B2M1322J
(1)
(2)
(3)
Piston
Piston pin
Circlip
(4)
(5)
Gasket
Service hole plug
13) Installing the piston:

(1) Turn the cylinder block so that #1 and #2 cylinders face upward.
(2) Using the 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.
ST2 398744300 PISTON GUIDE

T: 69 (7.0, 50.6)
14) Installing piston pin:

(1) Insert the ST3 into service hole to align piston pin hole with connecting rod small end.
CAUTION:
Apply a coat of engine oil to ST3 before insertion.
ST3 499017100 PISTON PIN GUIDE
G2M0189
S2M0306A
(2) Apply a coat of engine oil to the piston pin

and insert piston pin into piston and connecting
rod through service hole.
ME(TURBO)-77
CYLINDER BLOCK
MECHANICAL
(3) Install the circlip.

CAUTION:
Use new circlips.
S2M1828
(4) Apply fluid packing around the service hole

plug.
Fluid packing:
B2M2625
(5) Install the service hole plug and gasket.

CAUTION:
Use a new gasket.
B2M2620
ME(TURBO)-78
CYLINDER BLOCK
MECHANICAL
B2M1323K
(1)
(2)
(3)
(4)
Piston
Piston pin
Circlip
Gasket
(5)
(6)
(7)
Service hole plug

Service hole cover
O-ring
(6) Turn the cylinder block so that #3 and #4 cylinders face upward. Using the same procedures
as used for #1 and #2 cylinders, install the pistons and piston pins.

T1: 6.4 (0.65, 4.7)
T2: 69 (7.0, 50.6)

and then install the oil pan.
Fluid packing:
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
17) Install the oil strainer and O-ring
Tightening torque:
10 Nm (1.0 kgf-m, 7 ft-lb)
18) Install the oil strainer stay.
S2M1833A
ME(TURBO)-79
CYLINDER BLOCK
MECHANICAL

and then install the oil separator cover.
Fluid packing:
(2) Apply fluid packing to the matching surface

of oil pump.
Fluid packing:
B2M0390B
S2M1834A
21) Install the drive plate. (AT vehicles)

ST 498497100
CRANKSHAFT STOPPER
Tightening torque:
72 Nm (7.3 kgf-m, 52.8 ft-lb)
(A) O-ring
(3) Apply a coat of engine oil to the inside of the

oil seal.
S2M0118B
ST
EN1118
22) Install the flywheel. (MT vehicles) <Ref. to CL24, INSTALLATION, Flywheel.>
23) Install the clutch disc and cover. (MT vehicles)
<Ref. to CL-20, INSTALLATION, Clutch Disc and
Cover.>
24) Installation of oil pump:
(1) Discard the front oil seal after removal. Replace with a new one using the ST.
ST 499587100
OIL SEAL INSTALLER
(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 pump's inner rotor
with crankshaft before installation.
S2M0235
ME(TURBO)-80
CYLINDER BLOCK
MECHANICAL
25) Install the water pump and gasket.
29) Install the water by-pass pipe between oil cooler and water pump.
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:
When installing the water pump, tighten bolts
in two stages in alphabetical sequence as
EN0321
H2M1846D
26) Install the water by-pass pipe for heater.

27) Install the oil cooler.
Tightening torque:
T1: 55 Nm (5.5 kgf-m, 40 ft-lb)
T2: 69 Nm (7.0 kgf-m, 50.6 ft-lb)
NOTE:
Always use a new O-ring.
31) Install the cylinder head assembly. <Ref. to
ME(TURBO)-64, INSTALLATION, Cylinder Head
Assembly.>
32) Install the oil level gauge guide and tighten the
attaching bolt (left side only).
33) Install the rocker cover.
34) Install the crankshaft sprocket. <Ref. to
ME(TURBO)-58, INSTALLATION, Crankshaft
Sprocket.>
35) Install the camshaft sprocket. <Ref. to
ME(TURBO)-57,
INSTALLATION,
Camshaft
Sprocket.>
39) Install the generator and A/C compressor
brackets on cylinder head.
41) Install the intake manifold. <Ref. to FU(TURBO)-15, REMOVAL, Intake Manifold.>
EN0320
(A) O-ring
(B) Oil cooler
(C) Connector
28) Install the oil filter using ST.

ST 498547000
OIL FILTER WRENCH
ME(TURBO)-81
CYLINDER BLOCK
MECHANICAL
C: DISASSEMBLY
B2M1320I
(1)
(2)
Connecting rod cap

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

2) Remove the connecting rod bearing.
CAUTION:
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.
CAUTION:
Arrange the removed piston rings in proper order to prevent confusion.
5) Remove the circlip.
ME(TURBO)-82
(5)
(6)
Oil ring
Circlip
CYLINDER BLOCK
MECHANICAL
D: ASSEMBLY
B2M1320J
(1)
(2)
(3)
(4)

Connecting rod
Connecting rod cap
Oil ring
(5)
(6)
(7)
Second ring
Top ring
Circlip
1) Install the connecting rod bearings on connecting rods and connecting rod caps.
CAUTION:
Apply oil to the surfaces of the connecting rod
bearings.
2) Install the connecting rod on crankshaft.
CAUTION:
Position each connecting rod with the side
marked facing forward.
3) Install the connecting rod cap with connecting
rod nut.
Ensure the arrow on connecting rod cap faces the
front during installation.
CAUTION:
Each connecting rod has its own mating cap.
Make sure that they are assembled correctly by
checking their matching number.
When tightening the connecting rod nuts, apply oil on the threads.
4) Install 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.

T: 44.6 (4.55, 32.9)
E: INSPECTION
1. CYLINDER BLOCK
1) Visually check for cracks and damage. Especially, inspect the important parts by means of red lead
check.
2) Check the oil passages for clogging.
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:
0.05 mm (0.0020 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder block:
201.0 mm (7.91 in)
ME(TURBO)-83
CYLINDER BLOCK
MECHANICAL
2. CYLINDER AND PISTON

1) The cylinder bore size is stamped on cylinder
block's front upper surface.
CAUTION:
NOTE:
Standard sized pistons are classified into two
grades, A and B. These grades should be used
as a guide line in selecting a standard piston.
Standard diameter:
A: 92.005 92.015 mm (3.6222 3.6226
in)
B: 91.995 92.005 mm (3.6218 3.6222
in)
2) How to measure the inner diameter of each cylinder:

Measure the inner diameter of each cylinder in both
the thrust and piston pin directions at the heights
shown in the figure, using a cylinder bore gauge.
CAUTION:
Taper:
Standard
0.015 mm (0.0006 in)
Limit
0.050 mm (0.0020 in)
Out-of-roundness:
Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)
H2M1732C
(A)
(B)
(C)
(D)
(E)
(F)
Main journal size mark

Cylinder block RH-LH combination mark
S2M1821A
(A) Piston pin direction

(B) Thrust direction
3) When the piston is to be replaced due to general

or cylinder wear, determine a suitable sized piston
by measuring the piston clearance.
ME(TURBO)-84
CYLINDER BLOCK
MECHANICAL
4) How to measure the outer diameter of each piston:

Measure the outer diameter of each piston at the
height shown in the figure. (Thrust direction)
CAUTION:
Piston grade point H:
37.0 mm (1.457 in)
Piston outer diameter:
Standard
A: 91.985 91.995 mm
(3.6214 3.6218 in)
B: 91.975 91.985 mm
(3.6211 3.6214 in)
92.225 92.235 mm
(3.6309 3.6313 in)
92.475 92.485 mm
(3.6407 3.6411 in)
6) Boring and honing:

(1) If the value of taper, out-of-roundness, or
cylinder-to-piston clearance measured exceeds
the specified limit or if there is any damage on
the cylinder wall, rebore it to use an oversize piston.
CAUTION:
When any of the cylinders needs reboring, all
other cylinders must be bored at the same time,
and use oversize pistons. Do not perform boring on one cylinder only, nor use an oversize
piston for one cylinder only.
(2) If the cylinder inner diameter exceeds the
limit after boring and honing, replace the crankcase.
CAUTION:
Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, pay attention to this when
measuring the cylinder diameter.
Limit of cylinder enlarging (boring):
0.5 mm (0.020 in)
3. PISTON AND PISTON PIN
B2M1305A
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(TURBO)-84, 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.
5) Calculate the clearance between cylinder and

piston.
CAUTION:
Cylinder to piston clearance at 20C (68F):
Standard
0.010 0.030 mm (0.0004 0.0012 in)
Limit
0.050 mm (0.0020 in)
ME(TURBO)-85
CYLINDER BLOCK
MECHANICAL
3) Make sure that the piston pin can be inserted

into the piston pin hole with a thumb at 20C (68F).
Replace if defective.
Standard clearance between piston pin and
hole in piston:
Standard
0.004 0.008 mm (0.0002 0.0003 in)
Limit
0.020 mm (0.0008 in)
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:
Marks are shown on the end of top and second rings. When installing the rings to piston,
face this mark upward.
Oil ring consists of upper rail, expander and
lower rail. When installing on piston, be careful
of each rails direction.
(A)
(B)
B2M1401
(C)
(A)
(B)
(C)
B2M0084A
4) Check the circlip installation groove on piston for

burr (A). If necessary, remove the burr from groove
so that the piston pin can lightly move.
EN1514
(A) Upper rail

(B) Expander
(C) Lower rail
B2M0420B
5) Check the piston pin circlip for distortion, cracks

and wear.
ME(TURBO)-86
CYLINDER BLOCK
MECHANICAL
2) Squarely place the piston ring and oil ring in cylinder, and then measure the piston ring gap with a
thickness gauge.
Top ring
Piston
ring gap
Second
ring
Oil ring
rail
Standard
0.20 0.25
(0.0079 0.0098)
0.35 0.50
(0.0138 0.0197)
0.20 0.50
(0.0079 0.0197)
Unit: mm (in)
Limit
1.0 (0.039)
1.0 (0.039)
5. CONNECTING ROD
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.
Limit of bend or twist per 100 mm (3.94 in) in
length:
0.10 mm (0.0039 in)
1.5 (0.059)
S2M1823
3) Measure the clearance between piston ring and

piston ring groove with a thickness gauge.
CAUTION:
Before measuring the clearance, clean the piston ring groove and piston ring.
Clearance
between piston ring and
piston ring
groove
Top ring
Second
ring
Standard
0.055 0.090
(0.0022
0.0035)
0.030 0.070
(0.0012
0.0028)
Unit: mm (in)
Limit
B2M1184B
0.15 (0.0059)
(A) Thickness gauge
(B) Connecting rod
0.15 (0.0059)
3) Install the connecting rod fitted with bearing to

crankshaft, and then measure the side clearance
(thrust clearance). Replace the connecting rod if
the side clearance exceeds the specified limit.
Connecting rod side clearance:
Standard
0.070 0.330 mm (0.0028 0.0130 in)
Limit
0.4 mm (0.016 in)
B2M1402
EN0335
ME(TURBO)-87
CYLINDER BLOCK
MECHANICAL
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 specification, replace the
defective bearing with a new one of standard size
or undersize as necessary. (See the table below.)
Standard
0.020 0.046 mm (0.0008 0.0018 in)
Limit
0.05 mm (0.0020 in)
6) Inspect the bushing at connecting rod small end,

and replace if worn or damaged. Also measure the
piston pin clearance at connecting rod small end.
Clearance between piston pin and bushing:
Standard
0 0.022 mm (0 0.0009 in)
Limit
0.030 mm (0.0012 in)
Unit: mm (in)
Bearing
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
B2M0085
B2M0084
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.
ST 499037100
CONNECTING ROD BUSHING REMOVER AND INSTALLER
G2M0177
(3) Make two 3 mm (0.12 in) holes in bushing.

Ream the inside of bushing.
(4) After the completion of reaming, clean the
bushing to remove chips.
ME(TURBO)-88
CYLINDER BLOCK
MECHANICAL
6. CRANKSHAFT AND CRANKSHAFT

BEARING
1) Clean the crankshaft completely and check for
cracks by means of red lead check etc., and replace if defective.
2) Measure the crankshaft bend, and correct or replace if it exceeds the limit.
CAUTION:
If a suitable V-block is not available, install the
#1 and #5 crankshaft bearing on cylinder block,
position the crankshaft on these bearings and
measure the crankshaft bend using a dial
gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
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 then
When grinding the crank journal or crank pin, finish
them to specified dimensions according to the undersize bearing to be used.
Crank pin and crank journal:
Out-of-roundness
0.020 mm (0.0008 in) or less
Taper limit
0.07 mm (0.0028 in)
Grinding limit
0.250 mm (0.0098 in)
G2M0179
EN0339
Unit: mm (in)
Journal O.D.
Standard
0.03 (0.0012)
undersize
0.05 (0.0020)
undersize
0.25 (0.0098)
undersize
Crank journal diameter

#1, #3, #5
#2, #4
59.992 60.008
59.992 60.008
(2.3619 2.3625)
(2.3619 2.3625)
Crank pin diameter

51.984 52.000
(2.0466 2.0472)
Bearing size
1.998 2.011
(0.0787 0.0792)
2.000 2.013
(0.0787 0.0793)
1.486 1.498
(0.0585 0.0590)
Journal O.D.
59.962 59.978
(2.3607 2.3613)
59.962 59.978
(2.3607 2.3613)
51.954 51.970
(2.0454 2.0461)
Bearing size
2.017 2.020
(0.0794 0.0795)
2.019 2.022
(0.0795 0.0796)
1.504 1.512
(0.0592 0.0595)
Journal O.D.
59.942 59.958
(2.3599 2.3605)
59.942 59.958
(2.3599 2.3605)
51.934 51.950
(2.0447 2.0453)
Bearing size
2.027 2.030
(0.0798 0.0799)
2.029 2.032
(0.0799 0.0800)
1.514 1.522
(0.0596 0.0599)
Journal O.D.
59.742 59.758
(2.3520 2.3527)
59.742 59.758
(2.3520 2.3527)
51.734 51.750
(2.0368 2.0374)
Bearing size
2.127 2.130
(0.0837 0.0839)
2.129 2.132
(0.0838 0.0839)
1.614 1.622
(0.0635 0.0639)
ME(TURBO)-89
CYLINDER BLOCK
MECHANICAL
4) Measure the thrust clearance of crankshaft at

center bearing. If the clearance exceeds the limit,
replace the bearing.
Crankshaft thrust clearance:
Standard
0.030 0.115 mm (0.0012 0.0045 in)
Limit
0.25 mm (0.0098 in)
EN0341
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.
Unit: mm (in)
Crankshaft oil clearance
0.010 0.030 (0.0004
Standard
0.0012)
Limit
0.040 (0.0016)
ME(TURBO)-90

MECHANICAL
21.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)
TROUBLE
1. Engine will not start.
1) Starter does not turn.
2) Initial combustion does

not occur.
3) Initial combustion occur.
A Very often
B Sometimes
C Rarely
PROBLEM PARTS, ETC.

Starter
POSSIBLE CAUSE
Defective battery-to-starter harness

Defective starter switch
Defective inhibitor switch or neutral switch
Defective starter
Battery
Poor terminal connection
Run-down battery
Defective charging system
Friction
Seizure of crankshaft and connecting rod bearing
Seized camshaft
Seized or stuck piston and cylinder
Starter
Defective starter
Engine control system <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.>
Fuel line
Belt
Defective
Defective timing
Compression
Intake system
Fuel line
Clogged fuel line
Belt
Defective
Defective timing
Compression
ME(TURBO)-91
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
TROUBLE
4) Engine stalls after initial
combustion.
2. Rough idle and engine

stall
PROBLEM PARTS, ETC.

POSSIBLE CAUSE
Intake system
Fuel line
Clogged fuel line
Belt
Defective
Defective timing
Compression
Intake system
Defective PCV valve
Fuel line
Clogged fuel line
Belt
Defective timing
Compression
Lubrication system
Cooling system
Overheating
Others
ME(TURBO)-92
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
C

MECHANICAL
TROUBLE
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
Overheating
Over cooling
Others
Intake system
Defective PCV valve
Fuel line
Clogged fuel line
Belt
Defective timing
Compression
Cooling system
Overheating
Others
ME(TURBO)-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
TROUBLE
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
Others
Cooling system
Overheating
Others
Intake system
Defective PCV valve
Belt
Defective timing
Compression
Lubrication system
Cooling system
Over cooling
Others
Intake system
Belt
Defective timing
Compression
Cooling system
Overheating
Intake system
Defective PCV valve
Compression
Lubrication system
Loosened oil pump attaching bolts and defective
gasket
Defective oil filter o-ring
Defective crankshaft oil seal
Loosened oil drain plug or defective gasket
Loosened oil pan fitting bolts or defective oil pan
ME(TURBO)-94
RANK
A
A
A
B
A
B
B
A
C
C
B
B
C
B
B
C
C
B
C
C
C
A
C
C
C
A
B
B
C
B
A
A
B
C
A
A
B
B
B
B
B
B

MECHANICAL
TROUBLE
PROBLEM PARTS, ETC.
POSSIBLE CAUSE
10. Excessive fuel consump- Engine control system <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.>
tion
Intake system
Belt
Defective timing
Compression
Lubrication system
Cooling system
Over cooling
Others
ME(TURBO)-95
RANK
A
A
B
B
C
C
B
C
C
B
B
C
C
B
ENGINE NOISE
MECHANICAL
22.Engine Noise
A: INSPECTION
Type of sound
Regular clicking sound
Heavy and dull clank
High-pitched clank (Spark

knock)
Clank when engine speed is

medium (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
Oil pressure is low.
Worn connecting rod bearing (big end)
Loose flywheel mounting bolts
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
injector connector of noisy cyl- Worn bearing at crankshaft end of connecting rod
(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 case/adjacent part
NOTE*:
When disconnecting the fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code
is stored in ECM memory.
Therefore, carry out the CLEAR MEMORY MODE <Ref. to EN(TURBO)-45, OPERATION, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(TURBO)-42, OPERATION, Inspection Mode.> after connecting the fuel injector connector.
ME(TURBO)-96
EXHAUST
EX(TURBO)
1.
2.
3.
4.
5.
6.
Page
Center Exhaust Pipe ...................................................................................8
Joint Pipe ..................................................................................................12
Muffler .......................................................................................................14
GENERAL DESCRIPTION
EXHAUST
A: COMPONENT
1. FRONT EXHAUST PIPE
(25)
T6
(22)
T1
T3
(1)
T1
(2)
T3
(24)
(23)
(3)
(21)
(6)
A
(5)
T4
T5
(20)
(16)
(7)
(17)
(4)
(8)
(10)
(9)
(15)
T1
(18)
T3
(19)
(11)
T3
(14)
(12)
(13)
T4
T1
T2
T2
T2
EN1499
EX(TURBO)-2
GENERAL DESCRIPTION
EXHAUST
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Gasket
Upper exhaust manifold cover (RH)
Exhaust manifold (RH)
Lower exhaust manifold cover (RH)
Front exhaust pipe upper clamp
Front exhaust pipe upper cover
Front exhaust pipe upper insulator
(RH)
(8)
Front exhaust pipe upper insulator

(LH)
(9)
(10)
(11)
Gasket
Front exhaust pipe
Front exhaust pipe lower insulator
(RH)
(12)
Front exhaust pipe lower insulator

(LH)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
Front exhaust pipe lower cover

Front exhaust pipe lower clamp
T1: 19 (1.9, 13.7)
Gasket
T2: 25 (2.5, 18.1)
Gasket
T3: 35 (3.6, 26.0)
Upper exhaust manifold cover (LH) T4: 40 (4, 28.9)
Exhaust manifold (LH)
T5: <Ref. to FU(TURBO)-45,
INSTALLATION, Front Oxygen
Lower exhaust manifold cover (LH)
(A/F) Sensor.>
Gasket
Turbocharger joint pipe
INSTALLATION, Exhaust TemGasket
perature Sensor.>
Precatalytic converter
EX(TURBO)-3
(25)
Exhaust temperature sensor
GENERAL DESCRIPTION
EXHAUST
2. CENTER AND REAR EXHAUST PIPE, AND MUFFLER

(26)
(25)
(24)
(20)
(19)
(23)
(22)
(21)
(15)
(25)
T5
(14)
(17)
(18)
(12)
(16)
T6
T4
(10)
T4
(8)
T4
(1)
(27)
(3) (7)
T2
(13)
(4)
T4
T3
(9)
(2)
T4
(5)
T1
T1
(11)
T4
T1
(6)
EN1500
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Gasket
Upper center pipe cover (Front)
Center exhaust pipe (Front)
Lower center pipe cover (Front)
Bracket
Gasket
Upper center pipe cover (Rear)
Lower center pipe cover (Rear)
cover
(11)

cover
Rear oxygen sensor
(12)
(13)
(14)
(15)
(16)

Gasket
Rear exhaust pipe
Lower rear exhaust pipe cover
(Front)
(24)
(25)
(26)
(27)
(17)
(18)
(19)
(20)
(21)
Chamber
Cushion
Spring
Bolt
Upper rear exhaust pipe cover
(Front)
(22)
Upper rear exhaust pipe cover

(Rear)
Gasket

T1: 13 (1.3, 9.6)
T2: 18 (1.8, 13.0)
T3: 30 (3.1, 22.4)
T4: 35 (3.6, 26.0)
T5: 48 (4.9, 35.4)
INSTALLATION, Rear Oxygen
Sensor.>
(23)
EX(TURBO)-4
Muffler
Cushion
Muffler cutter
Center exhaust pipe (Rear)
GENERAL DESCRIPTION
EXHAUST
B: CAUTION
points.
cable from battery.
EX(TURBO)-5
FRONT EXHAUST PIPE

EXHAUST
10) Separate the front exhaust pipe from exhaust

manifolds.
A: REMOVAL
G2M0854
G6M0095
2) Remove the front oxygen (A/F) sensor. <Ref. to

FU(TURBO)-44, REMOVAL, Front Oxygen (A/F)
Sensor.>
4) Remove the lower exhaust manifold cover (RH).
5) Remove the lower and upper exhaust manifold
covers (LH).
B: INSTALLATION
NOTE:
1) Assemble the front exhaust pipe and exhaust
manifolds.
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
G2M0854
G2M0852
6) Remove the bolts and nuts which hold front exhaust pipe assembly to turbocharger joint pipe.
7) While holding the front exhaust pipe assembly
with one hand, remove the nuts which hold front exhaust pipe assembly to cylinder head exhaust port.
2) Install the front exhaust pipe covers.

Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
3) Install the upper exhaust manifold cover (RH).
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
4) Install the front exhaust pipe assembly.
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
G2M0853
8) Remove the front exhaust pipe assembly.

9) Remove the covers from exhaust manifold and
front exhaust pipe.
EX(TURBO)-6
FRONT EXHAUST PIPE

EXHAUST
5) Connect the exhaust manifold (RH) to turbocharger joint pipe.

Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
G2M0853
6) Install the upper and lower exhaust manifold

covers (LH).
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
7) Install the lower exhaust manifold cover (RH).
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
G2M0852
8) Install the front oxygen (A/F) sensor. <Ref. to

FU(TURBO)-45, INSTALLATION, Front Oxygen
(A/F) Sensor.>
G6M0095
EX(TURBO)-7
CENTER EXHAUST PIPE

EXHAUST

10) Remove the turbocharger upper cover.
A: REMOVAL
4) Remove the intercooler bracket.
H2M1733
11) Remove the bolts which install lower upper side

of turbocharger upper cover, and remove it.
EN0910

7) Remove the universal joint bolts and then remove the universal joint (RHD model only).
CAUTION:
Scribe alignment marks on the universal joint
so that it can be reassembled at the original
serration.
H2M1931
12) Separate the center exhaust pipe from turbocharger.
H2M1950
8) Remove the bolts which install lower side of turbocharger upper cover.
CAUTION:
Be careful, the turbocharger and exhaust pipe
are hot.
H2M1745

14) Disconnect the connector from rear oxygen
sensor.
EN0834
H2M1929
EX(TURBO)-8
CENTER EXHAUST PIPE

EXHAUST
15) Vertically draw out the clip from crossmember.
20) Remove the center exhaust pipe.
S2M2254
G2M0855
H2M1762
B: INSTALLATION
NOTE:
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
pipe to transmission.
3) Connect the center exhaust pipe to turbocharger.
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
17) Remove the bolt which holds center exhaust

pipe bracket to transmission.
H2M1745
H2M1746
18) Remove the intercooler bracket.

19) Remove the bolt which holds center exhaust
pipe to hanger bracket.
4) Install the center exhaust pipe to rear exhaust

pipe.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
CAUTION:
Be careful not to pull down the center exhaust
pipe.
G2M0855
S2M1723
EX(TURBO)-9
CENTER EXHAUST PIPE

EXHAUST
9) Tighten the bolts which hold intercooler bracket.

Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
11) Place the turbocharger lower cover, and tighten
the bolts which install upper side of lower cover.
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
EN0834
6) Secure the clip on crossmember.
H2M1931
12) Place the turbocharger upper cover, and tighten the bolts which install upper side of upper cover.
S2M2254
7) Tighten the bolt which holds center exhaust pipe

bracket to transmission.
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
Tightening torque:
30 Nm (3.1 kgf-m, 22.4 ft-lb)
H2M1930
H2M1746
8) Tighten the bolt which holds center exhaust pipe

to hanger bracket.

14) Tighten the bolts which install under side of turbocharger upper cover.
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
H2M1929
S2M1723
EX(TURBO)-10
CENTER EXHAUST PIPE

EXHAUST
15) Install the universal joint (RHD model only).

(1) Align the bolt hole on long yoke side of universal joint with the cutout at serrated section of
shaft end, and insert the universal joint.
(2) Align the bolt hole on short yoke side of universal joint with the cutout at serrated section of
gearbox assembly. Lower the universal joint
completely.
(3) Temporarily tighten the bolt on short yoke
side. Raise the universal joint to make sure the
bolt is properly passing through the cutout at
serrated section.
(4) Tighten the bolt on long yoke side, then that
on the short yoke side.
Tightening torque:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
CAUTION:
Make sure that the universal joint bolts are
tightened through notches in shaft serration.
Excessively large tightening torque of universal joint bolts may lead to heavy steering
wheel operation.
Standard clearance between gearbox to DOJ:
Over 15 mm (0.59 in)
H2M1950

18) Install the intercooler bracket.
EN0910

20) Align the center of roll connector. <Ref. to AB11, ROLL CONNECTOR, INSPECTION, Inspection Locations After a Collision.>
EX(TURBO)-11
JOINT PIPE
EXHAUST
4. Joint Pipe
6) Remove the lower exhaust manifold cover (RH).
A: REMOVAL
G2M0852
7) Remove the nuts which hold front exhaust manifold to joint pipe.
G6M0095
EN0917
EN0828
3) Disconnect the exhaust temperature sensor connector.

9) Remove the turbocharger. <Ref. to IN(TURBO)12, REMOVAL, Turbocharger.>
10) Take off the joint pipe in the upward direction.
B: INSTALLATION
Tightening torque:
T: 35 Nm (3.6 kgf-m, 26.0 ft-lb)
EN0896
4) Remove the front oxygen (A/F) sensor. <Ref. to

FU(TURBO)-44, REMOVAL, Front Oxygen (A/F)
Sensor.>
H2M1747A
EX(TURBO)-12
REAR EXHAUST PIPE

EXHAUST
B: INSTALLATION
A: REMOVAL
NOTE:
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
G6M0095

S2M0559

pipe.
CAUTION:
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
S2M0558

CAUTION:
pipe.
S2M0558

G6M0095
S2M0559
5) Remove the rear exhaust pipe.
C: INSPECTION
cracked.
EX(TURBO)-13
MUFFLER
EXHAUST
6. Muffler
B: INSTALLATION
A: REMOVAL
CAUTION:
NOTE:
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
S2M0559
S2M0559
2) Remove the rubber cushions, and detach the

muffler.
CAUTION:
Be careful not to drop the muffler during removal.
NOTE:
To facilitate removal, apply a coat of SUBARU
CRC to the mating area of rubber cushions in advance.
C: INSPECTION
cracked.
EN0897
EX(TURBO)-14
IGNITION
IG(TURBO)
1.
2.
3.
Page
Spark Plug...................................................................................................4
GENERAL DESCRIPTION
IGNITION
A: SPECIFICATIONS
Item
Ignition coil
and ignitor
assembly
Spark plug
Model
Designation
FK0140
Manufacturer
DIAMOND

Thread size
Spark gap
mm
mm (in)
IG(TURBO)-2
NGK: PFR6G
14, P = 1.25
0.7 0.8 (0.028 0.031)
GENERAL DESCRIPTION
IGNITION
B: COMPONENT
T2
T1
(2)
(1)
(1)
T1
(2)
T2
EN0853
(1)
(2)
Spark plug

T1: 21 (2.1, 15.2)
T2: 16 (1.6, 11.7)
C: CAUTION

points.
cable from battery.
IG(TURBO)-3
SPARK PLUG
IGNITION
2. Spark Plug

sockets.
A: REMOVAL
CAUTION:
Spark plug:
NGK: PFR6G
1. RH SIDE
EN0856
2. LH SIDE
1) Disconnect the battery cables, and then remove
the battery and battery carrier.
G6M0095
2) Remove the air cleaner lower case. <Ref. to

IN(TURBO)-7, REMOVAL, Air Cleaner.>
G6M0095
EN0854
4) Remove the ignition coil.

B6M0562

suitable cap.
EN0855
IG(TURBO)-4
SPARK PLUG
IGNITION

then take the tank away from working area.
B: INSTALLATION
1. RH SIDE
21 Nm (2.1 kgf-m, 15.2 ft-lb)
Tightening torque (Ignition coil):
16 Nm (1.6 kgf-m, 11.7 ft-lb)
B2M2023
CAUTION:
2. LH SIDE
21 Nm (2.1 kgf-m, 15.2 ft-lb)
Tightening torque (Ignition coil):
16 Nm (1.6 kgf-m, 11.7 ft-lb)
EN0857
6) Remove the ignition coil.
CAUTION:
EN0858

sockets.
EN0859
IG(TURBO)-5
SPARK PLUG
IGNITION
C: INSPECTION
3) Oil fouled:
S6M0420A
(A)
(B)
(C)
(D)
(E)
G6M0089
Electrode gap
Cracks
Damage
Damaged gasket
1) Normal:
4) Overheating:
colder heat range.
G6M0087
2) Carbon fouled:
cleaner, etc.
heat range.
G6M0088
IG(TURBO)-6
G6M0090
SPARK PLUG
IGNITION
D: ADJUSTMENT
porcelain.
If deposits are too stubborn, replace the plugs.
After cleaning the spark plugs, recondition the firing
surface of electrodes with file. Then correct the
spark plug gap using a gap gauge.
Spark plug gap: L
0.7 0.8 mm (0.028 0.031 in)
S6M0412B
NOTE:
worn to ball shape.
IG(TURBO)-7

IGNITION
C: INSPECTION
Ignitor is integrated with the coil. Therefore resistance cannot be measured.
A: REMOVAL
Direct ignition type has been adopted.
Refer to the Spark Plug Removal for removal procedure. <Ref. to IG(TURBO)-4, REMOVAL, Spark
Plug.>
B: INSTALLATION
Tightening torque:
16 Nm (1.6 kgf-m, 11.7 ft-lb)
IG(TURBO)-8
EN(TURBO)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Page
Electrical Components Location..................................................................8
Engine Condition Data ..............................................................................26
Data Link Connector .................................................................................31
OBD-II General Scan Tool ........................................................................32
Read Diagnostic Trouble Code .................................................................41
Inspection Mode........................................................................................42


A: PROCEDURE
1. ENGINE
Step
to EN(TURBO)-3, CHECK, Check List for
Interview.>
2)Start the engine.
Check
Yes
Go to step 2.
Go to step 3.
CHECK ILLUMINATION OF CHECK ENGINE Does the CHECK ENGINE
malfunction indicator lamp illuMALFUNCTION INDICATOR LAMP (MIL).
minate?

Does the Subaru Select MoniTROUBLE CODE (DTC) ON DISPLAY.
indicate DTC?
3)Turn the ignition switch to ON and the
Subaru Select Monitor or OBD-II general scan
tool switch to ON.
4)Read the DTC on Subaru Select Monitor or

EN(TURBO)-45, Clear Memory Mode.>
2)Perform the inspection mode. <Ref. to
EN(TURBO)-42, Inspection Mode.>
Record the DTC

code. Repair the
trouble cause.
<Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).> Go to
step 4.
Does the Subaru Select Moni- Inspect using

tor or OBD-II general scan tool Diagnostics Proindicate DTC?
cedure with Diagnostic Trouble
Code (DTC).
<Ref. to
EN(TURBO)-82,
(DTC).>
EN(TURBO)-2
No
Inspection using
Diagnostics for
Engine Start Failure. <Ref. to
EN(TURBO)-58,
Diagnostics for
Engine Starting
Failure.>
Inspection using
General Diagnostics Table. <Ref.
to EN(TURBO)350, General
Diagnostic Table.>
Repair the related
parts.
NOTE:
If a DTC is not
shown on display
although MIL illuminates, perform
diagnostics of MIL
(CHECK ENGINE
malfunction indicator lamp) circuit or
combination
meter. <Ref. to
EN(TURBO)-48,
(MIL).>
Complete the
diagnosis.


A: CHECK
1. CHECK LIST NO. 1
NOTE:
Customer's name
Date of sale
Date of repair
Vin No.
Weather
Engine No.
Fuel brand
Odometer reading
Fine
Cloudy
Rainy
Snowy
Various/Others:
C (F)
Outdoor temperature
Place
Engine temperature
Engine speed
Vehicle speed
Driving conditions
Headlight
Blower
A/C compressor
Cooling fan
Front wiper
Rear wiper
km
miles
Hot
Warm
Cool
Cold
Highway
Suburbs
Inner city
Uphill
Downhill
Rough road
Others:
Cold
Warming-up
After warming-up
Any temperature
Others:
rpm
MPH
Not affected
At starting
While idling
At racing
While accelerating
While cruising
While decelerating
ON/ OFF
ON/ OFF
ON/ OFF
ON/ OFF
ON/ OFF
ON/ OFF
Rear defogger
Radio
CD/Cassette
Car phone
CB
EN(TURBO)-3
ON/ OFF
ON/ OFF
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
No shift
EN(TURBO)-4
GENERAL DESCRIPTION

A: CAUTION
engine control module (ECM), main relay and fuel
pump relay.
CAUTION:
engine is running.
switch to OFF.
CAUTION:
H2M1154A

compartment.
EN0945

B3M1666E

not drop them.
EN(TURBO)-5
GENERAL DESCRIPTION

CAUTION:
matching.
complicated, difficult operations. The most important thing in diagnostics is to understand the customer's complaint, and distinguish between the
three causes.
B: INSPECTION
1. BATTERY
of electrolyte.
proper grounding.
2. ENGINE GROUNDING
Make sure the engine grounding terminal is properly connected to the engine.
EN0945
C: NOTE
1. DESCRIPTION
The on-board diagnostics (OBD) system detects
and indicates a fault in various inputs and outputs
of the complex electronic control. CHECK ENGINE
malfunction indicator lamp (MIL) in the combination
meter indicates occurrence of a fault or trouble.
Further, against such a failure or sensors as may
disable the drive, the fail-safe function is provided
to ensure the minimal driveability.
The OBD system incorporated with the vehicles
within this engine family complies with Section
1968.1, California Code of Regulations (OBD-II
regulation). The OBD system monitors the components and the system malfunction listed in Engine
Section which affects on emissions.
When the system decides that a malfunction occurs, MIL illuminates. At the same time of the MIL illumination or blinking, a diagnostic trouble code
(DTC) and a freeze frame engine conditions are
stored into on-board computer.
The OBD system stores freeze frame engine
condition data (engine load, engine coolant temperature, fuel trim, engine speed and vehicle
speed, etc.) into on-board computer when it detects
a malfunction first.
If the OBD system detects the various malfunctions including the fault of fuel trim or misfire, the
OBD system first stores freeze frame engine conditions about the fuel trim or misfire.
When the malfunction does not occur again for
three consecutive driving cycles, MIL is turned off,
but DTC remains at on-board computer.
The OBD-II system is capable of communication
with a general scan tool (OBD-II general scan tool)
formed by ISO 9141 CARB.
The OBD-II diagnostics procedure is different
from the usual diagnostics procedure. When troubleshooting OBD-II vehicles, connect Subaru Select Monitor or the OBD-II general scan tool to the
vehicle.
EN(TURBO)-6
GENERAL DESCRIPTION


D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
24082AA190
(Newly adapted tool)
DESCRIPTION
CARTRIDGE
REMARKS
systems.
22771AA030
SELECT MONITOR KIT

systems.
German: 22771AA070
(Without printer)
French: 22771AA080
(Without printer)
Spanish: 22771AA090
(Without printer)
B2M3876
B2M3877
EN(TURBO)-7


A: LOCATION
1. ENGINE
Module
LHD model
(1)
(3) (2)
(4)
EN1423
RHD model
(3) (2)
(4)
(1)
EN1424
(1)
(2)

(3)
(4)
Test mode connector

Data link connector
EN(TURBO)-8

(2)
EN0718
B3M1575A
(3)
EN0716
EN(TURBO)-9
(4)
EN1425

Sensor
(7)
(8)
(2)
(1)
(3)
(6)
(4)
(8)
(5)
EN0946
(1)
(2)
Pressure sensor
(3)
(4)
(5)
(6)
(7)
Knock sensor
Mass air flow and intake air temperature sensor
EN(TURBO)-10
(8)
Tumble generator valve position

sensor

(2)
(1)
EN1008
EN1009
EN1010
EN1011
EN1012
EN1013
(3)
(8)
(7)
EN1014
EN(TURBO)-11
EN1015

(1)
(2)
(3)
(4)
(5)
(6)
EN0948
(1)
(2)

Precatalytic converter
(3)
(4)

(5)
(6)
Rear oxygen sensor

(1)
(3)
(2)
EN1016
EN1017
(5)
(4)
EN0949
(6)
EN0950
EN(TURBO)-12
EN1018

LHD model
(1)
(2)
EN1019
RHD model
(1)
(2)
EN1020
(1)
Fuel level sensor
(2)
Fuel sub level sensor
EN1036
EN(TURBO)-13
EN1037

Solenoid Valve, Actuator, Emission Control System Parts and Ignition System Parts
(1)
(2)
(5)
(3)
(5)
(4)
EN0951
(1)
(2)

(3)
(4)

Ignition coil
EN(TURBO)-14
(5)

(2)
(1)
EN1021
EN1022
(3)
(4)
EN1023
(5)
EN0952
EN(TURBO)-15
EN1024

LHD model
(2)
(3)
(1)
(4)
(5) (6) (7) (8) (9)

EN1025
RHD model
(1)
(5) (6) (7) (8) (9)
(2)
(4)
(3)
EN1026
(1)
(2)
(3)
Fuel pump
Main relay
Fuel pump relay
(4)
(5)
(6)
Fuel pump controller

Radiator main fan relay 1
Radiator main fan relay 2
EN(TURBO)-16
(7)
(8)
(9)
Radiator sub fan relay 1

Radiator sub fan relay 2
Starter

LHD model
(2)
(3)
(1)
EN0953
RHD model
EN1027
(2)
(3)
(4)
EN1028
EN1029
EN0954
EN1030
(5)
(6)
(7)
(8)
EN(TURBO)-17

2. TRANSMISSION
Module
(2)
(1)
EN0751
(1)

(TCM) (for AT vehicles)
(1)
(2)
AT diagnostic indicator light (for

AT vehicles)
EN1071
EN(TURBO)-18
(2)
EN1072
EN1072

Sensor
B2M2258A
B2M2259A
B2M2260A
B2M2261A
OBD0653B
(1) Vehicle speed sensor 1 (for AT vehicles)

(2) Vehicle speed sensor 2 (for MT vehicles)
(3) Vehicle speed sensor 2 (for AT vehicles)
(4) Torque converter turbine speed sensor (for AT vehicles)
(5) ATF temperature sensor (for AT vehicles)
(6) Brake light switch
EN(TURBO)-19

Solenoid Valve and Switch (AT Vehicles)
B3M1670C
B2M2246B
B2M2263A
B2M2264A
(1) Dropping resistor

(2) Inhibitor switch
(5) Line pressure duty solenoid
(6) Lock-up duty solenoid
(7) Transfer duty solenoid
(8) 2-4 brake duty solenoid
(9) Low clutch timing solenoid valve
(10) 2-4 brake timing solenoid valve
Solenoid Valve and Switch (MT Vehicles)
B2M2265A
(1) Neutral position switch
EN(TURBO)-20

EN(TURBO)-21


To
To
B134
B135
To
9 8 7
6 5 4 3 2 1
19 18 17 16 15 14 13 12 11 10
28 27 26 25 24 23
22 21 20
7 6
5 4 3 2 1
15 14 13 12 11 10 9 8
22 21 20 19 18
17 16
To
2 1
7 6 5 4 3
16 15 14 13 12 11 10 9 8
21 20 19 18 17
24 23 22
To
B137
B136
9 8 7 6 4 5 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
B84
6 5 4 3 2 1
12 11 10 9 8 7
17 16
15 14 13
EN0955
Signal (V)
Ignition SW ON
Engine ON (Idling)
(Engine OFF)
0
7 +7
0
0
0
0
0
7 +7
0
0
0
0
Content
Connector
No.
Terminal No.
Signal (+)
Crankshaft posi- Signal ()
tion sensor Shield
Camshaft Signal (+)
position
Signal ()
sensor
Shield
B135
B135
B135
B135
B135
B135
2
11
21
1
10
21
B135
B135
B135
19
B135
B135
17
26
0
0
0 0.9
0
B135
19
B137
0 1.0
0 1.0
B137
0 1.0
0 1.0
B136
13
0 1.0
0 1.0
B135
18
1.0 1.4
1.0 1.4
B135
19
B134
0 or 5
0 or 5
Signal
Throttle
position
sensor
Rear oxygen sensor
Power
supply
GND (sensor)
Signal
Shield
GND (sensor)
Signal 1
Front oxygen (A/F)

sensor
Signal 2
heater
Rear oxygen sensor
heater signal
Engine
Signal
coolant
temperaGND (senture sensor)
sor
EN(TURBO)-22
Note
5 and 0 are repeatedly displayed when vehicle is driven.

Content
Signal
Shield
GND
sensor signal
Exhaust
Signal
gas temGND
perature
(sensor)
sensor
Signal (V)
Connector
No.
Terminal No.
B84
B84
B84
13
8
7
Ignition SW ON
(Engine OFF)
0
0
B135
27
B135
Engine ON (Idling)
Note
0.3 4.5
0
0
16
B135
19
B84
23
B135
B135
19
B84
13
B135
B135
19
B84
0 or 5
0 or 5
B84
0 or 5
0 or 5
B84
11
0 or 5
0 or 5
B84
10
0 or 5
0 or 5
B137
24
10 13
13 14
B134
16
A/C switch
B134
Ignition switch
B134
14
0
ON: 10 13
OFF: 0
10 13
0
ON: 13 14
OFF: 0
13 14
Mass air
flow sensor
Tumble
generator
valve position sensor
RH
Tumble
generator
valve position sensor
LH
Signal
Power
supply
GND
(sensor)
Signal
Power
supply
GND
(sensor)
Tumble generator valve
RH (open)
RH (close)
LH (open)
LH (close)
Starter switch
B134
Test mode connector

Signal
Knock
sensor
Shield
B134
B135
B135
B137
B137
B137
B135
B134
B136
B136
B136
B136
5
4
22
10
2
3
9
10
24
23
22
21

Sensor power supply
Line end check 1
#1
#2
Ignition
control
#3
#4


ON: 120.5
OFF: 0
5
2.8
0
10 13
10 13
10 13
5
0
0
0
0
0
EN(TURBO)-23
5
2.8
0
13 14
13 14
13 14
5
0
13 14
13 14
13 14
13 14
Cranking: 8 14
Switch is ON when gear is in

neutral position.
When connected: 0
Ignition switch OFF: 10 13
Waveform
Waveform
Waveform
Waveform

Signal (V)
Content
Connector
No.
Terminal No.
Fuel injector
#1
#2
#3
#4
B137
B136
B136
B136
1
6
5
4
Ignition SW ON
(Engine OFF)
10 13
10 13
10 13
10 13
Idle air
control
solenoid
valve
Signal
B136
10
Fuel pump
controller
Signal 1
Signal 2
B134
B136
13
16
B137
27
B137
17
B137
28
B137
A/C relay control
Engine ON (Idling)
Note
1 14
1 14
1 14
1 14
Waveform
Waveform
Waveform
Waveform
0 or 13 14
0 or 13 14
Waveform
ON: 0.5, or less

OFF: 10 13
ON: 0.5, or less
OFF: 10 13
ON: 0.5, or less
OFF: 10 13
ON: 0.5, or less

OFF: 13 14
ON: 0.5, or less
OFF: 13 14
ON: 0.5, or less
OFF: 13 14
15
B136
B137
16
B135
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
B135

control
control
lamp
Engine speed output
valve
Signal
Power
Pressure
supply
sensor
GND (sensor)
Fuel level sensor
B135
19
B135
25
Small light switch
B134
17
Blower fan switch
B134
B134
0.12 4.75
ON: 0
OFF: 10 13
ON: 0
OFF: 10 13
ON: 0
OFF: 10 13
B135
24
10 13
0.12 4.75
ON: 0
OFF: 13 14
ON: 0
OFF: 13 14
ON: 0
OFF: 13 14
ON: 0
OFF: 13 14
B137
19
2.8 3.2
2.8 3.2
B137
29
2.4 2.7
2.4 2.7
B136
B134
21
B134
B134
19
18
Less than 1 More

than 4
More than 4
More than 4
Less than 1 More

than 4
More than 4
More than 4
B136
14
B135
20
B135
B135
B136
B136
28
19
8
18
Less than 1 More

than 4
4.3 4.4
0
0
0
Less than 1 More

than 4
0.9 1.4
0
0
0
Power steering oil pressure switch

Front oxygen (A/F) sensor signal (+)
Front oxygen (A/F) sensor signal ()
Front oxygen (A/F) sensor shield
SSM/GST communication line
AT diagnosis input signal
AT load signal
GND (sensors)
GND (injectors)
EN(TURBO)-24
With A/C vehicles only

Light ON: 1, or less
Light OFF: 10 14
Waveform
Waveform

Content
GND (power supply)

GND (oxygen sensor
heater 1)
GND (oxygen sensor
heater 2)
Signal (V)
Connector
No.
Terminal No.
B136
B134
B134
B134
17
22
7
15
Ignition SW ON
(Engine OFF)
0
0
0
0
B137
B137
Engine ON (Idling)
Note
0
0
0
0
EN(TURBO)-25

6. Engine Condition Data

Content
Specified data
1.6 2.9 (%): Idling
6.4 12.8 (%): 2,500 rpm racing
Engine load
Measuring condition:
Gear position is in neutral position.
A/C is turned to OFF.
All accessory switches are turned to OFF.
EN(TURBO)-26

EN(TURBO)-27


S2M2131
NOTE:
Content
Inhibitor
switch
Brake switch
Connector
No.
B56
B54
B54
Terminal No.
1
23
24
P range
switch
B55
N range
switch
B55
14
R range
switch
B55
D range
switch
B55
3 range
switch
B55
2 range
switch
B55
1 range
switch
B55
B55
12
Voltage (V)
Resistance to
body (ohms)
Ignition switch OFF
10 13

engine OFF)
10 13

P range (except N range)
N range (except P range)
R range
D range
3 range
2 range
1 range
EN(TURBO)-28
Less than 1
More than 8
Less than 1
More than 8
Less than 1
More than 8
Less than 1
More than 8
Less than 1
More than 8
Less than 1
More than 8
Less than 1
More than 8
More than 10.5
Less than 1

Connector
No.
Terminal No.
AT OIL TEMP warning light
B56
11
B54
Throttle position sensor power

supply
B54
B54
11
Content
B55
24
B55
18

speed sensor
B55
B56
17
Engine speed signal
B55
17
Cruise set signal
B55
22
B56
B56
14
B55
10
Shift solenoid 1
B54
22
Shift solenoid 2
B54
B54
B54
B54
Voltage (V)
Light ON
Light OFF
Ignition switch ON (With
engine OFF)
ATF temperature 20C
(68F)
ATF temperature 80C
(176F)
Vehicle stopped.
km/h (12 MPH)
Vehicle stopped.
km/h (12 MPH)
(D range)
(N range)
km/h (6 MPH)
engine OFF)
engine ON)
(SET lamp ON)
set. (SET lamp OFF)
engine ON)
engine ON)
Ignition switch ON
1st or 4th gear
2nd or 3rd gear
1st or 2nd gear
3rd or 4th gear
Throttle fully closed (with
engine OFF) after warm-up.
Throttle fully open (with
Fuse on FWD switch
open and with select lever in
1st gear).
Less than 1
More than 9
Approx. 0.5
Approx. 4.3
EN(TURBO)-29
Resistance to
body (ohms)
Approx. 5.0
2.9 4.0
2.1 2.9 k
0.5 0.8
275 375
0
450 650
0
450 650
0
450 650
Less than 1
More than 5
8 11
Less than 1
More than 6.5

More than 4.8
More than 4.8
8
More than 9
Less than 1
More than 9
Less than 1
10 16
10 16
1.5 5.0
2.0 4.5
Less than 0.5
More than 8.5
Less than 0.5
More than 8.5
Less than 0.5
10 17
10 17

Content
2-4 brake dropping resistor
Connector
No.
B54
B54
Terminal No.
18
17
1st gear
3rd gear
2nd gear
4th gear
B54
16
B54
15

B54
B55
B56
B54
19
9
19
20
AT diagnosis signal
B56
21
Ignition switch ON

Select Monitor)
B56
15
6
System ground line
EN(TURBO)-30
Voltage (V)
Resistance to
body (ohms)
1.5 5.0
2.0 4.5
Less than 0.5
More than 8.5
9 15
Less than 0.5
Less than 1
More than 9
Less than 1
More than 9
0
0
Less than 1
Less than 1
Less than 1
Less than 1
More than 4
10 16
10 16
DATA LINK CONNECTOR

8. Data Link Connector

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

9. OBD-II General Scan Tool

A: OPERATION
1. HOW TO USE OBD-II GENERAL SCAN
TOOL
1) Prepare a general scan tool (OBD-II general
scan tool) required by SAE J1978.
2) Open the cover and connect the OBD-II general
scan tool to data link connector located in the lower
portion of instrument panel (on the driver's side).
3) Using the OBD-II general scan tool, call up diagnostic trouble code(s) (DTC(s)) and freeze frame
data.
OBD-II general scan tool functions consist of:
(1) MODE $01: Current powertrain diagnostic
data
(2) MODE $02: Powertrain freeze frame data
(3) MODE $03: Emission-related powertrain diagnostic trouble codes
(4) MODE $04: Clear/Reset emission-related
diagnostic information
Read out the data according to repair procedures.
(For detailed operation procedures, refer to the
OBD-II General Scan Tool Operation Manual.)
NOTE:
(DTC). <Ref. to EN(TURBO)-75, List of Diagnostic
EN0768
2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)

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
0B
0C
0D
0E
0F
10
11
13
15
24
1C
Data
Number of emission-related powertrain trouble codes and MIL status
Long term fuel trim
Engine revolution
Vehicle speed
Ignition timing advance
Air flow rate from pressure sensor
Throttle valve opening angle
Check whether oxygen sensor is installed.
Oxygen sensor output voltage and short term fuel trim associated with oxygen sensorbank
2
A/F sensor 1 output voltage and short term fuel trim associated with A/F sensor 1
On-board diagnosis system
Unit of measure
ON/OFF
%
C
%
%
kPa
rpm
km/h
C
g/sec
%
V and %
V and %
NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to access generic OBD-II PIDs (MODE
$01).
EN(TURBO)-32

3. MODE $02 (POWERTRAIN FREEZE FRAME DATA)

Refers to data denoting the operating condition when trouble is sensed by the on-board diagnosis system.
PID
02
03
04
05
06
07
0B
0C
0D
Data
Trouble code that caused CARB required freeze frame data storage
Long term fuel trim
Engine revolution
Vehicle speed
Unit of measure
%
C
%
%
kPa
rpm
km/h
NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to access freeze frame data (MODE
$02).
4. MODE $03 (EMISSION-RELATED POWERTRAIN DIAGNOSTIC TROUBLE CODE)

Refer to Read Diagnostic Trouble Code for information about data denoting emission-related powertrain diagnostic trouble codes. <Ref. to EN(TURBO)-41, Read Diagnostic Trouble Code.>
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION)

Refers to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic
information).
NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to clear or reset emission-related diagnostic information (MODE $04).
EN(TURBO)-33

10.Subaru Select Monitor

connector.
A: OPERATION
EN(TURBO)-7, PREPARATION TOOL, General
Description.>
CAUTION:
Do not connect the scan tools except for
Subaru Select Monitor and OBD-II general scan
tool.
S2M0288A
S2M0285

Monitor.
<Ref. to EN(TURBO)-7, PREPARATION TOOL,
General Description.>
6) Using the Subaru Select Monitor, call up diagnostic trouble code(s) (DTC(s)) and various data,
then record them.

(DTC) FOR ENGINE. (NORMAL MODE)
Refer to Read Diagnostic Trouble Code for information about how to indicate DTC. <Ref. to
EN(TURBO)-41, Read Diagnostic Trouble Code.>

(DTC) FOR ENGINE. (OBD MODE)
Refer to Read Diagnostic Trouble Code for information about how to indicate DTC. <Ref. to
EN(TURBO)-41, Read Diagnostic Trouble Code.>
S2M0286A

connector.
EN0768
EN(TURBO)-34

4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE)

key.
Contents
Battery voltage
Engine speed signal
Idle air control signal
Alternator duty control signal
Fuel pump duty control signal
A/F sensor current
A/F sensor resistance
Front oxygen (A/F) sensor output signal
Knock sensor signal
Display
Battery Voltage
Vehicle Speed
Engine Speed
Coolant Temp.
Ignition Timing
Fuel Injection #1 Pulse
ISC Valve Duty Ratio
ALT Duty
Fuel Pump Duty
A/F Sensor #1 Current
A/F Sensor #1 Resistance
A/F Sensor #1
Rear O2 Sensor
A/F Correction #1
Knocking Correction
Atmospheric absolute pressure signal
Atmosphere Pressure
Intake manifold relative pressure signal
Mani. Relative Pressure
A/F correction (short term fuel trim) by rear oxygen sensor

Long term whole fuel trim
Front oxygen (A/F) sensor heater current
Rear oxygen sensor heater voltage
Canister purge control solenoid valve duty ratio
Primary supercharged pressure control signal
Tumble generator valve position sensor signal (right side)
Tumble generator valve position sensor signal (left side)
Tumble generator valve drive signal
Fuel level signal
Learned ignition timing
Mass air flow sensor signal
Air conditioning signal
A/F Correction #3
A/F Learning #1
A/F Heater Current 1
Rear O2 Heater Voltage
CPC Valve Duty Ratio
Primary Control
TGV Position Sensor R
TGV Position Sensor L
TGV Drive
Fuel Level
Intake Air Temp.
Learned Ignition Timing
Mass Air Flow
Air Flow Sensor Voltage
Ignition Switch
Test Mode Signal
A/C Switch
A/C Compressor Signal
EN(TURBO)-35
Unit of measure
V
km/h or MPH
rpm
C or F
deg
%
V
ms
%
%
%
mA
V
%
deg
psi
psi
psi
%
%
A
V
%
%
V
V
OPEN or CLOSE
V
C or F
deg
g/s
V
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF

Contents
Knocking signal
Engine torque control permission signal
Idle switch signal
Small light switch signal
Tumble generator valve output signal
Display
Fuel Pump Relay
Knocking Signal
P/S Switch
Torque Permission Signal
Rear O2 Rich Signal
Starter Switch
Idle Switch
Rear Defogger SW
Blower Fan SW
Light Switch
TGV Output
Unit of measure
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
NOTE:
EN(TURBO)-36

5. READ CURRENT DATA FOR ENGINE. (OBD MODE)

key.
5) On the OBD Menu display screen, select the {Current Data Display & Save} and press [YES] key.
Contents
Number of diagnosis code
Malfunction indicator lamp status
Monitoring test of misfire
Monitoring test of fuel system
Monitoring test of comprehensive component
Test of catalyst
Test of heated catalyst
Test of evaporative emission purge control system
Test of secondary air system
Test of air conditioning system refrigerant
Test of oxygen sensor
Test of oxygen sensor heater
Test of EGR system
Engine load data
Display
Number of Diagnosis Code
MI (MIL)
Misfire monitoring
Fuel system monitoring
Component monitoring
Catalyst Diagnosis
Heated catalyst
Evaporative purge system
Secondary air system
A/C system refrigerant
Oxygen sensor
O2 Heater Diagnosis
EGR system
Fuel System for Bank 1
Calculated load value
Coolant Temp.
Engine speed signal

Ignition timing advance for #1 cylinder
Intake air amount
A/F sensor equipment
Air fuel ratio correction by rear oxygen sensor
On-board diagnostic system
Engine Speed
Vehicle Speed
Ignition timing adv. #1
Intake Air Temp.
Mass Air Flow
A/F sensor
Oxygen Sensor #12
Short term fuel trim #12
OBD System
Unit of measure
No support
No support
No support
No support
No support
No support
%
C or F
%
%
psi
rpm
km/h or MPH
C or F
g/s
%
ON or OFF
V
%
NOTE:
EN(TURBO)-37

6. READ FREEZE FRAME DATA FOR ENGINE. (OBD MODE)

key.
5) On the OBD Menu display screen, select the {Freeze Frame Data} and press [YES] key.
Contents
Diagnostic trouble code (DTC) for freeze frame data
Engine load data
Display
Freeze frame data
Fuel system for Bank1
Engine Load
Coolant Temp.
Engine speed signal

Engine Speed
Vehicle Speed
Unit of measure
DTC
ON or OFF
%
C or F
%
%
psi
rpm
km/h or MPH
NOTE:
7. READ OXYGEN SENSOR MONITORING TEST RESULTS DATA FOR ENGINE. (OBD
MODE)
key.
5) On the OBD Menu display screen, select the {O2 Sensor Monitor} and press [YES] key.
6) On the O2 Sensor Select display screen, select the {Bank 1-Sensor1} or {Bank 1-Sensor2} and press
[YES] key.
Bank 1-Sensor1 indicates the front oxygen or A/F sensor, and Bank 1-Sensor2 indicates the rear oxygen
sensor.
Contents
Oxygen sensor for monitoring test
Rich to lean oxygen sensor threshold voltage
Lean to rich oxygen sensor threshold voltage
Low oxygen sensor voltage for switch time calculation
High oxygen sensor voltage for switch time calculation
Rich to lean oxygen sensor switch time
Lean to rich oxygen sensor switch time
Maximum oxygen sensor voltage for test cycle
Minimum oxygen sensor voltage for test cycle
Display
<O2 Sensor Monitor (-------)>
Rich to lean sensor volt
Lean to rich sensor volt
Low sensor voltage
High sensor voltage
Rich to lean switch time
Lean to rich switch time
Maximum sensor Voltage
Minimum sensor Voltage
Unit of measure
V
V
V
V
sec
sec
V
V
NOTE:
EN(TURBO)-38


key.
5) On the Data Display Menu display screen, select the {Data & LED Display} and press [YES] key.
6) Using the scroll key, move the display screen up or down until the desired data is shown.
Contents
Air conditioning relay signal
Knocking signal
Display
Ignition Switch
Test Mode Signal
Neutral SW
A/C SW
A/C Relay
Knocking Signal
Message
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
Engine torque control permission

signal
Torque Control Permit
ON or OFF
Rear O2 Rich Signal
ON or OFF

Idle switch signal

Idle Switch Signal
ON or OFF
ON or OFF
ON or OFF
ON or OFF

Light switch signal
signal
Tumble generator valve drive signal
P/S SW
Rear Defogger SW
Blower Fan SW
Light SW
ON or OFF
ON or OFF
ON or OFF
ON or OFF
LED ON requirements
When ignition switch is turned to ON.
When neutral position signal is entered.
When air conditioning relay is in function.
When radiator main fan relay is in function.
When radiator sub fan relay is in function.
entered.
entered.
When engine torque control permission signal is entered.
When rear oxygen sensor mixture ratio is
rich.
When idle switch signal is entered.
When crankshaft position sensor signal is
entered.
When camshaft position sensor signal is
entered.
When power steering switch is entered.
When rear defogger switch is turned ON.
When blower fan switch is turned ON.
When small light switch is turned ON.
TGV Signal
ON or OFF
When TGV actuator signal is entered.
TGV Drive
ON or OFF
When TGV moves and valve opens.
NOTE:
EN(TURBO)-39

9. READ CURRENT DATA FOR AT

2) On the System Selection Menu display screen, select the {Transmission Control System} and press
[YES] key.
3) Press the [YES] key after displayed the information of transmission type.
4) On the Transmission Diagnosis display screen, select the {Current Data Display & Save} and press
[YES] key.
Contents
Battery voltage
Engine speed signal
Gear position
Neutral/Parking range signal
Drive range signal
3rd range signal
2nd range signal
1st range signal
Display
Battery Voltage
Rear Wheel Speed
Front Wheel Speed
Engine Speed
ATF Temp.
Gear Position
Lock Up Duty Ratio
Transfer Duty Ratio
Turbine Revolution Speed
Brake Clutch Duty Ratio
Stop Light Switch
ABS Signal
N/P Range Signal
R Range Signal
D Range Signal
3rd Range Signal
2nd Range Signal
1st Range Signal
Shift Solenoid #1
Shift Solenoid #2
Diagnosis Lamp
Unit of measure
V
km/h or MPH
km/h or MPH
rpm
C or F
V
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
ON or OFF
ON or OFF
ON or OFF
NOTE:
EN(TURBO)-40
READ DIAGNOSTIC TROUBLE CODE

11.Read Diagnostic Trouble

Code
A: OPERATION
MODE)
press [YES] key.
4) On the Engine Diagnosis display screen, select the {Diagnostic Code(s) Display} and press
[YES] key.

Refers to data denoting emission-related powertrain diagnostic trouble codes (DTCs).
NOTE:
Refer to OBD-II general scan tool manufacturer's
instruction manual to access emission-related
powertrain diagnostic trouble codes (DTCs)
(MODE $03).
NOTE:

MODE)
press [YES] key.
{Diagnosis Code(s) Display} and press [YES] key.
6) Make sure that a diagnostic trouble code (DTC)
is shown on the display screen.
NOTE:
EN(TURBO)-41
INSPECTION MODE
12.Inspection Mode
2. SUBARU SELECT MONITOR
A: OPERATION
After performing diagnostics and clearing the memory, check for any remaining unresolved trouble data.
Description.>
1. PREPARATION FOR THE INSPECTION

MODE
WARNING:
brake is applied.
safety stand.
S2M0285

Monitor.
S2M0286A
(A)
EN0773
B2M2969A
EN(TURBO)-42
INSPECTION MODE

connector.
link connector located in the lower portion of the
instrument panel (on the driver's side).
EN0768

connector.
CAUTION:
Do not connect scan tools except for the
tool.

If trouble still remains in the memory, corresponding diagnostic trouble code (DTC) appears
NOTE:
Release the parking brake.
wheels may light either the ABS warning light, but
this indicates no malfunctions. When the engine
control diagnosis is finished, perform the ABS

After performing diagnostics and clearing the memory, check for any remaining unresolved trouble data:
1) Connect the test mode connector (A) at the lower side of instrument panel (on the driver's side).
S2M0288A

press [YES] key.
10) On the Engine Diagnosis display screen, select the {Dealer Check Mode Procedure} and press
[YES] key.
Mode? is shown on the display screen, press
[YES] key.
(A)
EN0773
2) Connect the OBD-II general scan tool to its data

link connector in the lower portion of the instrument
panel (on the driver's side).
EN(TURBO)-43
INSPECTION MODE
CAUTION:
tool.
EN0768

NOTE:
Depress the clutch pedal when starting the engine.
4) Using the shift lever, turn the N position switch
to ON.
5) Keep engine speed in the 2,500 3,000 rpm
range for 40 seconds.
6) Place the shift lever in the 1st gear and drive
the vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
wheels may light the ABS warning light, but this indicates no malfunctions. When the engine control
diagnosis is finished, perform the ABS memory
7) Using the OBD-II general scan tool, check for diagnostic trouble code(s) (DTC(s)) and record the
result(s).
NOTE:
EN(TURBO)-44
CLEAR MEMORY MODE


A: OPERATION
MODE)
press [YES] key.
5) When the Done and Turn Ignition Switch OFF
are shown on the display screen, turn the Subaru
Select Monitor and ignition switch to OFF.
NOTE:

MODE)
press [YES] key.
{4. Diagnosis Code(s) Cleared} and press [YES]
key.
6) When the Clear Diagnostic Code? is shown on
the display screen, press [YES] key.
7) Turn the Subaru Select Monitor and ignition
switch to OFF.
NOTE:

For clear memory procedures using the OBD-II
general scan tool, refer to the OBD-II General Scan
Tool Instruction Manual.
EN(TURBO)-45


Check Mode

A: OPERATION
Description.>
EN0768

connector.
S2M0285

Monitor.
CAUTION:
tool.
S2M0288A
S2M0286A
(A)
EN0773

connector.

press [YES] key.
10) On the Engine Diagnosis display screen, select the {System Operation Check Mode} and press
[YES] key.
11) On the System Operation Check Mode display screen, select the {Actuator ON/OFF Operation} and press [YES] key.
12) Select the desired compulsory actuator on the
Actuator ON/OFF Operation display screen and
press [YES] key.
EN(TURBO)-46

13) Pressing the [NO] key completes the compulsory operation check mode. The display will then return to
the Actuator ON/OFF Operation screen.
Contents
Display
Fuel Pump Relay
Radiator Fan Relay
A/C Compressor Relay
CPC Solenoid Valve
NOTE:
The following parts will be displayed but not functional because they are not installed on the vehicle.
Display
EGR Solenoid Valve
ASV Solenoid Valve
PCV Solenoid Valve
Vent Control Solenoid Valve
FICD Solenoid
AAI Solenoid Valve
Fuel Tank Sensor Control Valve
EN(TURBO)-47


A: PROCEDURE
1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN(TURBO)-49, ACTIVATION OF CHECK ENGINE
MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).>
2. Check that the engine malfunction indicator lamp (MIL) does not come on. <Ref. to EN(TURBO)-50, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).>
3. Check that the engine malfunction indicator lamp (MIL) does not go off. <Ref. to EN(TURBO)-52, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT GO OFF., Engine Malfunction Indicator Lamp (MIL).>
4. Check that the engine malfunction indicator lamp (MIL) does not blink at a cycle of 3 Hz. <Ref. to EN(TURBO)-53, CHECK
ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 HZ., Engine Malfunction Indicator
Lamp (MIL).>
5. Check that the engine malfunction indicator lamp (MIL) remains blinking at a cycle of 3 Hz. <Ref. to EN(TURBO)-56, CHECK
ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 HZ., Engine Malfunction Indicator
Lamp (MIL).>
EN(TURBO)-48


LAMP (MIL)

off) or to START with the test mode connector connected, the MIL blinks at a cycle of 3 Hz.

off), the CHECK ENGINE malfunction indicator
NOTE:
of the CHECK ENGINE light circuit or the combination meter circuit. <Ref. to EN(TURBO)-50,
CHECK ENGINE MALFUNCTION INDICATOR
LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).>
EN0774

system is malfunctioning.
OBD0053A
3) If the diagnosis system senses a misfire which

could damage the catalyzer, the MIL will blink at a
cycle of 1 Hz.
OBD0054A
EN(TURBO)-49
OBD0055A


ON.
DIAGNOSIS:
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), MIL does not come on.
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
No.13
SBF-4
4
RHD
AT
i1
B38
22
B36
i1
B36
i3
MT
23
MT
LHD
SBF-1
LHD
RHD
AT
A7
C6
i2
i10
C:
i12
15
COMBINATION
METER
A:
LHD : 16
* RHD
: 13
B37
B137
B72
C:
1 2
3 4
ECM
A:
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
i10
1 2 3 4 5 6 7 8 9 10
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
B36
i3
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 21 22 23 24
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
(LHD)
i1
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
(RHD)
EN1426
Step
Check
CHECK POOR CONTACT.
EN(TURBO)-50
Yes
Go to step 4.
No
Go to step 2.
Repair the poor

contact in ECM
connector.
Go to step 3.

Step

combination meter.
(B137) No. 15 (i12) No. 6:
Check
Yes
Is the ECM connector correctly Replace the ECM.
connected?
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
Go to step 5.
?
CHECK POOR CONTACT.

Is there poor contact in combi- Repair the poor
contact in combinector.
nation meter connector.
CHECK HARNESS BETWEEN COMBINATION METER AND IGNITION SWITCH CONNECTOR.
No
Repair the connection of ECM
connector.

NOTE:
the following:
Open circuit in
harness between
Poor contact in
coupling connector
Go to step 6.

necessary.
NOTE:
Broken down
ignition relay
Blown out fuse
(No. 5)
If replaced fuse
circuit of harness
between fuse (No.
5) and ignition
relay connector.
Open or short
circuit in harness
between fuse (No.
Open circuit in
harness between
fuse (No. 5) and
Poor contact in
Poor contact in
ignition switch
connector
Is the lamp bulb condition OK? Repair the combi- Replace the lamp
CHECK LAMP BULB.
Remove the engine malfunction indicator lamp
nation meter con- bulb.
bulb.
nector.
EN(TURBO)-51


OFF.
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
No.13
SBF-4
4
RHD
AT
i1
B38
22
B36
i1
B36
i3
MT
23
MT
LHD
SBF-1
LHD
RHD
AT
A7
C6
i2
i10
C:
i12
15
COMBINATION
METER
A:
LHD : 16
* RHD
: 13
B37
B137
B72
C:
1 2
3 4
ECM
A:
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
i10
1 2 3 4 5 6 7 8 9 10
B36
i3
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 21 22 23 24
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
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
(LHD)
i1
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
(RHD)
EN1426
Step
Check
EN(TURBO)-52
Yes
Repair the short
circuit in harness
ECM connector.
No
Replace the ECM.
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>


AT A CYCLE OF 3 HZ.
DIAGNOSIS:
Test mode connector circuit is open.
TROUBLE SYMPTOM:
EN(TURBO)-53

WIRING DIAGRAM:
IGNITION
B72 SWITCH
BATTERY
SBF-4
No.13
4
AT
RHD
i1
i1
LHD
RHD
B38
22
B36
4
B36
i3
MT
23
MT
LHD
SBF-1
AT
A7
C:
i12
B126
B75
B76
D2
LHD
B209
16
LHD
F76
F60
:LHD
B22
:RHD
E3
A5
i10
B15
A:
B125
B37
RHD
COMBINATION
METER
i2
RHD
*5
C6
A : B134
ECM
B75
B76
B125
B126
1
2
1
2
A:
B72
F60
B22
1 2
3 4
1
5
9
13
2
6
10
14
3
7
11
15
: LHD
C:
: RHD
B209
i12
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
1 2 3
4 5 6
7 8 9 10 11 12 13 14
4
8
12
16
F1
G1G2
H1 H2
I1 I2
J1 J2
i10
1 2 3 4 5 6 7 8 9 10
B : B137
A : B134
i2
B : B137
1 2 3 4 5
6 7
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
1 2
3 4 5 6 7 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
(LHD)
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
B36
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
i3
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
(RHD)
EN1427
EN(TURBO)-54

Step
Check


?
CHECK POOR CONTACT.


connector?

1)Connect the test mode connector.
CHECK POOR CONTACT.

?

connector?
EN(TURBO)-55
Yes
Go to step 2.
No
Repair the MIL circuit. <Ref. to
EN(TURBO)-50,
CHECK ENGINE
MALFUNCTION
INDICATOR
LAMP (MIL)
DOES NOT
COME ON.,
Lamp (MIL).>
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
ground
Go to step 5.
Repair the open

circuit in harness
between ECM and
Replace the ECM.

<Ref. to
FU(TURBO)-49,
Engine Control
Module.>

DIAGNOSIS:
TROUBLE SYMPTOM:
MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON.
WIRING DIAGRAM:
IGNITION
B72 SWITCH
BATTERY
SBF-4
No.13
4
AT
RHD
i1
i1
LHD
RHD
B38
22
B36
4
B36
i3
MT
23
MT
LHD
SBF-1
AT
A7
i12
1
B126
B75
D2
LHD
B76
B209
16
LHD
F76
F60
:LHD
B22
:RHD
E3
A5
i10
C:
B125
B37
B15
A:
i2
RHD
COMBINATION
METER
RHD
*5
C6
A : B134
ECM
B75
B76
B72
F60
: LHD
B125
B126
1 2
3 4
B22
: RHD
1
2
1
2
A:
1
5
9
13
2
6
10
14
3
7
11
15
C:
B209
i12
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
1 2 3
4 5 6
7 8 9 10 11 12 13 14
4
8
12
16
F1
G1G2
H1 H2
I1 I2
J1 J2
i10
1 2 3 4 5 6 7 8 9 10
B : B137
A : B134
i2
B : B137
1 2 3 4 5
6 7
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H5
H3 H4
I4 I5
J3 J4 J5
1 2
3 4 5 6 7 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
(LHD)
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
B36
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
i3
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
(RHD)
EN1427
EN(TURBO)-56

Step
CHECK TEST MODE CONNECTOR.
Check
Yes
Does the MIL flash on and off? Go to step 2.

MINAL.
EN(TURBO)-57
No
System is in good
order.
NOTE:
MIL 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(TURBO)-49,
test mode connec- Engine Control
tor.
Module.>


A: PROCEDURE
1. Inspection of starter motor circuit. <Ref. to EN(TURBO)-60, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
2. Inspection of ECM power supply and ground line. <Ref. to EN(TURBO)-62, CONTROL MODULE POWER SUPPLY AND
GROUND LINE, Diagnostics for Engine Starting Failure.>
3. Inspection of ignition control system. <Ref. to EN(TURBO)-66, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.>
4. Inspection of fuel pump circuit. <Ref. to EN(TURBO)-70, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
5. Inspection of fuel injector circuit. <Ref. to EN(TURBO)-72, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
EN(TURBO)-58

EN(TURBO)-59


CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(TURBO)-45,
Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(TURBO)-42, Inspection Mode.> .
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-4
IGNITION
SWITCH
B72
P R N D 3
AT
MT
T3
T7
MT
B12
12
7
12
11
AT
B134 ECM
16
B14
STARTER
MOTOR
B72
1 2
3 4
B134
1 2 3 4 5
6 7
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
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
EN1428
1
2
Step
Check
(DTC).
<Ref. to EN(TURBO)-75, LIST,
<Ref. to EN(TURBO)-41, OPERATION, Read List of Diagnostic Trouble
Diagnostic Trouble Code.>
Code (DTC).>
EN(TURBO)-60
Yes
Go to step 2.
No
Go to step 3.

Repair the trouble
cause. <Ref. to
EN(TURBO)-82,
(DTC).>

Step
CHECK INPUT SIGNAL FOR STARTER MOTOR.
ground.
MOTOR.
ground.
motor and ECM.
1)Ignition the switch to OFF.
switch.
and chassis ground.
CHECK POOR CONTACT.
Check poor contact in ignition switch connector.
Check
Yes
No
Go to step 5.

?
Check the starter

motor. <Ref. to
SC-5, Starter.>
Repair the open

circuit of ground
cable.

?

short circuit.

?
Go to step 7.
Repair the ground

short circuit.
Repair the open

circuit in harness
between ignition
switch and battery.

Go to step 9.
circuit between
ignition switch and
Is there poor contact in ignition Repair the poor

switch connector?
contact in ignition
switch connector.
EN(TURBO)-61


CAUTION:
Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(TURBO)-42, Inspection Mode.>
WIRING DIAGRAM:
LHD model
MAIN RELAY
4
6
2
SBF-5
8
5
3
B61
F44
B72 IGNITION
SWITCH
2
1
BATTERY
No.11
SBF-4
B47
A2
D2
D3
D10
A14
SBF-1
A : B134
C : B136
ECM
D : B137
E:
D8
D9
A22
C17
C8
C18
A7
A15
E1
B84
C3
F1
D2
J3
A3
B209
15
13
14
16
F76
F60
E3
E
B72
B47
1
3
5
1 2
3 4
F1
G1G2
H1 H2
I1 I2
J1 J2
A : B134
F60
2
4
6
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
D : B137
B209
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2 3 4 5
6 7
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
E:
1 2
3 4 5 6 7 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
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1429
EN1429
EN(TURBO)-62

RHD model
MAIN RELAY
DATA LINK CONNECTOR
4
6
SBF-5
5
3
2
1
B72
IGNITION
SWITCH
BATTERY
No.11
B47
SBF-4
1
A2
D2
D3
D10
A14
SBF-1
A:
B134
C : B136
ECM
D : B137
B84
13
14
16
15
D8
D9
A22
C17
C8
C18
A7
A15
E1
E:
B22
E3
E
B72
1 2
3 4
E
B47
1
3
5
2
4
6
A : B134
B22
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
E:
C : B136
D : B137
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 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 31
B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
EN0960
Step
Check
CHECK MAIN RELAY.
?
No. 1 and No. 2.
terminals.
Terminals
No. 3 No. 5:
No. 4 No. 6:
EN(TURBO)-63
Yes
Go to step 2.
No
Replace the main
relay.

Step
and chassis ground.
chassis ground.
CHECK INPUT VOLTAGE OF MAIN RELAY.
Check
?
Yes
Go to step 3.
No
Repair the open
circuit in harness
between ECM
connector and
engine grounding
terminal.
Repair the open or


M?
Repair the ground

ECM connector
and main relay
connector, then
replace ECM.
Replace the ECM.
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
Go to step 5.

Go to step 8.
CHECK GROUND CIRCUIT OF MAIN RE?
LAY.
EN(TURBO)-64
Repair the open

circuit in harness
between ECM
connector and
Repair the open
circuit between
main relay and
chassis ground.
Repair the open or


Step
Check
EN(TURBO)-65
Yes
Check the ignition
control system.
<Ref. to
EN(TURBO)-66,
Diagnostics for
Engine Starting
Failure.>
No
Repair the open or
between ECM
connector and


CAUTION:
WIRING DIAGRAM:
LHD model
SBF-1
21
22
ECM
23
24
B136
No.11
SBF-4
4
E5
E1
D5
D4
H3
B209
IGNITION
SWITCH B72
F76
F60
E3
E34
3
E33
3
E32
E31
E
E
IGNITION COIL
No.1
E31
E32
E33
E34
F60
1
5
9
13
2
6
10
14
3
7
11
15
IGNITION COIL
No.2
B72
4
8
12
16
1 2
3 4
IGNITION COIL
No.3
IGNITION COIL
No.4
B209
B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
1
2
3
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1430
EN(TURBO)-66

RHD model
SBF-1
21
22
ECM
23
24
B136
No.11
SBF-4
4
1
IGNITION
SWITCH B72
B22
E3
E34
E33
3
E32
E31
E
E
IGNITION COIL
No.1
E31
E32
E33
E34
B22
1
5
9
13
2
6
10
14
3
7
11
15
IGNITION COIL
No.2
IGNITION COIL
No.3
B136
4
8
12
16
IGNITION COIL
No.4
B72
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
1 2
3 4
1
2
3
EN1431
Step
Check
Is the spark plugs status OK?
CHECK SPARK PLUG CONDITION.
1)Remove the spark plug. <Ref. to
IG(TURBO)-5, INSTALLATION, Spark Plug.>
2)Check the spark plug condition. <Ref. to
IG(TURBO)-6, INSPECTION, Spark Plug.>
CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each cyl1)Connect the spark plug to ignition coil.
inder?
2)Release the fuel pressure. <Ref. to
FU(TURBO)-53, RELEASING OF FUEL
PRESSURE, OPERATION, Fuel.>
engine.
EN(TURBO)-67
Yes
Go to step 2.
No
Replace the spark
plug.
Check the fuel

Go to step 3.
pump system.
<Ref. to
EN(TURBO)-70,
FUEL PUMP CIRCUIT, Diagnostics

Step
Check
Yes
ignitor assembly.
engine ground.
than 5 ?
ground.
ignitor assembly.
(B136) No. 21 (E34) No. 1:
(B136) No. 22 (E33) No. 1:
(B136) No. 23 (E32) No. 1:
(B136) No. 24 (E31) No. 1:
CHECK POOR CONTACT.

?
Go to step 6.
No
NOTE:
the following:
Open circuit in
harness between
ignition switch
connector
Poor contact in
coupling connectors
NOTE:
the following:
Open circuit in
harness between
grounding terminal
NOTE:
the following:
Open circuit in
harness between
ECM and ignition
coil & ignitor
assembly connector
Poor contact in
coupling connector

M?
Go to step 7.
Repair the ground

ECM and ignition
coil & ignitor
assembly connector.

connector?
Repair the poor

contact in ECM
connector.
Replace the ignition coil and ignitor

assembly.
EN(TURBO)-68

EN(TURBO)-69

*3
4
B97
RHD
RHD
CAUTION:
WIRING DIAGRAM:
LHD
FUEL PUMP
RELAY
B46
F44
10
R1
LHD
8
B61
BATTERY
SBF-5
FUEL PUMP
CONTROLLER
1
3
R15
9
8
*21
*
7
6
R122
R3
B99
A13
C16
2
1
R57
FUEL
PUMP
*1
LHD : 20
RHD : 15
*2
LHD : 19
RHD : 14
*3
LHD : 7
RHD : 5
ECM
R58
F44
B97
1 2 3 4
5 6 7 8
A : B134
1 2 3 4 5
6 7
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
A:
B134
C:
B136
B46
R122
1 2
3 4
1 2
3 4
5 6 7 8 9 10
B99
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
R58
1 2 3
4 5 6
C : B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
EN0991
EN(TURBO)-70

Step
Check
PUMP.
operating sound?
NOTE:
Fuel pump operation can also be executed using the Subaru Select Monitor (Function mode:
FD01).
For the procedure, refer to Compulsory Valve
Operation Check Mode. <Ref. to
EN(TURBO)-46, Compulsory Valve Operation
Check Mode.>
EN(TURBO)-71
Yes
Check the fuel
injector circuit.
<Ref. to
EN(TURBO)-72,
FUEL INJECTOR
Starting Failure.>
No
Record the DTC.
Repair the trouble
cause. <Ref. to
EN(TURBO)-82,
(DTC).>


CAUTION:
Check or repair only faulty parts.
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(TURBO)45, Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(TURBO)-42, Inspection Mode.>
WIRING DIAGRAM:
LHD model
MAIN RELAY
6
4
B61
BATTERY
F44
SBF-5
5
3
2
1
D:
B136
C5
C6
D1
C:
B137
ECM
C4
B47
I5
I4
J4
F44
J5
B61
B209
11
10
1
9
12
F76
F60
E3
2
1
E17
2
1
E6
2
1
E16
2
1
E5
#1
#2
#3
#4
FUEL INJECTORS
E5
E6
E16
E17
1 2
F44
1 2 3 4
5 6 7 8
D : B137
C : B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 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 31
1
5
9
13
2
6
10
14
3
7
11
15
B209
4
8
12
16
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
B47
1
3
5
F60
2
4
6
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1432
EN(TURBO)-72

RHD model
MAIN RELAY
6
4
BATTERY
SBF-5
5
3
2
1
B47
ECM
C4
B137
B22
12
11
10
1
9
D:
B136
C5
C6
D1
C:
E3
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 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 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
B47
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
1
3
5
2
4
6
EN0965
Step
Check
TOR.
operating sound?
for this check.
EN(TURBO)-73
Yes
No
Check the fuel
Go to step 2.
pressure. <Ref. to
ME(TURBO)-27,
INSPECTION,
Fuel Pressure.>

Step
Check
Yes
INJECTOR.
fuel injector.

?
(B137) No. 1 (E5) No. 1:
(B136) No. 6 (E16) No. 1:
(B136) No. 5 (E6) No. 1:
(B136) No. 4 (E6) No. 1:

injector terminals.
Terminals
No. 1 No. 2:
CHECK POOR CONTACT.

?
Go to step 4.
No
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
ECM and fuel
injector connector.

and 20 ?
Go to step 6.
Replace the faulty

fuel injector.

connector?
Repair the poor

contact in ECM
connector.
Inspection using
EN(TURBO)-350,
INSPECTION,
EN(TURBO)-74


A: LIST
DTC
No.
P0031
P0032
P0037
P0038
P0101
P0102
P0103
P0106
P0107
P0108
P0111
P0112
P0113
P0117
P0118
P0121
P0122
Item
Index
Front oxygen (A/F) sensor heater cir- <Ref. to EN(TURBO)-82, DTC P0031 FRONT OXYGEN (A/F) SENSOR
cuit low input
HEATER CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic
Front oxygen (A/F) sensor heater cir- <Ref. to EN(TURBO)-86, DTC P0032 FRONT OXYGEN (A/F) SENSOR
cuit high input
HEATER CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic
<Ref. to EN(TURBO)-88, DTC P0037 REAR OXYGEN SENSOR
malfunction
HEATER CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(TURBO)-92, DTC P0038 REAR OXYGEN SENSOR
high input
HEATER CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic
Mass air flow sensor circuit range/
<Ref. to EN(TURBO)-94, DTC P0101 MASS AIR FLOW SENSOR CIRperformance problem (high input)
CUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) , Diagnostic
Mass air flow sensor circuit low input <Ref. to EN(TURBO)-96, DTC P0102 MASS AIR FLOW SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Mass air flow sensor circuit high
<Ref. to EN(TURBO)-100, DTC P0103 MASS AIR FLOW SENSOR CIRinput
CUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Pressure sensor circuit range/perfor- <Ref. to EN(TURBO)-102, DTC P0106 PRESSURE SENSOR CIRCUIT
mance problem (low input)
RANGE/PERFORMANCE PROBLEM (LOW INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(TURBO)-105, DTC P0107 PRESSURE SENSOR CIRCUIT
(DTC).>
<Ref. to EN(TURBO)-109, DTC P0108 PRESSURE SENSOR CIRCUIT
(DTC).>
Intake air temperature sensor circuit <Ref. to EN(TURBO)-114, DTC P0111 INTAKE AIR TEMPERATURE
SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM , Diagnostic
low input
SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic
high input
SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic
<Ref. to EN(TURBO)-122, DTC P0117 ENGINE COOLANT TEMPERAcircuit low input
TURE SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(TURBO)-124, DTC P0118 ENGINE COOLANT TEMPERAcircuit high input
TURE SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Throttle position sensor circuit range/ <Ref. to EN(TURBO)-127, DTC P0121 THROTTLE POSITION SENSOR
performance problem (high input)
CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Throttle position sensor circuit low
<Ref. to EN(TURBO)-129, DTC P0122 THROTTLE POSITION SENSOR
input
Code (DTC).>
EN(TURBO)-75

DTC
No.
P0123
P0125
P0131
P0132
P0133
P0136
P0137
P0138
P0139
P0171
P0172
P0244
P0244
P0245
P0246
P0301
P0302
P0303
P0304
Item
Index
Throttle position sensor circuit high

input
<Ref. to EN(TURBO)-133, DTC P0123 THROTTLE POSITION SENSOR

Code (DTC).>
Insufficient coolant temperature for
<Ref. to EN(TURBO)-136, DTC P0125 INSUFFICIENT COOLANT TEMclosed loop fuel control
PERATURE FOR CLOSED LOOP FUEL CONTROL , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(TURBO)-138, DTC P0131 FRONT OXYGEN (A/F) SENSOR
range/performance problem (low
CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) , Diagnosinput)
tic Procedure with Diagnostic Trouble Code (DTC).>
range/performance problem (high
CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) , Diagnosinput)
slow response
CIRCUIT SLOW RESPONSE , Diagnostic Procedure with Diagnostic
Rear oxygen sensor circuit malfunc- <Ref. to EN(TURBO)-144, DTC P0136 REAR OXYGEN SENSOR CIRtion [MT vehicles]
CUIT MALFUNCTION [MT VEHICLES] , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Rear oxygen sensor circuit low input <Ref. to EN(TURBO)-148, DTC P0137 REAR OXYGEN SENSOR CIR[AT vehicles]
CUIT LOW INPUT [AT VEHICLES] , Diagnostic Procedure with Diagnostic
Rear oxygen sensor circuit high input <Ref. to EN(TURBO)-152, DTC P0138 REAR OXYGEN SENSOR CIR[AT vehicles]
CUIT HIGH INPUT [AT VEHICLES] , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Rear oxygen sensor circuit slow
<Ref. to EN(TURBO)-156, DTC P0139 REAR OXYGEN SENSOR CIRresponse
CUIT SLOW RESPONSE , Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Fuel trim malfunction (A/F too lean)
<Ref. to EN(TURBO)-158, DTC P0171 FUEL TRIM MALFUNCTION (A/F
TOO LEAN) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Fuel trim malfunction (A/F too rich)
<Ref. to EN(TURBO)-159, DTC P0172 FUEL TRIM MALFUNCTION (A/F
TOO RICH) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(TURBO)-162, DTC P0244 WASTEGATE CONTROL SOLEmalfunction (high input) [MT vehiNOID VALVE MALFUNCTION (HIGH INPUT) [MT VEHICLES] , Diagnoscles]
<Ref. to EN(TURBO)-164, DTC P0244 WASTEGATE CONTROL SOLEmalfunction (fail-safe) [AT vehicles]
NOID VALVE MALFUNCTION (FAIL-SAFE) [AT VEHICLES] , Diagnostic
Wastegate control solenoid valve cir- <Ref. to EN(TURBO)-166, DTC P0245 WASTEGATE CONTROL SOLEcuit low input
NOID VALVE CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Wastegate control solenoid valve cir- <Ref. to EN(TURBO)-170, DTC P0246 WASTEGATE CONTROL SOLEcuit high input
NOID VALVE CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(TURBO)-172, DTC P0301 CYLINDER 1 MISFIRE
DETECTED , Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
(DTC).>
(DTC).>
(DTC).>
EN(TURBO)-76

DTC
No.
P0327
P0328
P0335
P0336
P0340
P0341
P0420
P0444
P0445
P0458
P0459
P0461
P0462
P0463
P0464
P0480
P0483
P0500
P0506
P0507
Item
Index
<Ref. to EN(TURBO)-182, DTC P0327 KNOCK SENSOR CIRCUIT LOW

<Ref. to EN(TURBO)-184, DTC P0328 KNOCK SENSOR CIRCUIT HIGH
<Ref. to EN(TURBO)-186, DTC P0335 CRANKSHAFT POSITION SENmalfunction
SOR CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic
<Ref. to EN(TURBO)-188, DTC P0336 Crankshaft Position Sensor Circuit
Range/Performance Problem , Diagnostic Procedure with Diagnostic
Camshaft position sensor circuit mal- <Ref. to EN(TURBO)-190, DTC P0340 CAMSHAFT POSITION SENSOR
function
Code (DTC).>
Camshaft position sensor circuit
<Ref. to EN(TURBO)-192, DTC P0341 CAMSHAFT POSITION SENSOR
Catalyst system efficiency below
<Ref. to EN(TURBO)-196, DTC P0420 CATALYST SYSTEM EFFIthreshold
CIENCY BELOW THRESHOLD , Diagnostic Procedure with Diagnostic
Evaporative emission control system <Ref. to EN(TURBO)-198, DTC P0444 EVAPORATIVE EMISSION CONpurge control valve circuit low input
TROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT [MT
[MT vehicles]
VEHICLES] , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Evaporative emission control system <Ref. to EN(TURBO)-202, DTC P0445 EVAPORATIVE EMISSION CONpurge control valve circuit high input TROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT [MT
[MT vehicles]
Evaporative emission control system <Ref. to EN(TURBO)-204, DTC P0458 EVAPORATIVE EMISSION CONpurge control valve circuit low input
TROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT [AT
[AT vehicles]
Evaporative emission control system <Ref. to EN(TURBO)-208, DTC P0459 EVAPORATIVE EMISSION CONpurge control valve circuit high input TROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT [AT
[AT vehicles]
Fuel level sensor circuit range/perfor- <Ref. to EN(TURBO)-210, DTC P0461 FUEL LEVEL SENSOR CIRCUIT
mance problem
<Ref. to EN(TURBO)-212, DTC P0462 FUEL LEVEL SENSOR CIRCUIT
(DTC).>
<Ref. to EN(TURBO)-216, DTC P0463 FUEL LEVEL SENSOR CIRCUIT
(DTC).>
<Ref. to EN(TURBO)-220, DTC P0464 FUEL LEVEL SENSOR INTERMITTENT INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(TURBO)-223, DTC P0480 COOLING FAN RELAY 1 CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(TURBO)-227, DTC P0483 COOLING FAN FUNCTION
PROBLEM , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(TURBO)-230, DTC P0500 VEHICLE SPEED SENSOR MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Idle control system RPM lower than
<Ref. to EN(TURBO)-232, DTC P0506 IDLE CONTROL SYSTEM RPM
expected
LOWER THAN EXPECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Idle control system RPM higher than <Ref. to EN(TURBO)-234, DTC P0507 IDLE CONTROL SYSTEM RPM
expected
HIGHER THAN EXPECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(TURBO)-77

DTC
No.
P0508
P0509
P0512
P0513
P0545
P0546
P0604
P0703
P0705
P0710
P0715
P0720
P0725
P0731
P0732
P0733
P0734
P0741
P0743
P0748
P0753
P0758
P0778
Item
Index
Idle control system circuit low input
<Ref. to EN(TURBO)-236, DTC P0508 IDLE CONTROL SYSTEM CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Idle control system circuit high input <Ref. to EN(TURBO)-238, DTC P0509 IDLE CONTROL SYSTEM CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(TURBO)-240, DTC P0512 STARTER SWITCH CIRCUIT
(DTC).>
UNREGISTERED KEY), Diagnostics Chart with Diagnostic Trouble Code
(DTC).>
Exhaust gas temperature sensor cir- <Ref. to EN(TURBO)-242, DTC P0545 EXHAUST GAS TEMPERATURE
cuit low input
Exhaust gas temperature sensor cir- <Ref. to EN(TURBO)-244, DTC P0546 EXHAUST GAS TEMPERATURE
cuit high input
Internal control module memory
<Ref. to EN(TURBO)-247, DTC P0604 INTERNAL CONTROL MODULE
check sum error
MEMORY CHECK SUM ERROR , Diagnostic Procedure with Diagnostic
<Ref. to EN(TURBO)-250, DTC P0703 BRAKE SWITCH INPUT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Transmission range sensor circuit
<Ref. to AT-119, CHECK INHIBITOR SWITCH., Diagnostic Procedure for
malfunction
No-diagnostic Trouble Code (DTC).>
Transmission fluid temperature sen- <Ref. to AT-46, DTC 27 ATF TEMPERATURE SENSOR, Diagnostic Procesor circuit malfunction
dure with Diagnostic Trouble Code (DTC).>
Torque converter turbine speed sen- <Ref. to AT-62, DTC 36 TORQUE CONVERTER TURBINE SPEED SENsor circuit malfunction
SOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Output speed sensor (vehicle speed <Ref. to AT-57, DTC 33 FRONT VEHICLE SPEED SENSOR, Diagnostic
sensor 2) circuit malfunction
Engine speed input circuit malfunc<Ref. to AT-42, DTC 11 ENGINE SPEED SIGNAL, Diagnostic Procedure
tion
<Ref. to EN(TURBO)-252, DTC P0731 GEAR 1 INCORRECT RATIO ,
Torque converter clutch system mal- <Ref. to EN(TURBO)-254, DTC P0741 TORQUE CONVERTER CLUTCH
function
SYSTEM MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Torque converter clutch system
<Ref. to AT-94, DTC 77 LOCK-UP DUTY SOLENOID, Diagnostic Procedure
(Lock-up duty solenoid) electrical
Pressure control solenoid (Line pres- <Ref. to AT-86, DTC 75 LINE PRESSURE DUTY SOLENOID, Diagnostic
sure duty solenoid) electrical
Shift solenoid A (Shift solenoid 1)
electrical
Shift solenoid B (Shift solenoid 2)
electrical
2-4 brake pressure control solenoid
<Ref. to AT-90, DTC 76 2-4 BRAKE DUTY SOLENOID, Diagnostic Procevalve (2-4 brake duty solenoid) circuit dure with Diagnostic Trouble Code (DTC).>
malfunction
EN(TURBO)-78

DTC
No.
P0785
P0851
P0852
P0864
P1086
P1087
P1088
P1089
P1090
P1091
P1092
P1093
P1094
P1095
P1096
P1097
P1110
P1111
P1112
Item
Index
2-4 brake timing control solenoid

valve (2-4 brake timing solenoid) circuit malfunction
Neutral position switch circuit high
input [AT vehicles]
<Ref. to AT-82, DTC 74 2-4 BRAKE TIMING SOLENOID, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(TURBO)-256, DTC P0851 NEUTRAL POSITION SWITCH

CIRCUIT HIGH INPUT [AT VEHICLES] , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(TURBO)-260, DTC P0852 NEUTRAL POSITION SWITCH
input [AT vehicles]
CIRCUIT LOW INPUT [AT VEHICLES] , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(TURBO)-262, DTC P0864 AUTOMATIC TRANSMISSION
input signal circuit malfunction
DIAGNOSIS INPUT SIGNAL CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Tumble generator valve #2 (LH) posi- <Ref. to EN(TURBO)-264, DTC P1086 TUMBLE GENERATOR VALVE
tion sensor circuit low input
#2 (LH) POSITION SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Tumble generator valve #2 (LH) posi- <Ref. to EN(TURBO)-268, DTC P1087 TUMBLE GENERATOR VALVE
tion sensor circuit high input
#2 (LH) POSITION SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Tumble generator valve #1 (RH)
<Ref. to EN(TURBO)-271, DTC P1088 TUMBLE GENERATOR VALVE
position sensor circuit low input
#1 (RH) POSITION SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Tumble generator valve #1 (RH)
position sensor circuit high input
#1 (RH) POSITION SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Tumble generator valve system
#1 (RH) malfunction (stuck open)
SYSTEM #1 (RH) MALFUNCTION (STUCK OPEN) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
#1 (RH) malfunction (stuck close)
SYSTEM #1 (RH) MALFUNCTION (STUCK CLOSE) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
#2 (LH) malfunction (stuck open)
SYSTEM #2 (LH) MALFUNCTION (STUCK OPEN) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
#2 (LH) malfunction (stuck close)
SYSTEM #2 (LH) MALFUNCTION (STUCK CLOSE) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Tumble generator valve circuit #1
(open circuit)
CIRCUIT #1 (OPEN CIRCUIT) , Diagnostic Procedure with Diagnostic
(overcurrent)
CIRCUIT #1 (OVERCURRENT) , Diagnostic Procedure with Diagnostic
(open circuit)
CIRCUIT #2 (OPEN CIRCUIT) , Diagnostic Procedure with Diagnostic
(overcurrent)
CIRCUIT #2 (OVERCURRENT) , Diagnostic Procedure with Diagnostic
Atmospheric pressure sensor circuit <Ref. to EN(TURBO)-288, DTC P1110 ATMOSPHERIC PRESSURE
low input
high input
SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM , Diagnostic
EN(TURBO)-79

DTC
No.
P1130
P1131
P1134
P1139
P1141
P1142
P1146
P1152
P1153
P1230
P1244
P1245
P1301
P1312
P1480
P1507
P1518
P1544
P1560
Item
Index

malfunction (open circuit) [MT vehicles]
malfunction (short circuit) [MT vehicles]
Front oxygen (A/F) sensor microcomputer problem

CIRCUIT MALFUNCTION (OPEN CIRCUIT) [MT VEHICLES] , Diagnostic
CIRCUIT MALFUNCTION (SHORT CIRCUIT) [MT VEHICLES] , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
MICRO-COMPUTER PROBLEM , Diagnostic Procedure with Diagnostic
Front oxygen (A/F) sensor #1 heater <Ref. to EN(TURBO)-296, DTC P1139 FRONT OXYGEN (A/F) SENSOR
circuit range/performance problem
#1 HEATER CIRCUIT RANGE/PERFORMANCE PROBLEM , Diagnostic
Mass air flow sensor circuit range/
<Ref. to EN(TURBO)-298, DTC P1141 MASS AIR FLOW SENSOR CIRperformance problem (low input)
CUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) , Diagnostic
Throttle position sensor circuit range/ <Ref. to EN(TURBO)-300, DTC P1142 THROTTLE POSITION SENSOR
performance problem (low input)
CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Pressure sensor circuit range/perfor- <Ref. to EN(TURBO)-302, DTC P1146 PRESSURE SENSOR CIRCUIT
mance problem (high input)
RANGE/PERFORMANCE PROBLEM (HIGH INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
range/performance problem (low
CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) [AT VEHIinput) [AT vehicles]
CLES] , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
range/performance problem (high
CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) [AT VEHIinput) [AT vehicles]
CLES] , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Fuel pump controller malfunction
<Ref. to EN(TURBO)-310, DTC P1230 FUEL PUMP CONTROLLER
(DTC).>
<Ref. to EN(TURBO)-314, DTC P1244 WASTEGATE CONTROL SOLErange/performance problem (low
NOID VALVE RANGE/PERFORMANCE PROBLEM (LOW INPUT) [MT
input) [MT vehicles]
<Ref. to EN(TURBO)-316, DTC P1245 WASTEGATE CONTROL SOLEmalfunction (fail-safe) [MT vehicles]
NOID VALVE MALFUNCTION (FAIL-SAFE) [MT VEHICLES] , Diagnostic
Fire due to increased exhaust tem<Ref. to EN(TURBO)-318, DTC P1301 FIRE DUE TO INCREASED
perature
EXHAUST TEMPERATURE , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Exhaust gas temperature circuit mal- <Ref. to EN(TURBO)-320, DTC P1312 EXHAUST GAS TEMPERATURE
function
Code (DTC).>
Cooling fan relay 1 circuit high input <Ref. to EN(TURBO)-323, DTC P1480 COOLING FAN RELAY 1 CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Idle control system malfunction (fail- <Ref. to EN(TURBO)-326, DTC P1507 IDLE CONTROL SYSTEM MALsafe)
FUNCTION (FAIL-SAFE) , Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(TURBO)-328, DTC P1518 STARTER SWITCH CIRCUIT
(DTC).>
High exhaust temperature detected
<Ref. to EN(TURBO)-330, DTC P1544 HIGH EXHAUST TEMPERATURE DETECTED , Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(TURBO)-332, DTC P1560 BACK-UP VOLTAGE CIRCUIT
(DTC).>
EN(TURBO)-80

DTC
No.
P1570
Antenna
P1571
P1572
P1574
IMM circuit failure except antenna

circuit
P1576
P1577
P1595

input signal circuit low input
P1596

input signal circuit high input
P1698
P1699
P1700

P1701
P1703
P1711
P1712
Item
Low clutch timing control solenoid

malfunction
malfunction
Index
<Ref. to IM-24, DTC P1570 ANTENNA, Diagnostics Chart with Diagnostic
<Ref. to IM-17, DTC P1571 Reference Code Incompatibility, Diagnostics
<Ref. to IM-22, DTC P1576 EGI CONTROL MODULE EEPROM, Diagnostics Chart with Diagnostic Trouble Code (DTC).>
<Ref. to IM-22, DTC P1577 IMM CONTROL MODULE EEPROM, Diagnostics Chart with Diagnostic Trouble Code (DTC).>
DIAGNOSIS INPUT SIGNAL CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
DIAGNOSIS INPUT SIGNAL CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(TURBO)-340, DTC P1698 ENGINE TORQUE CONTROL
CUT SIGNAL CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
CUT SIGNAL CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to AT-50, DTC 31 THROTTLE POSITION SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(TURBO)-344, DTC P1701 CRUISE CONTROL SET SIGNAL
CIRCUIT MALFUNCTION FOR AUTOMATIC TRANSMISSION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to AT-78, DTC 73 LOW CLUTCH TIMING SOLENOID, Diagnostic
SIGNAL 1 CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
SIGNAL 2 CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(TURBO)-81


A: DTC P0031 FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT LOW INPUT
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(TURBO)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(TURBO)-42, Inspection Mode.> .
WIRING DIAGRAM:
RHD
RHD
B18
MAIN RELAY
6
4
LHD
BATTERY
SBF-5
LHD
2
B61
1 2
3 4
F44
B47
5
3
2
4
6
B137
1
5
9
13
18
29
F44
1 2 3 4
5 6 7 8
19
4
5
B18
4
FRONT OXYGEN
(A/F) SENSOR
B47
2
1
1
3
5
F60
: LHD
B22
: RHD
2
6
10
14
3
7
11
15
4
8
12
16
ECM
8
9
B137
RHD
LHD
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
A3
B209
F76
LHD
B209
RHD
F60
: LHD
B22
: RHD
E3
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1433
Step
Check
Yes
P0037 at the same time?
EN(TURBO)-82
No
Go to step 5.

Step
Check
Yes
CHECK POWER SUPPLY TO FRONT OXY- Is the voltage more than 10 V? Go to step 3.
GEN (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.


?

CHECK CURRENT DATA.
1)Start the engine.
NOTE:
<Ref. to EN(TURBO)-34, Subaru Select Monitor.>
OBD-II scan tool
and chassis ground.
and chassis ground.
Go to step 4.
Repair the poor

contact in connector.
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
NOTE:
the following:
Open circuit in
harness between
ECM and engine
ground cable
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 6.

Is the voltage less than 1.0 V?
Repair the poor

contact in ECM
connector.
Go to step 7.
Go to step 9.
Go to step 8.
EN(TURBO)-83

Step
and chassis ground.
2)Measure the resistance between front oxygen (A/F) sensor connector terminals.
Terminals
No. 2 No. 1:
Check
?
EN(TURBO)-84
Yes
Repair the poor
contact in ECM
connector.
No
Go to step 9.
Repair the harReplace the front

ness and connec- oxygen (A/F) sentor.
sor. <Ref. to
FU(TURBO)-44,
NOTE:
In this case, repair Front Oxygen (A/
F) Sensor.>
the following:
Open or ground
front oxygen (A/F)
sensor and ECM
connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector

EN(TURBO)-85

B: DTC P0032 FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT HIGH INPUT
CAUTION:
WIRING DIAGRAM:
RHD
RHD
B18
MAIN RELAY
6
4
LHD
SBF-5
LHD
2
B61
1 2
3 4
BATTERY
F44
B47
5
3
2
4
6
F44
1 2 3 4
5 6 7 8
B18
4
FRONT OXYGEN
(A/F) SENSOR
B47
2
1
1
3
5
F60
B137
18
29
19
4
5
B22
1
5
9
13
2
6
10
14
3
7
11
15
: LHD
: RHD
4
8
12
16
ECM
8
9
B137
RHD
LHD
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
A3
B209
F76
LHD
B209
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
RHD
F60
: LHD
B22
: RHD
E3
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1433
Step
Check
EN(TURBO)-86
Yes
Go to step 3.
No
Go to step 2.

Step
Check
CHECK FRONT OXYGEN (A/F) SENSOR
HEATER CURRENT.
between ECM and front oxygen (A/F) sensor
connector.
the OBD-II general scan tool.
NOTE:
and chassis ground.
Does the voltage change more

than 8 V by shaking harness
EN(TURBO)-87
Yes
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
Repair the battery END

ECM and front
No

C: DTC P0037 REAR OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION

RHD
RHD
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
*3
F44
1 2 3 4
5 6 7 8
*1
LHD : 2
RHD : 4
B47
1
3
5
2
4
6
LHD : 6
RHD : 1
*3
LHD : 2
RHD : 1
*4
LHD : 1
RHD : 2
LHD : 3
RHD : 4
RHD
LHD
B83
(RHD)
*6
B19
* 45
*
B19
1 2
3 4
(LHD)
2 1
4 3
REAR
OXYGEN SENSOR
1
5
9
13
F60
: LHD
B22
: RHD
2
6
10
14
3
7
11
15
1 2 3
4 5 6
(LHD)
1 2 3 4 5 6
(RHD)
4
8
12
16
B135
* 12
*
B260
1
B259
*6
B83
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
LHD : 4
RHD : 3
B136
LHD
B137
RHD
LHD
B26
B19
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 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 31
C : B136 ECM
A3
B : B135
B209
F76
LHD
F60
: LHD
B22
E3
: RHD
B259
B209
E
RHD
D : B137
D8
D9
B47
F44
RHD
2
1
LHD
2
B61
C13
B17
5
3
LHD
BATTERY
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1434
EN(TURBO)-88

Step
Check
?
Yes
Go to step 2.
CHECK CURRENT DATA.

1)Start the engine.
general scan tool.
No
NOTE:
the following:
Open circuit in
harness between
ECM and engine
ground cable
Poor contact in
ECM connector
Poor contact in
coupling connector
Go to step 3.
NOTE:
the following:
Poor contact in
NOTE:
rear oxygen senFor detailed operation procedure, refer to the
sor connector
Poor contact in
<Ref. to EN(TURBO)-34, Subaru Select Monirear oxygen sentor.>
sor connecting
OBD-II scan tool
harness connector
Poor contact in
ECM connector
Go to step 4.
Does the voltage change less Repair the poor
Go to step 5.
and chassis ground.
connector.
Is the voltage less than 1.0 V? Replace the ECM. Repair the battery
<Ref. to
short circuit in har1)Disconnect the connector from rear oxygen
FU(TURBO)-49,
ness between
sensor.
Engine Control
ECM and rear oxy2)Measure the voltage between ECM connecModule.>
gen sensor contor and chassis ground.
nector. After
repair, replace the
ECM. <Ref. to
FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-89

Step
Check
Yes
CHECK POWER SUPPLY TO REAR OXYGEN SENSOR.
sensor.
sensor connector and engine ground or chassis ground.
LHD model:
RHD model:
CHECK REAR OXYGEN SENSOR.
2)Measure the resistance between rear oxygen sensor connector terminals.
Terminals
No. 1 No. 2:

?
EN(TURBO)-90
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(TURBO)-46,
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

EN(TURBO)-91

D: DTC P0038 REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT

RHD
RHD
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
B47
*3
1
3
5
2
4
6
2 1
4 3
REAR
OXYGEN SENSOR
*1
B19
RHD
LHD
*2
LHD : 6
RHD : 1
*3
LHD : 2
RHD : 1
*4
LHD : 1
RHD : 2
LHD : 3
RHD : 4
B83
(RHD)
LHD : 2
RHD : 4
*6
2
1
F44
B47
1 2 3 4
5 6 7 8
1 2
3 4
(LHD)
LHD
2
B61
* 45
*
5
3
LHD
F44
B19
BATTERY
1
5
9
13
F60
: LHD
B22
: RHD
2
6
10
14
3
7
11
15
1 2 3
4 5 6
(LHD)
1 2 3 4 5 6
(RHD)
4
8
12
16
B135
* 12
*
B260
B259
*6
RHD
B83
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
LHD : 4
RHD : 3
B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
B137
RHD
LHD
B26
B19
C13
B17
LHD
1 2
3 4 5 6 7 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 ECM
A3
B : B135
B209
F76
RHD
F60
: LHD
B22
: RHD
E3
B259
B209
LHD
D8
D9
D : B137
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1434
Step
Check
and chassis ground.
EN(TURBO)-92
Yes
Go to step 2.
No
Go to step 3.

Step
Check
CHECK CURRENT DATA.
Is the value more than 7 A?
between ECM and rear oxygen sensor connector.
current using Subaru Select Monitor or the
NOTE:
CHECK POOR CONTACT.
connector?
EN(TURBO)-93
Yes
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
Repair the poor

contact in ECM
connector.
END
No

E: DTC P0101 MASS AIR FLOW SENSOR CIRCUIT RANGE/PERFORMANCE

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
RHD
RHD
MAIN RELAY
6
4
LHD
5
3
LHD
8
B61
BATTERY
SBF-5
F44
2
1
B47
MASS AIR FLOW AND

INTAKE AIR TEMPERATURE
E13
B27
E7
5
E8
B3
B:
B135
* 12
*
*1
LHD : 3
RHD : 2
*2
LHD : 6
RHD : 1
B19
B83
E:
B3
1 2 3 4 5
E
ECM
B47
1
3
5
2
4
6
B84
E:
B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
B : B135
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B83
1 2 3
4 5 6
(LHD)
1 2 3 4 5 6
F44
(RHD)
1 2 3 4
5 6 7 8
EN0970
EN(TURBO)-94

Step
Check
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0101.
EN(TURBO)-95
No
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(TURBO)-34,
Mass Air Flow and
Intake Air Temperature Sensor.>

F: DTC P0102 MASS AIR FLOW SENSOR CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
WIRING DIAGRAM:
RHD
RHD
MAIN RELAY
6
4
LHD
5
3
LHD
8
B61
BATTERY
SBF-5
F44
2
1
B47
MASS AIR FLOW AND

E13
B27
E7
5
E8
B3
B:
B135
* 12
*
*1
LHD : 3
RHD : 2
*2
LHD : 6
RHD : 1
B19
B83
E:
B3
1 2 3 4 5
E
ECM
B47
1
3
5
2
4
6
B84
E:
B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
B : B135
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B83
1 2 3
4 5 6
(LHD)
1 2 3 4 5 6
F44
(RHD)
1 2 3 4
5 6 7 8
EN0970
EN(TURBO)-96

Step
CONNECT SUBARU SELECT MONITOR OR
THE OBD-II GENERAL SCAN TOOL, AND
READ DATA.
switch to ON.
4)Start the engine.
5)Read the data of mass air flow sensor signal
scan tool.
Check
Is the value equal to or more
than 1.3 g/sec (0.172 lb/min) or
0.3 V and equal to or less than
240 g/sec (32 lb/min) or 4.58
V?
NOTE:
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 3.

and chassis ground while engine is idling.
CHECK INPUT SIGNAL FOR ECM (USING
SUBARU SELECT MONITOR).
and chassis ground while engine is idling.
Yes
No
Even if MIL lights Go to step 2.
up, the circuit has
of the connector or
harness may be
the cause. Repair
the harness or
connector in the
mass air flow sensor.

connector.
monitoring the value with

CHECK POWER SUPPLY TO MASS AIR
FLOW SENSOR.
2)Disconnect the connector from mass air flow
sensor.
4)Measure the voltage between mass air flow
sensor connector and chassis ground.
EN(TURBO)-97
Contact with your

Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.
Repair the open
circuit between
mass air flow sensor and main
relay.

Step
MASS AIR FLOW SENSOR CONNECTOR.
ECM and mass air flow sensor connector.
(B84) No. 13 (B3) No. 3:
(B135) No. 27 (B3) No. 4:
(B135) No. 19 (B3) No. 5:
MASS AIR FLOW SENSOR CONNECTOR
CHECK POOR CONTACT
Check poor contact in mass air flow sensor
connector.
Check
Yes
Is the resistance less than 1? Go to step 6.
No
Repair the open
circuit between
ECM and mass air
flow sensor connector.

1M?
Go to step 7.
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
flow sensor connector.
Replace the mass

air flow and intake
air temperature
sensor. <Ref. to
FU(TURBO)-34,
Mass Air Flow and
EN(TURBO)-98

EN(TURBO)-99

G: DTC P0103 MASS AIR FLOW SENSOR CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
RHD
RHD
MAIN RELAY
6
4
LHD
5
3
LHD
8
B61
BATTERY
SBF-5
F44
2
1
B47
MASS AIR FLOW AND

E13
B27
E7
5
E8
B3
B:
B135
* 12
*
*1
LHD : 3
RHD : 2
*2
LHD : 6
RHD : 1
B19
B83
E:
B3
1 2 3 4 5
E
ECM
B47
1
3
5
2
4
6
B84
E:
B : B135
B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B83
1 2 3
4 5 6
(LHD)
1 2 3 4 5 6
F44
(RHD)
1 2 3 4
5 6 7 8
EN0970
EN(TURBO)-100

Step
CONNECT SUBARU SELECT MONITOR OR
THE OBD-II GENERAL SCAN TOOL, AND
READ DATA.
switch to ON.
4)Start the engine.
scan tool.
Check
Is the value equal to or more
than 1.3 g/sec (0.172 lb/min) or
0.3 V and equal to or less than
240 g/sec (32 lb/min) or 4.58
V?
NOTE:
Is the value more than 240
MASS AIR FLOW SENSOR CONNECTOR.
g/sec (32 lb/min) or 4.58 V in
1)Turn the ignition switch to OFF and Subaru function mode F06?
switch to OFF.
sensor.
switch to ON.
scan tool.
NOTE:
EN(TURBO)-101
Yes
No
up, the circuit has
this time.
Repair the battery Replace the mass

short circuit in harair flow sensor.
ness between
mass air flow sensor and ECM connector. After
repair, replace the
ECM.

H: DTC P0106 PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (LOW INPUT)
TROUBLE SYMPTOM:
CAUTION:
LHD model:
THROTTLE BODY
2
3
1
PRESSURE SENSOR
E21
18
20
16
E2
F61
G2
A1
F5
F76
B209
1
6
19
9
8
B83
B135 ECM
E21
1 2 3
B83
1 2 3
4 5 6
1 2
5
6
9 10
13
14
17 18
3 4
7
8
11 12
15
16
19 20
B209
B135
F61
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1435
EN(TURBO)-102

RHD model:
THROTTLE BODY
2
3
1
PRESSURE SENSOR
E21
18
20
16
E2
B21
3
1
19
9
8
B83
B135 ECM
E21
B83
1 2 3
1 2 3 4 5 6
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
B135
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
EN0968
EN(TURBO)-103

Step
Check
CHECK IDLE SWITCH SIGNAL.
Does the LED of {Idle Switch
Signal} come on?
2)Operate the LED operation mode for engine
using Subaru Select Monitor.
Yes
Go to step 2.
NOTE:
LED OPERATION MODE FOR ENGINE.
Inspect the relevant DTC. List of

Diagnostic Trouble Code (DTC).
<Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
No
Check the throttle
position sensor circuit. <Ref. to
EN(TURBO)-127,
DTC P0121
CIRCUIT RANGE/
PERFORMANCE
PROBLEM (HIGH
INPUT) , Diagnostic Procedure
with Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0106.
Go to step 3.
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0106.
CHECK CONDITION OF INTAKE MANIFOLD Is the pressure sensor installa- Go to step 4.
Tighten the presPRESSURE SENSOR.
tion bolt tightened securely?
sure sensor installation bolt
securely.
CHECK CONDITION OF THROTTLE BODY. Is the throttle body installation Replace the pres- Tighten the throttle
bolt tightened securely?
sure sensor. <Ref. body installation
to FU(TURBO)-35, bolt securely.
Pressure Sensor.>
EN(TURBO)-104

I:
DTC P0107 PRESSURE SENSOR CIRCUIT LOW INPUT

CAUTION:
WIRING DIAGRAM:
LHD model
THROTTLE BODY
2
3
1
PRESSURE SENSOR
E21
18
20
16
E2
F61
G2
A1
F5
F76
B209
1
6
19
9
8
B83
B135 ECM
E21
1 2 3
B83
1 2 3
4 5 6
1 2
5
6
9 10
13
14
17 18
3 4
7
8
11 12
15
16
19 20
B209
B135
F61
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1435
EN(TURBO)-105

RHD model
THROTTLE BODY
2
3
1
PRESSURE SENSOR
E21
18
20
16
E2
B21
3
1
19
9
8
B83
B135 ECM
E21
B83
1 2 3
1 2 3 4 5 6
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
B135
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
EN0968
Step
Check
Yes
CHECK CURRENT DATA.
Is the value less than 7.2 kPa Go to step 3.
1)Start the engine.
(54 mmHg, 2.1 inHg)?
NOTE:
EN(TURBO)-106
No
Go to step 2.

Step
Check
Yes
CHECK POOR CONTACT.
contact in ECM or
sor connector.
pressure sensor
connector.
and chassis ground.
and chassis ground.

connector.


sensor.
ECM and intake manifold pressure sensor connector.
(B135) No. 19 (E21) No. 2:
intake manifold pressure sensor connector and
engine ground.
No
Even if MIL lights
up, the circuit has
this time.
Go to step 4.
Contact with your

Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.
Contact with your
Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.
Repair the open
circuit in harness
between ECM and
intake manifold
pressure sensor
connector.

?
Go to step 8.
Repair the open

circuit in harness
between ECM and
intake manifold
pressure sensor
connector.

M?
Go to step 9.
Repair the ground

ECM and intake
manifold pressure
sensor connector.
EN(TURBO)-107

Step
CHECK POOR CONTACT.
Check
EN(TURBO)-108
Yes
Repair the poor
No
to FU(TURBO)-35,
Pressure Sensor.>

J: DTC P0108 PRESSURE SENSOR CIRCUIT HIGH INPUT

CAUTION:
WIRING DIAGRAM:
LHD model
THROTTLE BODY
2
3
1
PRESSURE SENSOR
E21
18
20
16
E2
F61
G2
A1
F5
F76
B209
1
6
19
9
8
B83
B135 ECM
E21
B83
1 2 3
1 2 3
4 5 6
1 2
5
6
9 10
13
14
17 18
3 4
7
8
11 12
15
16
19 20
B209
B135
F61
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H5
H4
H3
I4 I5
J3 J4 J5
EN1435
EN(TURBO)-109

RHD model
THROTTLE BODY
2
3
1
PRESSURE SENSOR
E21
18
20
16
E2
B21
3
1
19
9
8
B83
B135 ECM
E21
B83
1 2 3
1 2 3 4 5 6
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
B135
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
EN0968
Step
Check
Yes
CHECK CURRENT DATA.
Is the value more than 282 kPa Go to step 9.
1)Start the engine.
(2121 mmHg, 83.50 inHg)?
NOTE:
EN(TURBO)-110
No
Go to step 2.

Step
and chassis ground.
and chassis ground.
Check
Yes
No
Go to step 3.

connector.
Contact with your

Subaru distributor
service.

and chassis ground.

sensor.
(B135) No. 8 (E21) No. 1:
CHECK HARNESS BETWEEN ECM AND INTAKE MANIFOLD PRESSURE SENSOR
CONNECTOR.
(B135) No. 19 (E21) No. 2:
CHECK POOR CONTACT.
NOTE:
Inspection by DTM
probable
parts.
Contact with your
Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.
Repair the open
circuit in harness
between ECM and
pressure sensor
connector.

?
Go to step 7.
Repair the open

circuit in harness
between ECM and
pressure sensor
connector.

?
Go to step 8.
Repair the open

circuit in harness
between ECM and
pressure sensor
connector.
Repair the poor

Replace the intake

manifold pressure
sensor. <Ref. to
FU(TURBO)-35,
Pressure Sensor.>
EN(TURBO)-111

Step
Check
Is the value more than 282 kPa
(2121 mmHg, 83.50 inHg)?
1)Turn the ignition switch to OFF and Subaru
switch to OFF.
sensor.
switch to ON.
NOTE:
EN(TURBO)-112
Yes
Repair the battery
ECM and pressure
sensor connector.
No
to FU(TURBO)-35,
Pressure Sensor.>

EN(TURBO)-113

K: DTC P0111 INTAKE AIR TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
RHD
RHD
MAIN RELAY
6
4
LHD
5
3
LHD
8
B61
BATTERY
SBF-5
F44
2
1
B47
MASS AIR FLOW AND

E13
B27
E7
5
E8
B3
B:
B135
* 12
*
*1
LHD : 3
RHD : 2
*2
LHD : 6
RHD : 1
B19
B83
E:
B3
1 2 3 4 5
E
ECM
B47
1
3
5
2
4
6
B84
E:
B : B135
B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B83
1 2 3
4 5 6
(LHD)
1 2 3 4 5 6
F44
(RHD)
1 2 3 4
5 6 7 8
EN0970
EN(TURBO)-114

Step
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0111.
CHECK ENGINE COOLANT TEMPERAIs the engine coolant tempera- Replace the mass
TURE.
ture between 75C (167F)
air flow and intake
1)Start the engine and warm it up completely. and 95C (203F)?
air temperature
2)Measure the engine coolant temperature
sensor. <Ref. to
FU(TURBO)-34,
scan tool.
Mass Air Flow and
Intake Air TemperNOTE:
ature Sensor.>
EN(TURBO)-115
Inspect the DTC

P0125 using List
of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>

L: DTC P0112 INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
RHD
RHD
MAIN RELAY
6
4
LHD
5
3
LHD
8
B61
BATTERY
SBF-5
F44
2
1
B47
MASS AIR FLOW AND

E13
B27
E7
5
E8
B3
B:
B135
* 12
*
*1
LHD : 3
RHD : 2
*2
LHD : 6
RHD : 1
B19
B83
E:
B3
1 2 3 4 5
E
ECM
B47
1
3
5
2
4
6
B84
E:
B : B135
B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B83
1 2 3
4 5 6
(LHD)
1 2 3 4 5 6
F44
(RHD)
1 2 3 4
5 6 7 8
EN0970
EN(TURBO)-116

Step
Check
Yes
CHECK CURRENT DATA.
1)Start the engine.
(131F)?
NOTE:
CHECK HARNESS BETWEEN MASS AIR
(97F)?
FLOW AND INTAKE AIR TEMPERATURE
SENSOR AND ECM CONNECTOR.
and intake air temperature sensor.
NOTE:
EN(TURBO)-117
Replace the mass

air flow and intake
air temperature
sensor. <Ref. to
FU(TURBO)-34,
Mass Air Flow and
No
Repair the poor
contact.
NOTE:
the following:
Poor contact
mass air flow and
intake air temperature sensor
Poor contact in
ECM
Poor contact in
joint connector
Repair the ground
mass air flow and
intake air temperature sensor and
ECM connector.

M: DTC P0113 INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
RHD
RHD
MAIN RELAY
6
4
LHD
5
3
LHD
8
B61
BATTERY
SBF-5
F44
2
1
B47
MASS AIR FLOW AND

E13
B27
E7
5
E8
B3
B:
B135
* 12
*
*1
LHD : 3
RHD : 2
*2
LHD : 6
RHD : 1
B19
B83
E:
B3
1 2 3 4 5
E
ECM
B47
1
3
5
2
4
6
B84
E:
B : B135
B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B83
1 2 3
4 5 6
(LHD)
1 2 3 4 5 6
F44
(RHD)
1 2 3 4
5 6 7 8
EN0970
EN(TURBO)-118

Step
Check
CHECK CURRENT DATA.
1)Start the engine.
(97F)?
NOTE:
and intake air temperature sensor.
and intake air temperature sensor connector
and engine ground.
CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 10 V?
TEMPERATURE AND PRESSURE SENSOR
AND ECM CONNECTOR.
and intake air temperature sensor connector
and engine ground.
Measure the voltage between mass air flow
and intake air temperature sensor and pressure sensor connector and engine ground.
EN(TURBO)-119
Yes
Go to step 2.
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.

mass air flow and
ECM connector.
Go to step 5.

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
joint connector

Step
Check
?
mass air flow and intake air temperature sensor and engine ground.
EN(TURBO)-120
Yes
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(TURBO)-34,
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

EN(TURBO)-121

N: DTC P0117 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW

INPUT
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
E8
1 2
3
ENGINE
COOLANT
TEMPERATURE
SENSOR
F61
: LHD
B21
: RHD
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
2
1
E8
B83
17
18
E2
: LHD
F61
: RHD
1 2 3
4 5 6
(LHD)
LHD
RHD
LHD
RHD
B21
1 2 3 4 5 6
(RHD)
G1
G2
F76
B209
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
LHD
LHD
B135
RHD
RHD
B209
* 21
*
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
B83
LHD : 6
RHD : 1
LHD : 1
RHD : 3
18
19
*1
*
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
B135 ECM
EN1436
EN(TURBO)-122

Step
Check
Yes
CHECK CURRENT DATA.
1)Start the engine.
(302F)?
NOTE:

COOLANT TEMPERATURE SENSOR AND (40F)?
ECM CONNECTOR.
NOTE:
EN(TURBO)-123
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
Replace the
Repair the ground
engine coolant
short circuit in hartemperature sen- ness between
sor. <Ref. to
engine coolant
FU(TURBO)-29,
temperature senEngine Coolant
sor and ECM conTemperature Sen- nector.
sor.>

O: DTC P0118 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH

INPUT
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
E8
1 2
3
ENGINE
COOLANT
TEMPERATURE
SENSOR
F61
: LHD
B21
: RHD
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
2
1
E8
B83
17
18
E2
: LHD
F61
: RHD
1 2 3
4 5 6
(LHD)
LHD
RHD
LHD
RHD
B21
1 2 3 4 5 6
(RHD)
G1
G2
F76
B209
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
LHD
LHD
B135
RHD
RHD
B209
* 21
*
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
B83
LHD : 6
RHD : 1
LHD : 1
RHD : 3
18
19
*1
*
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
B135 ECM
EN1436
EN(TURBO)-124

Step
Check
CHECK CURRENT DATA.
1)Start the engine.
(40F)?
NOTE:
Yes
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
ECM and engine

ECM CONNECTOR.
ground.
ECM CONNECTOR.
ground.
ECM CONNECTOR.
ground.
EN(TURBO)-125

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
Check
ECM CONNECTOR.
and engine ground.
EN(TURBO)-126
Yes
Replace the
engine coolant
temperature sensor. <Ref. to
FU(TURBO)-29,
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

P: DTC P0121 THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT)
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Fuel is cut.
CAUTION:
WIRING DIAGRAM:
LHD model
THROTTLE
POSITION
SENSOR
E13
F61
1 2 3
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
1 2
1
3
2
E13
B83
1 2 3
4 5 6
20
19
18
E2
F61
A1
i2
G2
F76
B135
B209
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
1
6
B83
B209
9
7
19
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
B135 ECM
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1437
EN(TURBO)-127

RHD model
THROTTLE
POSITION
SENSOR
E13
1
3
2
1 2 3
E13
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
20
19
18
E2
B21
B83
3
1
1 2 3 4 5 6
B83
B135
9
7
19
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B135 ECM
EN0972
Step
Check
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0121.
EN(TURBO)-128
No
<Ref. to
FU(TURBO)-33,
Throttle Position
Sensor.>

Q: DTC P0122 THROTTLE POSITION SENSOR CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
LHD model
THROTTLE
POSITION
SENSOR
E13
F61
1 2 3
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
1 2
1
3
2
E13
B83
1 2 3
4 5 6
20
19
18
E2
F61
A1
i2
G2
F76
B135
B209
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
1
6
B83
B209
9
7
19
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
B135 ECM
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1437
EN(TURBO)-129

RHD model
THROTTLE
POSITION
SENSOR
E13
1
3
2
1 2 3
E13
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
20
19
18
E2
B21
B83
3
1
1 2 3 4 5 6
B83
B135
9
7
19
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B135 ECM
EN0972
EN(TURBO)-130

Step
Check
CHECK CURRENT DATA.
1)Start the engine.
general scan tool.
Yes
Go to step 2.
NOTE:

closed.
and chassis ground.

and chassis ground.
and chassis ground.

connector.

connector.
EN(TURBO)-131
No
Even if MIL lights
up, the circuit has
of the connector
may be the cause.
NOTE:
the following:
Poor contact in
throttle position
sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Go to step 3.
Contact with your

Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.
Go to step 5.
Go to step 6.

Step
Check
Yes

THROTTLE POSITION SENSOR CONNEC- ?
TOR.
connector.
(B135) No. 7 (E13) No. 3:

ground.
CHECK POOR CONTACT.
connector.

?
Go to step 8.
NOTE:
the following:
Open circuit in
harness between
throttle position
sensor and ECM
connector
Poor contact in
throttle position
sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector
NOTE:
the following:
Open circuit in
harness between
throttle position
sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
throttle position
sensor connector
Poor contact in
coupling connector
throttle position
sensor and ECM
connector.

contact in throttle
position sensor
connector.
EN(TURBO)-132
No

<Ref. to
FU(TURBO)-33,
Throttle Position
Sensor.>

R: DTC P0123 THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
LHD model
THROTTLE
POSITION
SENSOR
E13
F61
1 2 3
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
1 2
1
3
2
E13
B83
1 2 3
4 5 6
20
19
18
E2
F61
A1
i2
G2
F76
B135
B209
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
1
6
B83
B209
9
7
19
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
B135 ECM
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1437
EN(TURBO)-133

RHD model
THROTTLE
POSITION
SENSOR
E13
1
3
2
1 2 3
E13
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
20
19
18
E2
B21
B83
3
1
1 2 3 4 5 6
B83
B135
9
7
19
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B135 ECM
EN0972
EN(TURBO)-134

Step
Check
CHECK CURRENT DATA.
1)Start the engine.
general scan tool.
Yes
Go to step 2.
NOTE:

?
ground.

Go to step 3.
No
Even if MIL lights
up, the circuit has
of the connector
may be the cause.
NOTE:
the following:
Poor contact in
throttle position
sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connector
NOTE:
the following:
Open circuit in
harness between
throttle position
sensor and ECM
connector
Poor contact in
coupling connector
Poor contact in
joint connector
Is the voltage more than 4.9 V? Repair the battery Replace the throtshort circuit in har- tle position sensor.
ness between
<Ref. to
throttle position
FU(TURBO)-33,
sensor and ECM Throttle Position
connector. After
Sensor.>
repair, replace the
ECM. <Ref. to
FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-135

S: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED

LOOP FUEL CONTROL
TROUBLE SYMPTOM:
Engine will not return to idling.
CAUTION:
WIRING DIAGRAM:
E8
1 2
3
ENGINE
COOLANT
TEMPERATURE
SENSOR
F61
: LHD
B21
: RHD
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
2
1
E8
B83
17
18
E2
: LHD
F61
: RHD
1 2 3
4 5 6
(LHD)
LHD
RHD
LHD
RHD
B21
1 2 3 4 5 6
(RHD)
G1
G2
F76
B209
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
LHD
LHD
B135
RHD
RHD
B209
*
*
2
1
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
B83
LHD : 6
RHD : 1
LHD : 1
RHD : 3
18
19
*1
*
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H5
H4
H3
I4 I5
J3 J4 J5
B135 ECM
EN1436
EN(TURBO)-136

Step
CHECK ENGINE COOLING SYSTEM.

NOTE:
Thermostat open stuck
Coolant level
Coolant freeze
Tire diameter
Check
Is there a fault in engine cooling system?
EN(TURBO)-137
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0125.
Replace the thermostat. <Ref. to
CO-37, Thermostat.>
Replace the
engine coolant
FU(TURBO)-29,
Engine Coolant

T: DTC P0131 FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT)
NOTE:
For the diagnostic procedure, refer to DTC P0132. <Ref. to EN(TURBO)-140, DTC P0132 FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(TURBO)-138

EN(TURBO)-139

U: DTC P0132 FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT)
CAUTION:
WIRING DIAGRAM:
RHD
RHD
B18
MAIN RELAY
6
4
LHD
SBF-5
LHD
2
B61
1 2
3 4
BATTERY
F44
B47
5
3
2
2
4
6
F44
1 2 3 4
5 6 7 8
B18
4
FRONT OXYGEN
(A/F) SENSOR
F60
18
1
5
9
13
2
6
10
14
3
7
11
15
: LHD
: RHD
4
8
12
16
ECM
B137
8
9
RHD
LHD
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
A3
B209
F76
LHD
B209
E
RHD
B137
29
B22
19
B47
4
5
2
1
1
3
5
F60
: LHD
B22
: RHD
E3
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1433
EN(TURBO)-140

Step
Check
CHECK FRONT (A/F) OXYGEN SENSOR DA- Is the value equal to or more
TA.
1)Start the engine.
70C (158F).
general scan tool.
NOTE:
CHECK REAR OXYGEN SENSOR SIGNAL. Does the LED of {Rear O2
1)Race the engine at speeds from idling to
Rich Signal} blink?
5,000 rpm for a total of 5 cycles.
NOTE:
slowly depress accelerator pedal, taking approx. 5 seconds, and quickly release accelerator pedal to decrease engine speed.
2)Operate the LED operation mode for engine.
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC).<Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
Go to step 3.
Go to step 4.
Repair the poor

contact in front
connector.
NOTE:
LED OPERATION MODE FOR ENGINE.
tem?
the faulty parts.
NOTE:
EN(TURBO)-141
Check the rear

oxygen sensor circuit. <Ref. to
FU(TURBO)-46,
Rear Oxygen Sensor.>
Replace the front

oxygen (A/F) sensor. <Ref. to
FU(TURBO)-44,
Front Oxygen (A/
F) Sensor.>

V: DTC P0133 FRONT OXYGEN (A/F) SENSOR CIRCUIT SLOW RESPONSE

CAUTION:
WIRING DIAGRAM:
RHD
RHD
B18
MAIN RELAY
6
4
LHD
SBF-5
LHD
2
B61
1 2
3 4
BATTERY
F44
B47
5
3
2
2
4
6
F44
1 2 3 4
5 6 7 8
B18
4
FRONT OXYGEN
(A/F) SENSOR
F60
18
1
5
9
13
2
6
10
14
3
7
11
15
: LHD
: RHD
4
8
12
16
ECM
B137
8
9
RHD
LHD
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
A3
B209
F76
LHD
B209
E
RHD
B137
29
B22
19
B47
4
5
2
1
1
3
5
F60
: LHD
B22
: RHD
E3
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1433
EN(TURBO)-142

Step
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0133.
Is there a fault in exhaust sys- Repair the exhaust Replace the front
tem?
system.
oxygen (A/F) senNOTE:
sor. <Ref. to
FU(TURBO)-44,
Loose installation of front portion of exhaust
Front Oxygen (A/
pipe onto cylinder heads
F) Sensor.>
Loose connection between front exhaust pipe
and front catalytic converter
Damage of exhaust pipe resulting in a hole
EN(TURBO)-143

W: DTC P0136 REAR OXYGEN SENSOR CIRCUIT MALFUNCTION [MT VEHICLES]

RHD
RHD
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
B47
*3
F44
B19
F44
1 2
3 4
(LHD)
1 2 3 4
5 6 7 8
B47
1
3
5
2
4
6
2 1
4 3
REAR
OXYGEN SENSOR
B19
*1
LHD : 2
RHD : 4
LHD : 6
RHD : 1
*3
LHD : 2
RHD : 1
*4
LHD : 1
RHD : 2
LHD : 3
RHD : 4
RHD
LHD
B83
(RHD)
*6
2
1
LHD
2
B61
* 45
*
5
3
LHD
BATTERY
1
5
9
13
F60
: LHD
B22
: RHD
2
6
10
14
3
7
11
15
1 2 3
4 5 6
(LHD)
1 2 3 4 5 6
(RHD)
4
8
12
16
B135
* 12
*
B260
B259
*6
RHD
B83
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
LHD : 4
RHD : 3
B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
B137
RHD
LHD
B26
B19
C13
B17
LHD
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
A3
B : B135
C : B136 ECM
B209
F76
D8
D9
RHD
F60
: LHD
B22
E3
: RHD
B259
B209
LHD
D : B137
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1434
Step
Check
Yes
EN(TURBO)-144
No
Go to step 3.

Step
Check
P0132.
Inspect the DTC P0131 or P0132 using List of
Diagnostic Trouble Code (DTC). <Ref. to
EN(TURBO)-75, List of Diagnostic Trouble
Code (DTC).>
2 minutes.
scan tool.
Yes
Check the fuel
system.
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0136.
Go to step 7.
Go to step 4.
NOTE:
READ CURRENT DATA SHOWN ON DISPLAY FOR ENGINE. <Ref. to EN(TURBO)34, Subaru Select Monitor.>
and 0.4 V?
scan tool.

?
rear oxygen sensor.
(B135) No. 26 (B19) No. 4:
sensor.
or chassis ground.
EN(TURBO)-145
No
Go to step 3.
Repair the open

circuit in harness
between ECM and
Replace the rear

oxygen sensor.
<Ref. to
FU(TURBO)-46,
Replace the rear

oxygen sensor.
<Ref. to
FU(TURBO)-46,
Go to step 6.

NOTE:
the following:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector

Step
Check
Yes
tem?
the faulty parts.
NOTE:
EN(TURBO)-146
No
Replace the rear
oxygen sensor.
<Ref. to
FU(TURBO)-46,

EN(TURBO)-147

X: DTC P0137 REAR OXYGEN SENSOR CIRCUIT LOW INPUT [AT VEHICLES]
RHD
RHD
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
B47
*3
F44
B19
F44
1 2
3 4
(LHD)
1 2 3 4
5 6 7 8
B47
1
3
5
2
4
6
2 1
4 3
REAR
OXYGEN SENSOR
B19
*1
LHD : 2
RHD : 4
LHD : 6
RHD : 1
*3
LHD : 2
RHD : 1
*4
LHD : 1
RHD : 2
LHD : 3
RHD : 4
RHD
LHD
B83
(RHD)
*6
2
1
LHD
2
B61
* 45
*
5
3
LHD
BATTERY
1
5
9
13
F60
: LHD
B22
: RHD
2
6
10
14
3
7
11
15
1 2 3
4 5 6
(LHD)
1 2 3 4 5 6
(RHD)
4
8
12
16
B135
* 12
*
B260
B259
*6
RHD
B83
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
LHD : 4
RHD : 3
B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
B137
RHD
LHD
B26
B19
C13
B17
LHD
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
A3
B : B135
C : B136 ECM
B209
F76
D8
D9
RHD
F60
: LHD
B22
E3
: RHD
B259
B209
LHD
D : B137
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1434
Step
Check
Yes
EN(TURBO)-148
No
Go to step 3.

Step
Check
P0132.
Code (DTC).>
2 minutes.
scan tool.
Yes
Check the fuel
system.
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0137.
Go to step 7.
Go to step 4.
NOTE:
and 0.4 V?
scan tool.

?
rear oxygen sensor.
(B135) No. 26 (B19) No. 4:
sensor.
or chassis ground.
EN(TURBO)-149
No
Go to step 3.
Repair the open

circuit in harness
between ECM and
Replace the rear

oxygen sensor.
<Ref. to
FU(TURBO)-46,
Replace the rear

oxygen sensor.
<Ref. to
FU(TURBO)-46,
Go to step 6.

NOTE:
the following:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector

Step
Check
Yes
tem?
the faulty parts.
NOTE:
EN(TURBO)-150
No
Replace the rear
oxygen sensor.
<Ref. to
FU(TURBO)-46,

EN(TURBO)-151

Y: DTC P0138 REAR OXYGEN SENSOR CIRCUIT HIGH INPUT [AT VEHICLES]
RHD
RHD
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
B47
*3
F44
B19
F44
1 2
3 4
(LHD)
1 2 3 4
5 6 7 8
B47
1
3
5
2
4
6
2 1
4 3
REAR
OXYGEN SENSOR
B19
*1
LHD : 2
RHD : 4
LHD : 6
RHD : 1
*3
LHD : 2
RHD : 1
*4
LHD : 1
RHD : 2
LHD : 3
RHD : 4
RHD
LHD
B83
(RHD)
*6
2
1
LHD
2
B61
* 45
*
5
3
LHD
BATTERY
1
5
9
13
F60
: LHD
B22
: RHD
2
6
10
14
3
7
11
15
1 2 3
4 5 6
(LHD)
1 2 3 4 5 6
(RHD)
4
8
12
16
B135
* 12
*
B260
B259
*6
RHD
B83
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
LHD : 4
RHD : 3
B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
B137
RHD
LHD
B26
B19
C13
B17
LHD
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
A3
B : B135
C : B136 ECM
B209
F76
D8
D9
RHD
F60
: LHD
B22
E3
: RHD
B259
B209
LHD
D : B137
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1434
Step
Check
Yes
EN(TURBO)-152
No
Go to step 3.

Step
Check
P0132.
Code (DTC).>
2 minutes.
scan tool.
Yes
Check the fuel
system.
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0138.
Go to step 7.
Go to step 4.
NOTE:
and 0.4 V?
scan tool.

?
rear oxygen sensor.
(B135) No. 26 (B19) No. 4:
sensor.
or chassis ground.
EN(TURBO)-153
No
Go to step 3.
Repair the open

circuit in harness
between ECM and
Replace the rear

oxygen sensor.
<Ref. to
FU(TURBO)-46,
Replace the rear

oxygen sensor.
<Ref. to
FU(TURBO)-46,
Go to step 6.

NOTE:
the following:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector

Step
Check
Yes
tem?
the faulty parts.
NOTE:
EN(TURBO)-154
No
Replace the rear
oxygen sensor.
<Ref. to
FU(TURBO)-46,

EN(TURBO)-155

Z: DTC P0139 REAR OXYGEN SENSOR CIRCUIT SLOW RESPONSE

RHD
RHD
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
*3
*1
2
4
6
RHD
LHD
*2
LHD : 6
RHD : 1
*3
LHD : 2
RHD : 1
*4
LHD : 1
RHD : 2
LHD : 3
RHD : 4
B83
(RHD)
LHD : 2
RHD : 4
*6
* 45
*
B19
1
5
9
13
F60
: LHD
B22
: RHD
2
6
10
14
3
7
11
15
1 2 3
4 5 6
(LHD)
1 2 3 4 5 6
(RHD)
4
8
12
16
B135
* 12
*
B260
1
B259
*6
B83
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
LHD : 4
RHD : 3
B136
LHD
B137
RHD
LHD
B26
B19
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 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 31
C : B136 ECM
A3
B : B135
B209
F76
LHD
F60
: LHD
B22
E3
: RHD
B259
B209
E
RHD
D : B137
D8
D9
B47
1
3
5
2 1
4 3
REAR
OXYGEN SENSOR
RHD
2
1
F44
B47
1 2 3 4
5 6 7 8
1 2
3 4
(LHD)
LHD
2
B61
C13
B17
5
3
LHD
F44
B19
BATTERY
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1434
EN(TURBO)-156

Step
Check
In any other DTC displayed?
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0139.
EN(TURBO)-157
No
Replace the rear
oxygen sensor.
<Ref. to
FU(TURBO)-46,

AA:DTC P0171 FUEL TRIM MALFUNCTION (A/F TOO LEAN)

NOTE:
For the diagnostic procedure, refer to DTC P0172. <Ref. to EN(TURBO)-159, DTC P0172 FUEL TRIM
MALFUNCTION (A/F TOO RICH) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(TURBO)-158

AB:DTC P0172 FUEL TRIM MALFUNCTION (A/F TOO RICH)

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
Step

Warning:
Place NO FIRE signs near the working
area.
1)Release the fuel pressure.
(1) Disconnect the connector from fuel
pump relay.
(2) Start the engine and run it until it stalls.
(3) After the engine stalls, crank it for 5
more seconds.
2)Connect the connector to fuel pump relay.
3)Disconnect the fuel delivery hose from fuel
filter, and connect fuel pressure gauge.
4)Install the fuel filler cap.
5)Start the engine and idle while gear position
is neutral.
6)Measure the fuel pressure while disconnecting pressure regulator vacuum hose from
intake manifold.
Check
Are there holes or loose bolts
on exhaust system?
Are there holes, loose bolts or
intake system?
284 314 kPa (2.9 3.2
kg/cm2, 41 46 psi)?
Warning:
NOTE:
If the fuel pressure does not increase, squeeze
fuel return hose 2 to 3 times, then measure fuel
pressure again.
EN(TURBO)-159
Yes
No
system.
Repair the air
Go to step 3.
intake system.
Go to step 4.

Fuel pressure too
high:
Clogged fuel
return line or
bent hose
Fuel pressure too
low:
Improper fuel
pump discharge
Clogged fuel
supply line

Step
After connecting the pressure regulator vacuum hose, measure fuel pressure.
Check
206 235 kPa (2.1 2.4
kg/cm2, 30 34 psi)?
Yes
Go to step 5.
Warning:
NOTE:
If the fuel pressure does not increase,
squeeze fuel return hose 2 to 3 times, then
measure fuel pressure again.
If out of specification as measured at this
step, check or replace the pressure regulator
and pressure regulator vacuum hose.
CHECK ENGINE COOLANT TEMPERATURE Is the temperature greater than Go to step 6.

SENSOR.
60C (140F)?
1)Start the engine and warm-up completely.
NOTE:
Is the value within the specifiCHECK INTAKE MANIFOLD PRESSURE
cations?
SENSOR.
(140F).
2)Place the shift lever in neutral position.
NOTE:
Specification:
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)
EN(TURBO)-160
Go to step 7.
No
Fuel pressure too
high:
Clogged fuel
return line or
bent hose
Fuel pressure too
low:
Improper fuel
pump discharge
Clogged fuel
supply line
Replace the
engine coolant
FU(TURBO)-29,
Engine Coolant
Replace the mass

air flow and intake
manifold pressure
sensor. <Ref. to
FU(TURBO)-34,
Mass Air Flow and

Step
(140F).
2)Place the shift lever in neutral position.
5)Open the front hood.
6)Measure the ambient temperature.
Check
Is the value obtained when
ambient temperature is subtracted from intake air temperature greater than 10C
(14F) and less than 50C
(122F)?
NOTE:
EN(TURBO)-161
Yes
No
Contact with your Check the mass
Subaru distributor air flow and intake
service.
air temperature
sensor. <Ref. to
NOTE:
Inspection by DTM FU(TURBO)-34,
is required, be- Mass Air Flow and
cause
probable Intake Air Tempercause is deteriora- ature Sensor.>
tion of multiple
parts.

AC:DTC P0244 WASTEGATE CONTROL SOLENOID VALVE MALFUNCTION

(HIGH INPUT) [MT VEHICLES]
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
5
3
RHD
6
4
RHD
MAIN RELAY
LHD
F44
LHD
8
B61
BATTERY
SBF-5
1 2 3 4
5 6 7 8
F44
2
1
B47
B47
1
3
5
B137
2
4
6
ECM
B137
24
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
B127
1 2
2
1
B127
WASTEGATE
CONTROL SOLENOID
VALVE
EN0974
EN(TURBO)-162

Step
Check
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0244.
EN(TURBO)-163
No
Replace the
wastegate control
solenoid valve.
<Ref. to
FU(TURBO)-43,
Wastegate Control Solenoid
Valve.>

AD:DTC P0244 WASTEGATE CONTROL SOLENOID VALVE MALFUNCTION

(FAIL-SAFE) [AT VEHICLES]
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
B47
SBF-5
5
3
1
3
5
2
1
2
4
6
B47
B137
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
B137
ECM
B127
24
1 2
2
1
B127
WASTEGATE
CONTROL SOLENOID
VALVE
EN1438
EN(TURBO)-164

Step
Check
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0244.
EN(TURBO)-165
No
Replace the
wastegate control
solenoid valve.
<Ref. to
FU(TURBO)-43,
Valve.>

AE:DTC P0245 WASTEGATE CONTROL SOLENOID VALVE CIRCUIT LOW

INPUT
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
5
3
RHD
6
4
RHD
MAIN RELAY
LHD
F44
LHD
8
B61
BATTERY
SBF-5
1 2 3 4
5 6 7 8
F44
2
1
B47
B47
1
3
5
B137
2
4
6
ECM
B137
24
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
B127
1 2
2
1
B127
WASTEGATE
CONTROL SOLENOID
VALVE
EN0974
EN(TURBO)-166

Step
chassis ground.
CHECK HARNESS BETWEEN WASTEGATE

CONTROL SOLENOID VALVE AND ECM
CONNECTOR.
2)Disconnect the connectors from wastegate
control solenoid valve and ECM.
wastegate control solenoid valve connector
and engine ground.
CHECK HARNESS BETWEEN WASTEGATE
CONTROL SOLENOID VALVE AND ECM
CONNECTOR.
ECM and wastegate control solenoid valve of
harness connector.
(B137) No. 24 (B127) No. 1:
Check
Yes
No
up, the circuit has
this time. Contact
with your Subaru

?

?
NOTE:
Inspection by DTM
probable
parts.
ECM and wastegate control solenoid valve
connector.
Go to step 4.

CHECK WASTEGATE CONTROL SOLEand 34 ?
NOID VALVE.
Terminals
No. 1 No. 2:
CHECK POWER SUPPLY TO WASTEGATE Is the voltage more than 10 V? Go to step 6.

2)Measure the voltage between wastegate
control solenoid valve and engine ground.
EN(TURBO)-167
Go to step 5.
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(TURBO)-43,
Valve.>
Repair the open
circuit in harness
between main
relay and wastegate control solenoid valve
connector.

Step
Check
Yes
CHECK POOR CONTACT.
Is there poor contact in waste- Repair the poor
Check poor contact in wastegate control sole- gate control solenoid valve
contact in wastenoid valve connector.
connector?
gate control solenoid valve
connector.
EN(TURBO)-168
No
Contact with your
Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.

EN(TURBO)-169

AF:DTC P0246 WASTEGATE CONTROL SOLENOID VALVE CIRCUIT HIGH

INPUT
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
5
3
RHD
6
4
RHD
MAIN RELAY
LHD
F44
LHD
8
B61
BATTERY
SBF-5
1 2 3 4
5 6 7 8
F44
2
1
B47
B47
1
3
5
B137
2
4
6
ECM
B137
24
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
B127
1 2
2
1
B127
WASTEGATE
CONTROL SOLENOID
VALVE
EN0974
Step
chassis ground.
Check
Yes
EN(TURBO)-170
No
Go to step 2.

Step
CHECK POOR CONTACT.
Check
connector?
No
Replace the ECM.
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
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(TURBO)-49,
Engine Control
Module.>
CHECK WASTEGATE CONTROL SOLEIs the resistance less than 1
Replace the
Go to step 5.
NOID VALVE.
?
wastegate control
solenoid valve
2)Measure the resistance between wastegate
<Ref. to
control solenoid valve terminals.
FU(TURBO)-43,
Terminals
Wastegate ConNo. 1 No. 2:
trol Solenoid
Valve.> and ECM
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
Repair the poor
Replace the ECM.
CHECK POOR CONTACT.
connector?
contact in ECM
<Ref. to
connector.
FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-171
Yes
Repair the poor
contact in ECM
connector.

AG:DTC P0301 CYLINDER 1 MISFIRE DETECTED

NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(TURBO)-173, DTC P0304 CYLINDER 4
MISFIRE DETECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AH:DTC P0302 CYLINDER 2 MISFIRE DETECTED

NOTE:
AI: DTC P0303 CYLINDER 3 MISFIRE DETECTED

NOTE:
EN(TURBO)-172

AJ: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:
EN(TURBO)-173

LHD model
MAIN RELAY
6
4
B61
BATTERY
F44
SBF-5
5
3
2
1
D:
B136
C5
C6
D1
C:
B137
ECM
C4
B47
I5
I4
J4
F44
J5
B61
B209
11
10
1
9
12
F76
F60
E3
2
1
E17
2
1
E6
2
1
E16
2
1
E5
#1
#2
#3
#4
FUEL INJECTORS
E5
E6
E16
E17
1 2
F44
1 2 3 4
5 6 7 8
C : B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
D : B137
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
1
5
9
13
2
6
10
14
3
7
11
15
B209
4
8
12
16
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
B47
1
3
5
F60
2
4
6
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1432
EN(TURBO)-174

RHD model
MAIN RELAY
6
4
BATTERY
SBF-5
5
3
2
1
B47
ECM
C4
B137
B22
12
11
10
1
9
D:
B136
C5
C6
D1
C:
E3
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 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 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
B47
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
1
3
5
2
4
6
EN0965
Step
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0301,
P0302,
P0303 and P0304.
EN(TURBO)-175

Step
2)Measure the voltage between ECM connector and chassis ground on faulty cylinders.
():
():
():
():
on faulty cylinders.
4)Measure the resistance between ECM connector and engine ground on faulty cylinders.
between ECM connector and fuel injector on
faulty cylinders.
#1 (B137) No. 1 (E5) No. 1:
#2 (B136) No. 6 (E16) No. 1:
#3 (B136) No. 5 (E6) No. 1:
#4 (B136) No. 4 (E17) No. 1:
Check
Yes

Measure the resistance between fuel injector
Terminals
No. 1 No. 2:

and 20 ?
No
Go to step 3.

?

injector and ECM
connector.

?
Go to step 5.
EN(TURBO)-176
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(TURBO)-37,
Fuel Injector.>

10
Step
CHECK POWER SUPPLY LINE.
2)Measure the voltage between fuel injector
and engine ground on faulty cylinders.
Check
Yes
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
cylinders
CHECK HARNESS BETWEEN FUEL INJEC- Is the voltage more than 10 V? Repair the battery Go to step 8.
short circuit in harTOR AND ECM CONNECTOR.
ness between
ECM and fuel
injector. After
on faulty cylinder.
repair, replace the
ECM. <Ref. to
4)Measure the voltage between ECM connecFU(TURBO)-49,
tor and chassis ground on faulty cylinders.
Engine Control
Module.>
():
():
():
():
Replace the faulty Go to step 9.
?
fuel injector <Ref.
2)Measure the resistance between fuel injector
to FU(TURBO)-37,
Fuel Injector.> and
Terminals
ECM <Ref. to
No. 1 No. 2:
FU(TURBO)-49,
Engine Control
Module.>
CHECK INSTALLATION OF CAMSHAFT PO- Is the camshaft position sensor Tighten the cam- Go to step 10.
SITION SENSOR/CRANKSHAFT POSITION or crankshaft position sensor shaft position senSENSOR.
loosely installed?
sor or crankshaft
position sensor.
Is the crankshaft sprocket
Remove the timing belt cover.
rusted or does it have broken shaft sprocket.
teeth?
<Ref. to
ME(TURBO)-58,
Crankshaft
Sprocket.>
EN(TURBO)-177

11
12
13
14
15
Step
Check
TIMING BELT.
Turn the crankshaft using ST, and align alignment mark on crankshaft sprocket with alignment mark on cylinder block.
ST 499987500 CRANKSHAFT SOCKET
CHECK FUEL LEVEL.
Is the fuel meter indication
higher than the Lower level?
Yes
No
Repair the installa- Go to step 12.
tion condition of
timing belt. <Ref.
to ME(TURBO)48, Timing Belt
Assembly.>
Go to step 13.
Replenish the fuel
so fuel meter indication is higher
than the Lower
level. After replenishing fuel; Go to
step 13.
Go to step 15.
Go to step 14.
CHECK STATUS OF CHECK ENGINE MAL- Is the MIL coming on or blinking?

1)Clear the memory using Subaru Select Monitor.
<Ref. to EN(TURBO)-45, Clear Memory
Mode.>
2)Start the engine, and drive the vehicle more
than 10 minutes.
CHECK CAUSE OF MISFIRE DIAGNOSED. Was the cause of misfire diag- Finish the diagnosed when the engine is run- nostics operation,
ning?
if the engine has
no abnormality.
Repair the poor

contact.
NOTE:
the following:
NOTE:
Ex. Remove spark Poor contact in
plug cord, etc.
ignitor connector
Poor contact in
ignition coil connector
Poor contact in
cylinders
Poor contact in
ECM connector
Poor contact in
coupling connector
Go to step 16.
Is there a fault in air intake sys- Repair the air
tem?
intake system.
NOTE:
Check the following items:
Are there air
leaks or air suction
caused by loose or
dislocated nuts
and bolts?
Are there cracks
or any disconnection of hoses?
EN(TURBO)-178

16
17
18
19
20
21
Step
Check
Yes
CHECK MISFIRE SYMPTOM.
indicate only one DTC?
2)Read the diagnostic trouble code (DTC).
OBD-II General Scan Tool Operation Manual.
NOTE:
Perform diagnosis according to the items listed
below.
Does the Subaru Select Moni(DTC) ON DISPLAY.
P0302?
P0304?
Does the Subaru Select MoniCHECK DIAGNOSTIC TROUBLE CODE
(DTC) ON DISPLAY.
P0303?
P0304?
ONLY ONE CYLINDER
Is there a fault in that cylinder?
Go to step 22.
Go to step 18.
Go to step 23.
Go to step 19.
Go to step 24.
Go to step 20.
Go to step 25.
Go to step 26.
Repair or replace
the faulty parts.
Go to DTC P0171
and P0172. <Ref.
to EN(TURBO)158, DTC P0171
FUEL TRIM
MALFUNCTION
(A/F TOO LEAN)
, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Go to DTC P0171
and P0172. <Ref.
FUEL TRIM
MALFUNCTION
(A/F TOO LEAN)
Code (DTC).>
NOTE:
Spark plug
Spark plug cord
Fuel injector
Compression
ratio
22

cylinders?
Repair or replace
the faulty parts.
NOTE:
Spark plugs
Fuel injectors
Ignition coil
Compression ratio
If no abnormal is
discovered, check
for IGNITION
CONTROL SYSTEM of #1 and #2
cylinders side.
<Ref. to
EN(TURBO)-66,
Ignition Control
System.>
EN(TURBO)-179
No
Go to step 17.

23
Step
Check
cylinders?
24

cylinders?
25

cylinders?
26
CYLINDER AT RANDOM
Is the engine idle rough?
EN(TURBO)-180
Yes
Repair or replace
the faulty parts.
No
Go to DTC P0171
and P0172. <Ref.
to EN(TURBO)NOTE:
158, DTC P0171
Check the fol FUEL TRIM
lowing items.
Spark plugs MALFUNCTION
Fuel injectors (A/F TOO LEAN)
, Diagnostic Pro Ignition coil
If no abnormal is cedure with Diagdiscovered, check nostic Trouble
Code (DTC).>
for 16. D: IGNITION CONTROL
SYSTEM of #3
and #4 cylinders
side. <Ref. to
EN(TURBO)-66,
Ignition Control
System.>
Repair or replace Go to DTC P0171
and P0172. <Ref.
the faulty parts.
to EN(TURBO)NOTE:
Check the follow- 158, DTC P0171
FUEL TRIM
ing items.
MALFUNCTION
Spark plugs
(A/F TOO LEAN)
Fuel injectors
Skipping timing , Diagnostic Procedure with Diagbelt teeth
nostic Trouble
Code (DTC).>
Repair or replace Go to DTC P0171
and P0172. <Ref.
the faulty parts.
to EN(TURBO)NOTE:
Check the follow- 158, DTC P0171
FUEL TRIM
ing items.
MALFUNCTION
Spark plugs
(A/F TOO LEAN)
Fuel injectors
, Diagnostic Pro Compression
cedure with Diagratio
Skipping timing nostic Trouble
Code (DTC).>
belt teeth
Go to DTC P0171
and P0172. <Ref.
FUEL TRIM
MALFUNCTION
(A/F TOO LEAN)
Code (DTC).>
Repair or replace
the faulty parts.
NOTE:
Spark plugs
Fuel injectors
Compression
ratio

EN(TURBO)-181

AK:DTC P0327 KNOCK SENSOR CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
WIRING DIAGRAM:
KNOCK
SENSOR
E14
E14
1 2
B20
1 2 3 4
6
5
7
9 10
8
E1
B20
B135
22
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B135 ECM
EN0975
EN(TURBO)-182

Step
Check
CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance more than
700 k?
3)Measure the resistance between ECM harness connector and chassis ground.
Yes
Go to step 2.
CHECK KNOCK SENSOR.

1)Disconnect the connector from knock sen700 k?
sor.
Terminal
Go to step 3.
CHECK CONDITION OF KNOCK SENSOR

INSTALLATION.
Is the knock sensor installation bolt tightened securely?
EN(TURBO)-183
No
NOTE:
the following:
Open circuit in
harness between
knock sensor and
ECM connector
Poor contact in
Poor contact in
coupling connector
NOTE:
the following:
Open circuit in
harness between
knock sensor and
ECM connector
Poor contact in
Poor contact in
coupling connector
Replace the knock Tighten the knock
sensor. <Ref. to
sensor installation
FU(TURBO)-32,
bolt securely.
Knock Sensor.>

AL:DTC P0328 KNOCK SENSOR CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
WIRING DIAGRAM:
KNOCK
SENSOR
E14
E14
1 2
B20
1 2 3 4
6
5
7
9 10
8
E1
B20
B135
22
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B135 ECM
EN0975
Step
Check
Yes
CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance less than 400 Go to step 2.
k?
EN(TURBO)-184
No
Go to step 3.

Step
Check
CHECK KNOCK SENSOR.
1)Disconnect the connector from knock senk?
sor.
Terminal

1)Connect the connectors to ECM and knock
sensor.
chassis ground.
Yes
Replace the knock
sensor. <Ref. to
FU(TURBO)-32,
Knock Sensor.>
NOTE:
is
shielded. Repair
the short circuit of
harness together
with shield.
Even if MIL lights Repair the poor
up, the circuit has contact in ECM
returned to a nor- connector.
mal condition at
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
EN(TURBO)-185
No
Repair the ground
knock sensor connector and ECM
connector.

AM:DTC P0335 CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
2
1
CRANKSHAFT
POSITION
SENSOR
E10
E10
1 2
B20
B20
1 2 3 4
6
5
7
9 10
8
2
1
E1
B135
11
2
21
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B135 ECM
EN0976
EN(TURBO)-186

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.
engine ground.

CHECK HARNESS BETWEEN CRANKSHAFT POSITION SENSOR AND ECM CON- ?
NECTOR.
engine ground.

NECTOR.
engine ground.
Yes
No
ness and connector.
NOTE:
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
Go to step 4.
NOTE:
the following:
Open circuit in
harness between
ECM connector
Poor contact in
ECM connector
Poor contact in
coupling connector
securely.
Repair the poor
CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1
Replace the crank1)Remove the crankshaft position sensor.
and 4 k?
contact in crankshaft position sen2)Measure the resistance between connector
shaft position sensor. <Ref. to
terminals of crankshaft position sensor.
sor connector.
FU(TURBO)-30,
Terminals
Crankshaft PosiNo. 1 No. 2:
tion Sensor.>
EN(TURBO)-187

AN:DTC P0336 CRANKSHAFT POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
2
1
CRANKSHAFT
POSITION
SENSOR
E10
E10
1 2
B20
B20
1 2 3 4
6
5
7
9 10
8
2
1
E1
B135
11
2
21
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B135 ECM
EN0976
EN(TURBO)-188

Step
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
shaft position senTurn the ignition switch to OFF.
securely?
securely.
Are the crankshaft sprocket
Remove the front belt cover.
shaft sprocket.
<Ref. to
FU(TURBO)-30,
Crankshaft Position Sensor.>
Repair the installa- Replace the crankTIMING BELT.
tion condition of
shaft position senTurn the crankshaft using ST, and align aligntiming belt. <Ref. sor. <Ref. to
ment mark on crankshaft sprocket with alignto ME(TURBO)FU(TURBO)-30,
ment mark on cylinder block.
48, Timing Belt
Crankshaft PosiST 499987500 CRANKSHAFT SOCKET
Assembly.>
tion Sensor.>
EN(TURBO)-189

AO:DTC P0340 CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
2
1
CAMSHAFT
POSITION
SENSOR
E15
E15
1 2
B20
B20
1 2 3 4
6
5
7
9 10
8
4
3
E1
B135
10
1
21
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B135 ECM
EN0977
EN(TURBO)-190

Step
Check
TOR.
position sensor.
engine ground.

engine ground.

?

engine ground.

?

Terminals
No. 1 No. 2:
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
together
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
Tighten the caminstallation bolt tightened
securely.
Repair the poor
Replace the camand 4 k?
contact in camshaft position senshaft position sensor. <Ref. to
sor connector.
FU(TURBO)-31,
Camshaft Position
Sensor.>
EN(TURBO)-191

AP:DTC P0341 CAMSHAFT POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
2
1
CAMSHAFT
POSITION
SENSOR
E15
E15
1 2
B20
B20
1 2 3 4
6
5
7
9 10
8
4
3
E1
B135
10
1
21
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B135 ECM
EN0977
EN(TURBO)-192

Step
Check

TOR.
position sensor.
engine ground.
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
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.

engine ground.

?

engine ground.

?

securely?
EN(TURBO)-193
NOTE:
are
shielded. Repair
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
securely.

Step
Terminals
No. 1 No. 2:
Check
and 4 k?
Yes
Go to step 7.

securely?
CHECK CAMSHAFT SPROCKET.

Remove the front belt cover. <Ref. to ME-48,
Belt Cover.>
Are the camshaft sprocket


TIMING BELT.
Turn the camshaft using ST, and align alignment mark on camshaft sprocket with alignment mark on timing belt cover LH.
ST 499207100 CAMSHAFT SPROCKET
WRENCH

EN(TURBO)-194
Replace the camshaft sprocket.

<Ref. to
ME(TURBO)-57,
Camshaft
Sprocket.>
Repair the installation condition of
timing belt. <Ref.
to ME(TURBO)48, Timing Belt
Assembly.>
No
Replace the camshaft position sensor. <Ref. to
FU(TURBO)-31,
Camshaft Position
Sensor.>
securely.
Go to step 9.
Replace the camshaft position sensor. <Ref. to

FU(TURBO)-31,
Camshaft Position
Sensor.>

EN(TURBO)-195

AQ:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD

TROUBLE SYMPTOM:
Engine stalls.
RHD
RHD
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
LHD
6
4
F61
B18
*6
*4
*5
*3
LHD : 2
RHD : 1
*4
LHD : 1
RHD : 2
LHD : 3
RHD : 4
LHD : 4
RHD : 3
RHD
LHD
LHD : 6
RHD : 1
B260
1
*2
B259
* 12
*
LHD
LHD : 2
RHD : 4
4
3
B19
D19
D29
2
FRONT OXYGEN
(A/F) SENSOR
REAR OXYGEN
SENSOR
B47
*1
F44
A22
A23
2
1
LHD
*3
5
3
BATTERY
B83
A: B134
B18
B19
F44
1 2
3 4
1 2
3 4
(LHD)
1 2 3 4
5 6 7 8
2 1
4 3
(RHD)
B47
1
3
5
2
4
6
B: B135
C: B136
C23
B26
B17
B19
C13
RHD
D: B137 ECM
B83
B259
B134
B135
1 2 3
4 5 6
(LHD)
1 2
6 7
1 2 3 4 5
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B136
B137
1 2 3 4 5 6
(RHD)
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 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 31
EN1439
EN(TURBO)-196

Step

Check for gas leaks or air suction caused by
loose or dislocated nuts and bolts, and open
hole at exhaust pipes.
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0420.
Is there a fault in exhaust sys- Repair or replace Go to step 3.
tem?
the exhaust system. <Ref. to
EX(TURBO)-2,
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
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(TURBO)-3,
Front Catalytic
Converter.> and
rear catalytic converter <Ref. to
EC(TURBO)-4,
Rear Catalytic
Converter.>
CHECK FRONT CATALYTIC CONVERTER. Is there damage at rear face or Replace the front
Remove the front catalytic converter.
front face of front catalyst?
catalytic converter. <Ref. to
EC(TURBO)-3,
Front Catalytic
Converter.>
EN(TURBO)-197
Go to step 4.
Contact with your

Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.

AR:DTC P0444 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT [MT VEHICLES]
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
B47
5
3
RHD
RHD
F44
6
4
LHD
1
3
5
1 2 3 4
5 6 7 8
SBF-5
LHD
8
B61
BATTERY
2
4
6
F44
2
1
B137
B47
ECM
16
B137
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
29 30 31
22 23 24 25 26
27 28
G4
B61
: LHD
B22
: RHD
2
6
10
14
3
7
11
15
4
8
12
16
LHD
RHD
LHD
RHD
1
5
9
13
F60
E4
F76
1 2
LHD
LHD
F44
B209
RHD
RHD
B209
: LHD
B22
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
: RHD
1
2
F60
E3
1
2
E4
E
PURGE CONTROL
SOLENOID VALVE
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H5
H3 H4
I4 I5
J3 J4 J5
EN1440
EN(TURBO)-198

Step
chassis ground.
engine ground.
(B137) No. 16 (E4) No. 2:
Check
Yes
No
up, the circuit has
this time. Contact
with your Subaru

?

?
NOTE:
Inspection by DTM
probable
parts.
ECM and purge
control solenoid
valve connector.
Go to step 4.

VALVE.
and 100 ?
Terminals
No. 1 No. 2:
EN(TURBO)-199
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(TURBO)-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.
EN(TURBO)-200
No
Contact with your
Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.

EN(TURBO)-201

AS:DTC P0445 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT [MT VEHICLES]
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
B47
5
3
RHD
RHD
F44
6
4
LHD
1
3
5
1 2 3 4
5 6 7 8
SBF-5
LHD
8
B61
BATTERY
2
4
6
F44
2
1
B137
B47
ECM
16
B137
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
29 30 31
22 23 24 25 26
27 28
G4
B61
: LHD
B22
: RHD
2
6
10
14
3
7
11
15
4
8
12
16
LHD
RHD
LHD
RHD
1
5
9
13
F60
E4
F76
1 2
LHD
LHD
F44
B209
RHD
RHD
B209
: LHD
B22
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
: RHD
1
2
F60
E3
1
2
E4
E
PURGE CONTROL
SOLENOID VALVE
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H5
H3 H4
I4 I5
J3 J4 J5
EN1440
EN(TURBO)-202

Step
Check
Does the voltage change
between 0 and 10 V?
driver's side).
chassis ground.
Yes
Go to step 2.
NOTE:
procedure, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(TURBO)-46,
Compulsory Valve Operation Check Mode.>
chassis ground.
CHECK POOR CONTACT.
Repair the poor
Check the poor contact in ECM connector.
connector?
contact in ECM
connector.
No
Even if MIL lights
up, 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(TURBO)-49,
Engine Control
Module.>
NECTOR.
ECM and purge
control solenoid
valve connector.
solenoid valve.
After repair,
replace the ECM.
<Ref. to
chassis ground.
FU(TURBO)-49,
Engine Control
Module.>
VALVE.
?
control solenoid
valve <Ref. to
2)Measure the resistance between purge conEC(TURBO)-7,
Purge Control
Terminals
Solenoid Valve.>
No. 1 No. 2:
and ECM <Ref. to
FU(TURBO)-49,
Engine Control
Module.>
CHECK POOR CONTACT.
Repair the poor
Replace the ECM.
connector?
contact in ECM
<Ref. to
connector.
FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-203

AT:DTC P0458 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT [AT VEHICLES]
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
B47
6
4
BATTERY
1
3
5
SBF-5
5
3
2
4
6
2
1
B137
B47
ECM
16
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
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
E4
1 2
B209
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
1
2
B22
E3
1
2
E4
E
PURGE CONTROL
SOLENOID VALVE
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H5
H3 H4
I4 I5
J3 J4 J5
EN1441
EN(TURBO)-204

Step
chassis ground.
engine ground.
(B137) No. 16 (E4) No. 2:
Check
Yes
No
up, the circuit has
this time. Contact
with your Subaru

?

?
NOTE:
Inspection by DTM
probable
parts.
ECM and purge
control solenoid
valve connector.
Go to step 4.

VALVE.
and 100 ?
Terminals
No. 1 No. 2:
EN(TURBO)-205
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(TURBO)-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.
EN(TURBO)-206
No
Contact with your
Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.

EN(TURBO)-207

AU:DTC P0459 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT [AT VEHICLES]
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
B47
6
4
BATTERY
1
3
5
SBF-5
5
3
2
4
6
2
1
B137
B47
ECM
16
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
B22
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
E4
1 2
B209
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
1
2
B22
E3
1
2
E4
E
PURGE CONTROL
SOLENOID VALVE
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H5
H3 H4
I4 I5
J3 J4 J5
EN1441
EN(TURBO)-208

Step
Check
between 0 and 10 V?
driver's side).
chassis ground.
Yes
Go to step 2.
NOTE:
procedure, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(TURBO)-46,
Compulsory Valve Operation Check Mode.>
chassis ground.
CHECK POOR CONTACT.
Repair the poor
Check the poor contact in ECM connector.
connector?
contact in ECM
connector.
No
Even if MIL lights
up, 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(TURBO)-49,
Engine Control
Module.>
NECTOR.
ECM and purge
control solenoid
valve connector.
solenoid valve.
After repair,
replace the ECM.
<Ref. to
chassis ground.
FU(TURBO)-49,
Engine Control
Module.>
VALVE.
?
control solenoid
valve <Ref. to
2)Measure the resistance between purge conEC(TURBO)-7,
Purge Control
Terminals
Solenoid Valve.>
No. 1 No. 2:
and ECM <Ref. to
FU(TURBO)-49,
Engine Control
Module.>
CHECK POOR CONTACT.
Repair the poor
Replace the ECM.
connector?
contact in ECM
<Ref. to
connector.
FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-209

AV:DTC P0461 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM
CAUTION:
WIRING DIAGRAM:
No.13
SBF-4
4
RHD
IGNITION SWITCH
B72
B36
4
23
B36
SBF-1
i1
i1
A7
RHD
A6
C2
*1
*2
FUEL
GAUGE
COMBINATION
METER
A:
i10
C:
i12
*1
LHD : 24
RHD : 21
*2
LHD : 3
RHD : 2
i2
B37
B135
25
D2
LHD
ECM
B209
16
F76
RHD
E3
16
B22
B99
E3
11
F60
R3
R15
R57
3
5
R59
1
2
FUEL SUB
LEVEL SENSOR
R58
FUEL LEVEL
SENSOR
B72
i1
1 2
3 4
1 2 3
4 5 6
7 8 9 10 11 12 13 14
A:
i10
C:
B135
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B209
R59
R58
F60
: LHD
1 2 3
4 5 6
B22
: RHD
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
B36
B99
7 8 9 10 11
1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN(TURBO)-210
R15
2
1
3 4 5 6
i2
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
(LHD)
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
(RHD)
EN1442

Step
Check
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0461.
EN(TURBO)-211
No
Replace the fuel
level sensor. <Ref.
to FU(TURBO)-62,
Fuel Level Sensor.> and fuel sub
level sensor <Ref.
to FU(TURBO)-63,
Fuel Sub Level
Sensor.>

AW:DTC P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT

CAUTION:
WIRING DIAGRAM:
No.13
SBF-4
4
RHD
IGNITION SWITCH
B72
B36
4
23
B36
SBF-1
i1
i1
A7
RHD
COMBINATION
METER
A:
i10
C:
i12
*2
*1
C2
A6
FUEL
GAUGE
*1
LHD : 24
RHD : 21
*2
LHD : 3
RHD : 2
i2
B37
B135
25
D2
LHD
ECM
B209
16
F76
RHD
E3
16
B22
B99
E3
11
F60
R3
R15
R57
3
5
R59
1
2
FUEL SUB
LEVEL SENSOR
R58
FUEL LEVEL
SENSOR
B72
i1
1 2
3 4
1 2 3
4 5 6
7 8 9 10 11 12 13 14
A:
i10
C:
B135
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B209
R59
R58
F60
: LHD
1 2 3
4 5 6
B22
: RHD
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
B36
B99
7 8 9 10 11
1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
F5
G4 G5
H5
H3 H4
I4 I5
J3 J4 J5
EN(TURBO)-212
R15
2
1
3 4 5 6
i2
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
(LHD)
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
(RHD)
EN1442

Step
METER.
Check
Yes
Go to step 2.

Read the data of fuel level sensor signal using

V?
NOTE:

COMBINATION METER.
2)Disconnect the connector from connector
(i10), (i12) and ECM connector.
chassis ground.
COMBINATION METER.
combination meter connector.
(B135) No. 25 (i12) No. 2:
Go to step 6.
Does the value change less

Repair the poor
than 0.12 V by shaking harcontact in ECM
ness and connector of ECM
connector.
while monitoring the value with
No
Repair or replace
the combination
meter. <Ref. to
Go to step 3.
Even if MIL lights

up, the circuit has
of the connector
may be the cause.
NOTE:
the following:
Poor contact in
combination meter
connector
Poor contact in
ECM connector
Poor contact in
coupling connectors
Go to step 7.

V?
Go to step 4.

M?
Go to step 6.
Repair the ground


?
Repair or replace
the combination
meter. <Ref. to
Repair the open

circuit between
EN(TURBO)-213
NOTE:
the following:
Poor contact in
coupling connector

10
Step
sensor.
level sensor and chassis ground.
assembly.
FU(TURBO)-60, Fuel Pump.>
position.
Terminals
No. 3 No. 5:
FU(TURBO)-63, Fuel Sub Level Sensor.>
level sensor and terminals with its float set to
the full position.
Terminals
No. 1 No. 2:
Check
M?
Yes
Go to step 8.
No
Repair the ground
tank cord.

M?
Go to step 9.
Repair the ground

tank cord.

and 2.5 ?
Go to step 10.
Replace the fuel

level sensor.

and 2.5 ?
Repair the poor

Replace the fuel
contact in harness sub level sensor.
between ECM and
combination meter
connector.
EN(TURBO)-214

EN(TURBO)-215

AX:DTC P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT

CAUTION:
WIRING DIAGRAM:
No.13
SBF-4
4
RHD
IGNITION SWITCH
B72
B36
4
23
B36
SBF-1
i1
i1
A7
RHD
COMBINATION
METER
A:
i10
C:
i12
*2
*1
C2
A6
FUEL
GAUGE
*1
LHD : 24
RHD : 21
*2
LHD : 3
RHD : 2
i2
B37
B135
25
D2
LHD
ECM
B209
16
F76
RHD
E3
16
B22
B99
E3
11
F60
R3
R15
R57
3
5
R59
1
2
FUEL SUB
LEVEL SENSOR
R58
FUEL LEVEL
SENSOR
B72
i1
1 2
3 4
1 2 3
4 5 6
7 8 9 10 11 12 13 14
A:
i10
C:
B135
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B209
R59
R58
F60
: LHD
1 2 3
4 5 6
B22
: RHD
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
B36
B99
7 8 9 10 11
1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
F5
G4 G5
H5
H3 H4
I4 I5
J3 J4 J5
EN(TURBO)-216
R15
2
1
3 4 5 6
i2
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
(LHD)
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
(RHD)
EN1442

Step
METER.
Check
Yes
Go to step 2.


2)Disconnect the combination meter connector
FUEL TANK CORD.
fuel tank cord.
(B135) No. 25 (R15) No. 2:
CHECK HARNESS BETWEEN FUEL TANK
CORD AND CHASSIS GROUND.
Measure the resistance between fuel tank cord
and chassis ground.

sensor.
(R57) No. 6 (R58) No. 5:
Go to step 3.
No
Repair or replace
the combination
meter. <Ref. to
Even if MIL lights
up, the circuit has
of the connector
may be the cause.
NOTE:
the following:
Poor contact in
fuel pump connector
Poor contact in
coupling connector
Repair the battery
short circuit
between ECM and
combination meter
connector.

V?
Go to step 4.

?
Go to step 5.
Repair the open

circuit between
ECM and fuel tank
cord.

?
Go to step 6.
Repair the open

circuit between
fuel tank cord and
chassis ground.

?
EN(TURBO)-217
Go to step 7.
NOTE:
the following:
Poor contact in
coupling connectors
Repair the open
circuit between
coupling connector

10
Step
sensor.
sensor and fuel sub level sensor.
(R58) No. 3 (R59) No. 2:
Measure the resistance between fuel sub level
(R57) No. 2 (R59) No. 1:
and down, measure the resistance between
fuel level sensor terminals.
Terminals
No. 3 No. 5:
up and down, measure the resistance between
fuel sub level sensor terminals.
Terminals
No. 1 No. 2:
Check
?
Yes
Go to step 8.
No
Repair the open
circuit between
fuel level sensor
and fuel sub level
sensor.

?
Go to step 9.
Repair the open

circuit between
coupling connector
and fuel sub level
sensor.
Go to step 10.

?
level sensor. <Ref.
to FU(TURBO)-62,
Fuel Level Sensor.>

?
sub level sensor.
<Ref. to
FU(TURBO)-63,
Fuel Sub Level
Sensor.>
EN(TURBO)-218

<Ref. to IDI-15,
Combination
Meter Assembly.>

EN(TURBO)-219

AY:DTC P0464 FUEL LEVEL SENSOR INTERMITTENT INPUT

CAUTION:
WIRING DIAGRAM:
No.13
SBF-4
4
RHD
IGNITION SWITCH
B72
B36
4
23
B36
SBF-1
i1
i1
A7
RHD
COMBINATION
METER
A:
i10
C:
i12
*2
*1
C2
A6
FUEL
GAUGE
*1
LHD : 24
RHD : 21
*2
LHD : 3
RHD : 2
i2
B37
B135
25
D2
LHD
ECM
B209
16
F76
RHD
E3
16
B22
B99
E3
11
F60
R3
R15
R57
3
5
R59
1
2
FUEL SUB
LEVEL SENSOR
R58
FUEL LEVEL
SENSOR
B72
i1
1 2
3 4
1 2 3
4 5 6
7 8 9 10 11 12 13 14
A:
i10
C:
B135
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B209
R59
R58
F60
: LHD
1 2 3
4 5 6
B22
: RHD
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
B36
B99
7 8 9 10 11
1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
F5
G4 G5
H5
H3 H4
I4 I5
J3 J4 J5
EN(TURBO)-220
R15
2
1
3 4 5 6
i2
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
(LHD)
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
(RHD)
EN1442

Step

and down, make sure that the resistance
smoothly.
Terminals
No. 3 No. 5:
up and down, make sure that the resistance
smoothly.
Terminals
No. 1 No. 2:
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
Go to step 3.
Replace the fuel
smoothly between approx. 0.5
level sensor. <Ref.
and approx. 52 ?
to FU(TURBO)-62,
Fuel Level Sensor.>

Repair the poor
smoothly between approx. 0.5 contact in ECM,
and approx. 44 ?
combination meter
EN(TURBO)-221
Replace the fuel

sub level sensor.
<Ref. to
FU(TURBO)-63,
Fuel Sub Level
Sensor.>

EN(TURBO)-222

AZ:DTC P0480 COOLING FAN RELAY 1 CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
Overheating
CAUTION:
EN(TURBO)-223

WIRING DIAGRAM:
BATTERY
SBF-1
B72
IGNITION
SWITCH
No.18
SBF-4
*1
LHD : 2
RHD : 7
*2
LHD : 12
RHD : 17
17
28
* 12
*
F29
F28
1
3
2
1
3
2
F16
B72
1 2
3 4
(BLUE)
F27
SUB FAN
MOTOR
F28
F17
F29
4
3
MAIN FAN MAIN FAN

RELAY1
RELAY2
30A
SUB FAN
RELAY1
2
1
SUB FAN
RELAY2
30A
25
27
28
26
24
22
21
23
F45
8
6
5
7
B62
17
19
20
18
B137 ECM
No.17
MAIN FAN
MOTOR
F30
5 6 9 13 14 17 21 22 25
7
10
15
18
23
26
8 11 12 16 19 20 24 27 28
F66
29
30
F30
F66
F27
B137
F45
F16
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
(LHD)
F17
3 2 1
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
(RHD)
EN0981
EN(TURBO)-224

Step
driver's side).
4)While operating the radiator fan relay, measure the voltage between ECM terminal and
ground.
NOTE:
Check Mode.<Ref. to EN(TURBO)-34, Subaru
Select Monitor.>
CHECK GROUND SHORT CIRCUIT IN RADIATOR MAIN FAN RELAY CONTROL CIRCUIT.
CHECK POWER SUPPLY FOR RELAY.
1)Remove the main fan relay 1 and 2 from A/C
relay holder.
3)Measure the voltage between fuse and relay
box (F/B) connector and chassis ground.
relay terminals.
Terminal
No. 27 No. 28:(Main fan relay 1)
No. 22 No. 21:(Main fan relay 2)
CHECK OPEN CIRCUIT IN MAIN FAN RELAY CONTROL CIRCUIT.
ECM and main fan relay connector.
(B137) No. 17 (F66) No. 28:
(B137) No. 28 (F30) No. 21:
CHECK POOR CONTACT.

Check poor contact in ECM or main fan relay
connector.
Check
between 0 and 10 V?
Yes
Repair the poor
contact in ECM
connector.
No
Go to step 2.

?

short circuit in radiator main fan relay
control circuit.
Repair the open

circuit in harness
between ignition
switch and fuse
and relay box
(F/B) connector.

and 107 ?
Go to step 5.
Replace the main

fan relay.

?
Go to step 6.
NOTE:
the following:
Open circuit in
harness between
ECM and main fan
relay connector
Poor contact in
coupling connector
Contact with your
main fan relay connector?
contact in ECM or Subaru distributor
main fan relay
service.
connector.
EN(TURBO)-225

EN(TURBO)-226

BA:DTC P0483 COOLING FAN FUNCTION PROBLEM

TROUBLE SYMPTOM:
Occurrence of noise
Overheating
CAUTION:
NOTE:
If the vehicle, with the engine idling, is placed very close to a wall or another vehicle, preventing normal cooling function, the OBD system may detect malfunction.
EN(TURBO)-227

WIRING DIAGRAM:
BATTERY
SBF-1
B72
IGNITION
SWITCH
No.18
SBF-4
*1
LHD : 2
RHD : 7
*2
LHD : 12
RHD : 17
17
28
* 12
*
F29
F28
1
3
2
1
3
2
F16
B72
1 2
3 4
(BLUE)
F27
SUB FAN
MOTOR
F28
F17
F29
4
3
MAIN FAN MAIN FAN

RELAY1
RELAY2
30A
SUB FAN
RELAY1
2
1
SUB FAN
RELAY2
30A
25
27
28
26
24
22
21
23
F45
8
6
5
7
B62
17
19
20
18
B137 ECM
No.17
MAIN FAN
MOTOR
F30
5 6 9 13 14 17 21 22 25
7
10
15
18
23
26
8 11 12 16 19 20 24 27 28
F66
29
30
F30
F66
F27
B137
F45
F16
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
(LHD)
F17
3 2 1
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
(RHD)
EN0981
EN(TURBO)-228

Step
Check
EN(TURBO)-229
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
No
Check the radiator
fan, fan motor and
thermostat. <Ref.
to CO-10, Radiator
Main Fan System.> and <Ref. to
CO-18, Radiator
Sub Fan System.> If thermostat
is stuck, replace
thermostat.

BB:DTC P0500 VEHICLE SPEED SENSOR MALFUNCTION

CAUTION:
WIRING DIAGRAM:
B157
IGNITION
RELAY
BATTERY
No.15
* 12
*
B157
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
LHD : 10
RHD : 38
i2
LHD : 9
RHD : 37
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
(LHD)
LHD : 9
RHD : 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
(RHD)
*1
*2
*3
VEHICLE
SPEED
SENSOR
B17
1
2
B209
B56
TCM
AT
17
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
MT
RHD
F1
G1G2
H1 H2
I1 I2
J1 J2
LHD
COMBINATION
METER
N2
i10
*3
F5
G4 G5
H5
H4
H3
I4 I5
J3 J4 J5
F76
B37
LHD
i2
B209
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2
3 4
1 2 3 4 5 6 7 8 9 10
RHD
: LHD
B22
: RHD
16
F60
1
B17
i10
E3
B134
B134 ECM
1 2 3 4 5
6 7
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
1
5
9
13
F60
: LHD
B22
: RHD
2
6
10
14
3
7
11
15
4
8
12
16
EN1443
Step
Check
Is the transmission type AT?
EN(TURBO)-230
Yes
Go to step 2.
No
Go to step 3.

Step

COMBINATION METER.

meter.
combination meter.
(B134) No. 1 (i10) No. 2:
Check
Yes
No
Go to step 3.
sor signal circuit.
<Ref. to AT-57,
DTC 33 FRONT
VEHICLE SPEED
with Diagnostic
Trouble Code
(DTC).>
<Ref. to IDI-17,
Speedometer.>
and <Ref. to AT32, Front Vehicle
Speed Sensor.>
Repair the har?
contact in ECM
tor.
EN(TURBO)-231
NOTE:
the following:
Open circuit in
harness between
Poor contact in
ECM connector
Poor contact in
combination meter
connector
Poor contact in
coupling connector

BC:DTC P0506 IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED

TROUBLE SYMPTOM:
Engine is difficult to start.
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
RHD
6
4
RHD
MAIN RELAY
LHD
5
3
B61
RHD
F44
B209
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
LHD
F44
LHD
2
1
BATTERY
SBF-5
B47
F1
G1G2
H1 H2
I1 I2
J1 J2
B61
LHD
F44
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2 3 4
5 6 7 8
B47
F5
G4 G5
H5
H3 H4
I4 I5
J3 J4 J5
1
3
5
RHD
: LHD
B22
: RHD
: LHD
B22
: RHD
F60
F60
2
4
6
E3
2
1
5
9
13
2
6
10
14
IDLE
AIR CONTROL
SOLENOID
VALVE
3
7
11
15
4
8
12
16
E7
E7
1
3
1 2 3
LHD
: RHD
B136
12
RHD
B21
1 2
E2
B21
G5
: LHD
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
F76
B209
F61
10
12
F61
RHD
E2
LHD
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
B136 ECM
E
EN1444
EN(TURBO)-232

Step
Check
CHECK IDLE AIR CONTROL SOLENOID

Does air flow out?
VALVE.
from throttle body. <Ref. to FU(TURBO)-36,
REMOVAL, Idle Air Control Solenoid Valve.>
control solenoid valve by-pass air inlet. Confirm that forced air subsequently escapes from
both main air passage and assist air passage.
Is the value more than 60 %?
CHECK IDLE AIR CONTROL SOLENOID
VALVE DUTY RATIO.
2)Start the engine, and warm-up the engine.
4)Read the data of idle air control solenoid
valve duty ratio using Subaru Select Monitor or
NOTE:
CHECK BY-PASS AIR LINE.
Does air flow out?
REMOVAL, Idle Air Control Solenoid Valve.>
3)Remove the throttle body to intake manifold.
<Ref. to FU(TURBO)-14, REMOVAL, Throttle
Body.>
4)Using an air gun, force air into the solenoid
valve installation area and throttle valve interior. Confirm that forced air subsequently
escapes from both these areas.
EN(TURBO)-233
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0506.
Go to step 4.
Replace the idle
valve. <Ref. to
FU(TURBO)-36,
Idle Air Control
Solenoid Valve.>
After replace, Go
to step 3.
Go to step 4.
END.
Replace the idle

valve. <Ref. to
FU(TURBO)-36,
Idle Air Control
Solenoid Valve.>

FU(TURBO)-14,
Throttle Body.>

BD:DTC P0507 IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
RHD
6
4
RHD
MAIN RELAY
LHD
5
3
B61
RHD
F44
B209
SBF-5
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
LHD
F44
LHD
2
1
BATTERY
B47
F1
G1G2
H1 H2
I1 I2
J1 J2
B61
LHD
F44
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2 3 4
5 6 7 8
B47
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
1
3
5
RHD
: LHD
B22
: RHD
: LHD
B22
: RHD
F60
F60
2
4
6
E3
2
1
5
9
13
2
6
10
14
IDLE
AIR CONTROL
SOLENOID
VALVE
3
7
11
15
4
8
12
16
E7
E7
1
3
1 2 3
LHD
: RHD
B136
12
RHD
B21
1 2
E2
B21
G5
: LHD
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
F76
B209
F61
10
12
F61
RHD
E2
LHD
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
B136 ECM
E
EN1444
EN(TURBO)-234

Step

gasket
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0507.
Go to step 3.
Adjust the throttle
Control Cable.>
Is there a fault in air intake sys- Repair the air suc- Replace the idle
tem?
tion and leaks.
valve. <Ref. to
FU(TURBO)-36,
Idle Air Control
Solenoid Valve.>
EN(TURBO)-235

BE:DTC P0508 IDLE CONTROL SYSTEM CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Engine breathing
CAUTION:
WIRING DIAGRAM:
RHD
6
4
RHD
MAIN RELAY
LHD
5
3
B61
RHD
F44
B209
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
LHD
F44
LHD
2
1
BATTERY
SBF-5
B47
F1
G1G2
H1 H2
I1 I2
J1 J2
B61
LHD
F44
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2 3 4
5 6 7 8
B47
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
1
3
5
RHD
: LHD
B22
: RHD
F60
: LHD
B22
: RHD
F60
2
4
6
E3
2
1
5
9
13
2
6
10
14
IDLE
AIR CONTROL
SOLENOID
VALVE
3
7
11
15
4
8
12
16
E7
E7
1
3
1 2 3
LHD
: RHD
B136
12
RHD
B21
1 2
E2
B21
G5
: LHD
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
F76
B209
F61
10
12
F61
RHD
E2
LHD
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
B136 ECM
E
EN1444
EN(TURBO)-236

Step
Check
chassis ground.
CHECK POWER SUPPLY TO IDLE AIR CON- Is the voltage more than 10 V?
Yes
Repair the poor
contact in ECM
connector.
No
Go to step 2.
Go to step 3.

?
CONNECTOR.
ECM and idle air control solenoid valve connector.
(B136) No. 10 (E7) No. 1:
Go to step 4.

CONNECTOR.
CHECK GROUND CIRCUIT OF IDLE AIR
idle air control solenoid valve connector and
engine ground.
CHECK POOR CONTACT.
Check poor contact in ECM and idle air control
solenoid valve connectors.

?

?

and idle air control solenoid
valve connectors?
EN(TURBO)-237
NOTE:
the following:
Open circuit in
harness between
idle air control
solenoid valve and
Poor contact in
coupling connector
NOTE:
the following:
Open circuit in
harness between
ECM and idle air
control solenoid
valve connector
Poor contact in
coupling connector
ECM and idle air
control solenoid
valve connector.
Go to step 6.
Repair the open

circuit in harness
between idle air
control solenoid
valve connector
and engine ground
cable.
Repair the poor
Replace the idle
contact in ECM
and idle air control valve. <Ref. to
solenoid valve
FU(TURBO)-36,
connectors.
Idle Air Control
Solenoid Valve.>

BF:DTC P0509 IDLE CONTROL SYSTEM CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Engine breathing
CAUTION:
WIRING DIAGRAM:
RHD
6
4
RHD
MAIN RELAY
LHD
5
3
B61
RHD
F44
B209
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
LHD
F44
LHD
2
1
BATTERY
SBF-5
B47
F1
G1G2
H1 H2
I1 I2
J1 J2
B61
LHD
F44
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2 3 4
5 6 7 8
B47
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
1
3
5
RHD
: LHD
B22
: RHD
F60
: LHD
B22
: RHD
F60
2
4
6
E3
2
1
5
9
13
2
6
10
14
IDLE
AIR CONTROL
SOLENOID
VALVE
3
7
11
15
4
8
12
16
E7
E7
1
3
1 2 3
LHD
: RHD
B136
12
RHD
B21
1 2
E2
B21
G5
: LHD
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
F76
B209
F61
10
12
F61
RHD
E2
LHD
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
B136 ECM
E
EN1444
Step
Check
EN(TURBO)-238
Yes
Go to step 2.
No
Adjust the throttle
Control Cable.>

Step
chassis ground.
chassis ground.
Check
Yes

ECM and idle air
control solenoid
valve connector.
After repair,
replace the ECM.
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
Does the voltage change more Repair the battery
Measure the voltage between ECM and chas- than 10 V by shaking harness short circuit in harand connector of ECM while
ness between
sis ground.
monitoring the value with volt- ECM and idle air
control solenoid
(B136) No. 10 (+) Chassis ground (): age meter?
valve connector.
After repair,
replace the ECM.
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-239
No
Go to step 4.
Replace the idle

valve. <Ref. to
FU(TURBO)-36,
Idle Air Control
Solenoid Valve.>
and ECM <Ref. to
FU(TURBO)-49,
Engine Control
Module.>
Contact with your

Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.

BG:DTC P0512 STARTER SWITCH CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-4
IGNITION
SWITCH
B72
P R N D 3
AT
MT
T3
T7
MT
B12
12
7
12
11
AT
B134 ECM
16
B14
STARTER
MOTOR
B72
1 2
3 4
B134
1 2 3 4 5
6 7
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
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
EN1428
EN(TURBO)-240

Step
Check
NOTE:
turned to ON?
Place the inhibitor switch in each position.
EN(TURBO)-241
Yes
Repair the battery
short circuit in
starter motor circuit. After repair,
replace the ECM.
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
No
Check the starter
to EN(TURBO)-60,
STARTER
MOTOR CIRCUIT, Diagnostics

BH:DTC P0545 EXHAUST GAS TEMPERATURE SENSOR CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B83
1 2 3
4 5 6
(LHD)
EXHAUST GAS
TEMPERATURE
SENSOR
1 2 3 4 5 6
1
2
(RHD)
B279
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
B279
1 2
5
LHD : 6
RHD : 1
16
19
B83
B136 ECM
EN0984
EN(TURBO)-242

Step
CHECK CURRENT DATA.
1)Start the engine.
2)Read the data of exhaust gas temperature
Check
Is the value greater than
1200C (2192F)?
NOTE:
CHECK HARNESS BETWEEN EXHAUST
(702F)?
GAS TEMPERATURE SENSOR AND ECM
CONNECTOR.
2)Disconnect the connector from exhaust gas
temperature sensor.
NOTE:
EN(TURBO)-243
Yes
Go to step 2.
No
Repair the poor
contact.
NOTE:
the following:
Poor contact in
exhaust gas temperature sensor
Poor contact in
ECM
Poor contact in
joint connector
Replace the
exhaust gas temperature sensor.
<Ref. to
FU(TURBO)-48,
Exhaust Temperature Sensor.>
Repair the ground

and ECM connector.

BI: DTC P0546 EXHAUST GAS TEMPERATURE SENSOR CIRCUIT HIGH INPUT
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B83
1 2 3
4 5 6
(LHD)
EXHAUST GAS
TEMPERATURE
SENSOR
1 2 3 4 5 6
1
2
(RHD)
B279
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
B279
1 2
5
LHD : 6
RHD : 1
16
19
B83
B136 ECM
EN0984
EN(TURBO)-244

Step
CHECK CURRENT DATA.
1)Start the engine.
Check
(702F)?
NOTE:
CONNECTOR.
2)Disconnect the connector from exhaust gas
temperature sensor.
3)Measure the voltage between exhaust gas
ground.
CONNECTOR.
2)Measure the voltage between exhaust gas
ground.
CONNECTOR.
Measure the voltage between exhaust gas
ground.
EN(TURBO)-245
Yes
Go to step 2.
No
Repair the poor
contact.
NOTE:
the following:
Poor contact in
Poor contact in
ECM
Poor contact in
joint connector

ECM and exhaust
gas temperature
sensor connector.

ECM and exhaust
gas temperature
sensor connector.
Go to step 5.

NOTE:
the following:
Open circuit in
harness between
ECM and exhaust
gas temperature
sensor connector
Poor contact in
connector
Poor contact in
ECM connector
Poor contact in
joint connector

Step
Check
?
CONNECTOR.
exhaust gas temperature sensor connector
and engine ground.
EN(TURBO)-246
Yes
Replace the
<Ref. to
FU(TURBO)-48,
No
NOTE:
the following:
Open circuit in
harness between
ECM and exhaust
gas temperature
sensor connector
Poor contact in
connector
Poor contact in
ECM connector
Poor contact in
joint connector

BJ:DTC P0604 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN(TURBO)-247

LHD model
MAIN RELAY
4
6
2
SBF-5
8
5
3
B61
F44
B72 IGNITION
SWITCH
2
1
BATTERY
No.11
SBF-4
B47
A2
D2
D3
D10
A14
SBF-1
A : B134
C : B136
ECM
D : B137
E:
D8
D9
A22
C17
C8
C18
A7
A15
E1
B84
C3
F1
D2
J3
A3
B209
15
13
14
16
F76
F60
E3
E
B72
B47
1
3
5
1 2
3 4
F1
G1G2
H1 H2
I1 I2
J1 J2
A : B134
F60
2
4
6
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
D : B137
B209
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2 3 4 5
6 7
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
E:
1 2
3 4 5 6 7 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
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1429
EN1429
EN(TURBO)-248

RHD model
MAIN RELAY
DATA LINK CONNECTOR
4
6
SBF-5
5
3
2
1
B72
IGNITION
SWITCH
BATTERY
No.11
B47
SBF-4
1
A2
D2
D3
D10
A14
SBF-1
A:
B134
C : B136
ECM
D : B137
B84
13
14
16
15
D8
D9
A22
C17
C8
C18
A7
A15
E1
E:
B22
E3
E
B72
1 2
3 4
E
B47
1
3
5
2
4
6
A : B134
B22
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
E:
C : B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 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
B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
EN0960
Step
Check
Yes
No
tor or OBD-II general scan tool <Ref. to
to inspect DTC
indicate DTC P0604?
FU(TURBO)-49,
P0604.
Engine Control
Module.>
EN(TURBO)-249

BK:DTC P0703 BRAKE SWITCH INPUT MALFUNCTION

CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(TURBO)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(TURBO)-42, Inspection Mode.>.
WIRING DIAGRAM:
SBF-2
SBF-1
BATTERY
BRAKE LIGHT
SWITCH
1
2
NO. 16
B65
12
TO STOP LIGHTS
B55 TCM
B65
1 2
3 4
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7 8 9
16 17 18
22 23 24
B2M4366
Step
CHECK OPERATION OF BRAKE LIGHT.
Check
Does the brake light come on
when depressing the brake
pedal?
EN(TURBO)-250
Yes
Go to step 2.
No
Repair or replace
the brake light circuit.

Step
Check
?
brake light switch.
TCM and brake light switch connector.
(B55) No. 12 (B65) No. 3:

1)Connect the connectors to TCM and brake
light switch.
chassis ground.
Yes
Go to step 3.

M?
Go to step 4.

when releasing the brake
pedal?
Go to step 5.

Measure the voltage between TCM and chas- when depressing the brake
sis ground.
pedal?
CHECK POOR CONTACT.


connector?
EN(TURBO)-251
Go to step 6.
Repair the poor

contact in TCM
connector.
No
Repair or replace
the harness and
connector.
NOTE:
the following:
Open circuit in
harness between
TCM and brake
light switch connector
Poor contact in
TCM connector
Poor contact in
brake light switch
connector
Repair the ground
TCM and brake
light switch connector.
Adjust or replace
the brake light
SWITCH,
INSPECTION,
Stop Light System.>
Adjust or replace
the brake light
SWITCH,
INSPECTION,
Stop Light System.>
Replace the TCM.
<Ref. to AT-46,
(TCM).>

BL:DTC P0731 GEAR 1 INCORRECT RATIO

NOTE:
For the diagnostic procedure, refer to DTC P0734. <Ref. to EN(TURBO)-253, DTC P0734 GEAR 4 INCORRECT RATIO , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BM:DTC P0732 GEAR 2 INCORRECT RATIO

NOTE:
BN:DTC P0733 GEAR 3 INCORRECT RATIO

NOTE:
EN(TURBO)-252

BO:DTC P0734 GEAR 4 INCORRECT RATIO

TROUBLE SYMPTOM:
Shift point too high or too low; engine brake not effective in 3 range; excessive shift shock; excessive
tight corner braking
CAUTION:
WIRING DIAGRAM:
Step
Check

CIRCUIT.
CIRCUIT.
Check the front vehicle speed sensor circuit.
Code (DTC).>
CHECK POOR CONTACT.


Is there any trouble in vehicle

speed sensor 2 circuit?
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
Repair or replace
the vehicle speed
sensor 2 circuit.
Go to step 4.

verter turbine
Go to step 5.

connector?
Go to step 6.
Repair the poor

contact in TCM
connector.
transmission.
<Ref. to AT-12,
INSPECTION,
Road Test.>
EN(TURBO)-253
Replace the TCM.

<Ref. to AT-46,
(TCM).>

BP:DTC P0741 TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION

TROUBLE SYMPTOM:
No lock-up (after engine warm-up)
No shift or excessive tight corner braking
CAUTION:
Step
Check
CHECK LOCK-UP DUTY SOLENOID CIRCUIT.

Check the lock-up duty solenoid circuit. <Ref.
to AT-94, DTC 77 LOCK-UP DUTY SOLENOID, Diagnostic Procedure with Diagnostic
CIRCUIT.
Code (DTC).>
CHECK ENGINE SPEED INPUT CIRCUIT.
Check the engine speed input circuit. <Ref. to
AT-42, DTC 11 ENGINE SPEED SIGNAL,
Code (DTC).>
Check the inhibitor switch circuit. <Ref. to AT119, CHECK INHIBITOR SWITCH., Diagnostic
(DTC).>
CHECK BRAKE LIGHT SWITCH CIRCUIT.
Check the brake light switch circuit. <Ref. to
AT-110, CHECK BRAKE SWITCH., Diagnostic
(DTC).>
Is there any trouble in lock-up


Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
the lock-up duty
solenoid circuit.


verter turbine
Go to step 5.
Is there any trouble in engine

speed input circuit?
Go to step 6.
Repair or replace
the engine speed
input circuit.
Is there any trouble in inhibitor Repair or replace Go to step 7.

switch circuit?
the inhibitor switch
circuit.
Is there any trouble in brake

light switch circuit?
EN(TURBO)-254
Repair or replace
the brake light
switch circuit.
Go to step 8.

10
Step
CHECK ATF TEMPERATURE SENSOR CIRCUIT.
Check the ATF temperature sensor circuit.
CHECK POOR CONTACT.
Check
Is there any trouble in ATF

connector?
Yes
No
the ATF temperature sensor circuit.
Repair the poor

contact in TCM
connector.
transmission.
<Ref. to AT-12,
INSPECTION,
Road Test.>
EN(TURBO)-255
Go to step 10.
Replace the TCM.

<Ref. to AT-46,
(TCM).>

BQ:DTC P0851 NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT [AT VEHICLES]
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B134 ECM
B134
7 6
5 4 3 2 1
15 14 13 12 11 10 9 8
22 21 20 19 18
17 16
INHIBITOR SWITCH
P
12
12
11
B12
T3
R N D
1
B12
1
5
9
13
T7
STARTER MOTOR
2
6
10
14
3
7
11
15
4
8
12
16
T7
1 2 3 4 5 6
7 8 9 10 11 12
B14
B2M4370
EN(TURBO)-256

Step

positions.
Measure the voltage between ECM and chassis ground in selector lever except for N and
P positions.
CHECK POOR CONTACT.
Check
Yes
indicate DTC P0705?
of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
Go to step 3.
No
Go to step 2.
Go to step 5.

5.5 V?
Go to step 5.

connector?
Contact with your

Subaru distributor
service.
Repair the poor

contact in ECM
connector.
NOTE:
Inspection by DTM
probable
parts.
Measure the voltage between ECM and chasshort circuit in harsis ground.
ness between
ECM and inhibitor
switch connector.
Go to step 7.
Repair the harHIBITOR SWITCH CONNECTOR.
?
ness and connec1)Turn the ignition switch to OFF.
tor.
NOTE:
inhibitor switch.
the following:
Open circuit in
harness between
(B134) No. 8 (T7) No. 12:
ECM and inhibitor
switch connector
Poor contact in
coupling connector
Poor contact in
inhibitor switch
connector
Poor contact in
ECM connector
EN(TURBO)-257

Step
Check
CHECK INHIBITOR SWITCH GROUND LINE. Is the resistance less than 5
?

?
selector lever N and P positions.
Terminals
No. 7 No. 12:
CHECK SELECTOR CABLE CONNECTION. Is there any fault in selector
switch?
EN(TURBO)-258
Yes
Go to step 8.
Go to step 9.
Repair the selector

cable connection.
<Ref. to CS-10,
INSPECTION,
Select Cable.>
No
Repair the open
circuit in harness
between inhibitor
switch connector
and starter motor
ground line.
NOTE:
the following:
Open circuit in
harness between
inhibitor switch
connector and
starter motor
ground line
Poor contact in
starter motor connector
Poor contact in
starter motor
ground
Starter motor
AT-28, Inhibitor
Switch.>
Contact with your

Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.

EN(TURBO)-259

BR:DTC P0852 NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT [AT VEHICLES]
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B134 ECM
B134
7 6
5 4 3 2 1
15 14 13 12 11 10 9 8
22 21 20 19 18
17 16
INHIBITOR SWITCH
P
12
12
11
B12
T3
R N D
1
B12
1
5
9
13
T7
STARTER MOTOR
2
6
10
14
3
7
11
15
4
8
12
16
T7
1 2 3 4 5 6
7 8 9 10 11 12
B14
B2M4370
EN(TURBO)-260

Step

chassis ground.
transmission harness connector (T3).
CHECK TRANSMISSION HARNESS CONNECTOR.
switch.
ground.
selector lever except for N position.
Terminals
No. 7 No. 12:
CHECK SELECTOR CABLE CONNECTION.
Check
Yes
No
Go to step 2.
indicate DTC P0705?
of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
Is the voltage between 4.5 and Even if MIL lights Go to step 3.
5.5 V at except N and P
up, the circuit has
positions?
this time.
?

connector.

?

transmission harness and inhibitor
switch connector.

M at except N and P positions?
Is there any fault in selector

switch?
EN(TURBO)-261
Repair the selector

cable connection.
<Ref. to CS-10,
INSPECTION,
Select Cable.>

AT-28, Inhibitor
Switch.>
Contact with your

Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.

BS:DTC P0864 AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT MALFUNCTION
CAUTION:
WIRING DIAGRAM:
TCM
20
21
B56
B135
B55
5 6
1 2 3 4
10 11 12 13 14 15
19 20 21
ECM
B135
8
9
7
16 17 18
22 23 24
7 6
5 4 3 2 1
15 14 13 12 11 10 9 8
22 21 20 19 18
17 16
B2M4371
Step
Check
Yes
Is the AT shift control function- Go to step 2.
CHECK DRIVING CONDITION.
1)Start and warm-up the engine until the radia- ing properly?
tor fan makes one complete rotation.
2)Drive the vehicle.
EN(TURBO)-262
No
Replace the TCM.
<Ref. to AT-46,
(TCM).>

Step
CHECK ACCESSORY.
Check
Are car phone and/or CB
installed on vehicle?
EN(TURBO)-263
Yes
Repair the grounding line of car
phone or CB system.
No
Replace the TCM.
<Ref. to AT-46,
(TCM).>

BT: DTC P1086 TUMBLE GENERATOR VALVE #2 (LH) POSITION SENSOR

CIRCUIT LOW INPUT
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
LHD model
E50
TUMBLE GENERATOR VALVE

POSITION SENSOR
1 2 3
F61
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
1
3
2
1 2
E50
B209
E2
20
10
18
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F61
A4 A5
B4 B5
C4 C5
D4 D5
E5
A1
B2
G2
F76
F1
G1G2
H1 H2
I1 I2
J1 J2
B209
1
6
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
B83
B83
1 2 3
4 5 6
B135
9
13
19
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B135 ECM
EN1445
EN(TURBO)-264

RHD model

POSITION SENSOR
E50
1
3
2
1 2 3
E50
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
20
10
18
E2
B21
B83
3
1
1 2 3 4 5 6
B83
B135
9
13
19
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B135 ECM
EN0986
EN(TURBO)-265

Step
Check
CHECK CURRENT DATA.
1)Start the engine.
general scan tool.
Yes
Go to step 2.
NOTE:

and chassis ground while tumble generator
valve is fully closed.
and chassis ground.

and chassis ground.
and chassis ground.

connector.

connector.
EN(TURBO)-266
No
Even if MIL lights
up, the circuit has
of the connector
may be the cause.
NOTE:
the following:
Poor contact in
throttle position
sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Go to step 3.
Contact with your

Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.
Go to step 5.
Go to step 6.

Step
Check
Yes
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.

?
SENSOR CONNECTOR.
ECM connector and tumble generator valve
position sensor connector.
(B135) No. 13 (E50) No. 3:

SENSOR CONNECTOR.
tumble generator valve position sensor connector and engine ground.
CHECK POOR CONTACT.
Check poor contact in tumble generator valve

?
Go to step 8.
NOTE:
the following:
Open circuit in
harness between
tumble generator
valve position sensor and ECM connector
Poor contact in
tumble generator
valve position sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector
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
tumble generator
valve position sensor and ECM connector.
Is there poor contact in tumble Repair the poor

generator valve position sen- contact in tumble
sor connector?
generator valve
position sensor
connector.
EN(TURBO)-267
No
Replace the tumble generator

valve assembly.
<Ref. to
FU(TURBO)-41,
Tumble Generator
Valve Assembly.>

BU:DTC P1087 TUMBLE GENERATOR VALVE #2 (LH) POSITION SENSOR

CIRCUIT HIGH INPUT
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
E50

POSITION SENSOR
1 2 3
F61
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
1
3
2
1 2
E50
B209
E2
20
10
18
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F61
A4 A5
B4 B5
C4 C5
D4 D5
E5
A1
B2
G2
F76
F1
G1G2
H1 H2
I1 I2
J1 J2
B209
1
6
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
B83
B83
1 2 3
4 5 6
B135
9
13
19
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B135 ECM
EN1445
EN(TURBO)-268


POSITION SENSOR
E50
1
3
2
1 2 3
E50
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
20
10
18
E2
B21
B83
3
1
1 2 3 4 5 6
B83
B135
9
13
19
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B135 ECM
EN0986
EN(TURBO)-269

Step
Check
CHECK CURRENT DATA.
1)Start the engine.
general scan tool.
Yes
Go to step 2.
NOTE:
CHECK HARNESS BETWEEN TUMBLE

GENERATOR VALVE POSITION SENSOR
?
AND ECM CONNECTOR.
ground.

Go to step 3.
Is the voltage more than 4.9 V? Repair the battery

tumble generator
valve position sensor and ECM connector. After
repair, replace the
ECM. <Ref. to
FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-270
No
Even if MIL lights
up, the circuit has
of the connector
may be the 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
valve assembly.
<Ref. to
FU(TURBO)-41,
Tumble Generator
Valve Assembly.>

BV: DTC P1088 TUMBLE GENERATOR VALVE #1 (RH) POSITION SENSOR

CIRCUIT LOW INPUT
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
LHD model

POSITION SENSOR
E54
1
3
2
1 2 3
F61
E54
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
20
9
18
E2
B209
F61
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
A1
B1
G2
F76
B209
F1
G1G2
H1 H2
I1 I2
J1 J2
1
6
B83
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
B83
9
23
19
1 2 3
4 5 6
B135
B135 ECM
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
EN1446
EN(TURBO)-271

RHD model

POSITION SENSOR
E54
1
3
2
1 2 3
E54
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
20
9
18
E2
B21
B83
3
1
1 2 3 4 5 6
B83
B135
9
13
19
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B135 ECM
EN0988
EN(TURBO)-272

Step
CHECK CURRENT DATA.
1)Start the engine.
2)Read the data of tumble generator valve
position sensor signal using Subaru Select
Monitor or OBD-II general scan tool.
Check
Yes
Go to step 2.
NOTE:

closed.
and chassis ground.

and chassis ground.
and chassis ground.

connector.

connector.
EN(TURBO)-273
No
Even if MIL lights
up, the circuit has
of the connector
may be the cause.
NOTE:
the following:
Poor contact in
tumble generator
Poor contact in
ECM connector
Poor contact in
coupling connector
Go to step 3.
Contact with your

Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.
Go to step 5.
Go to step 6.

Step
Check
Yes
SENSOR CONNECTOR.

?
SENSOR CONNECTOR.
connector.
(B135) No. 23 (E54) No. 3:

CHECK POOR CONTACT.
Check poor contact in tumble generator valve

?
Go to step 8.
NOTE:
the following:
Open circuit in
harness between
tumble generator
Poor contact in
throttle position
sensor connector
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
tumble generator
valve position sensor and ECM connector.

generator valve position sen- contact in tumble
sor connector?
generator valve
position sensor
connector.
EN(TURBO)-274
No

valve assembly.
<Ref. to
FU(TURBO)-41,
Tumble Generator
Valve Assembly.>

BW:DTC P1089 TUMBLE GENERATOR VALVE #1 (RH) POSITION SENSOR

CIRCUIT HIGH INPUT
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
LHD model

POSITION SENSOR
E54
1
3
2
1 2 3
F61
E54
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
20
9
18
E2
B209
F61
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
A1
B1
G2
F76
B209
F1
G1G2
H1 H2
I1 I2
J1 J2
1
6
B83
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
B83
9
23
19
1 2 3
4 5 6
B135
B135 ECM
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
EN1446
EN(TURBO)-275

RHD model

POSITION SENSOR
E54
1
3
2
1 2 3
E54
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
20
9
18
E2
B21
B83
3
1
1 2 3 4 5 6
B83
B135
9
13
19
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B135 ECM
EN0988
EN(TURBO)-276

Step
CHECK CURRENT DATA.
1)Start the engine.
2)Read the data of tumble generator valve
position sensor signal using Subaru Select
Monitor or OBD-II general scan tool.
Check
Yes
Go to step 2.
NOTE:

?
AND ECM CONNECTOR.

AND ECM CONNECTOR.
Go to step 3.
Is the voltage more than 4.9 V? Repair the battery

tumble generator
valve position sensor and ECM connector. After
repair, replace the
ECM. <Ref. to
FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-277
No
Even if MIL lights
up, the circuit has
of the connector
may be the 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
valve assembly.
<Ref. to
FU(TURBO)-41,
Tumble Generator
Valve Assembly.>

BX:DTC P1090 TUMBLE GENERATOR VALVE SYSTEM #1 (RH) MALFUNCTION (STUCK OPEN)
CAUTION:
Step
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC) <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
Replace the tum- Clean the tumble
CHECK TUMBLE GENERATOR VALVE RH Does the tumble generator
1)Remove the tumble generator valve assem- valve move smoothly? (No dirt ble generator
generator valve.
or foreign materials clogged)
bly.
valve assembly.
2)Check the tumble generator valve body.
<Ref. to
FU(TURBO)-41,
Tumble Generator
Valve Assembly.>
BY:DTC P1091 TUMBLE GENERATOR VALVE SYSTEM #1 (RH) MALFUNCTION (STUCK CLOSE)
CAUTION:
Step
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC) <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
generator valve.
bly.
valve assembly.
<Ref. to
FU(TURBO)-41,
Tumble Generator
Valve Assembly.>
EN(TURBO)-278

BZ:DTC P1092 TUMBLE GENERATOR VALVE SYSTEM #2 (LH) MALFUNCTION (STUCK OPEN)
CAUTION:
Step
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC) <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
generator valve.
bly.
valve assembly.
<Ref. to
FU(TURBO)-41,
Tumble Generator
Valve Assembly.>
CA:DTC P1093 TUMBLE GENERATOR VALVE SYSTEM #2 (LH) MALFUNCTION (STUCK CLOSE)
CAUTION:
Step
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC) <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
generator valve.
bly.
valve assembly.
<Ref. to
FU(TURBO)-41,
Tumble Generator
Valve Assembly.>
EN(TURBO)-279

CB:DTC P1094 TUMBLE GENERATOR VALVE CIRCUIT #1 (OPEN CIRCUIT)

CAUTION:
WIRING DIAGRAM:
TUMBLE
GENERATOR VALVE
ACTUATOR RH
E55
E2
F61
RHD
: LHD
B21
: RHD
LHD
LHD
A2
A4
RHD
LHD
LHD
F76
B209
RHD
RHD
B84 ECM
E55
F61
: LHD
1 2
B21
: RHD
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
B84
B209
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
F5
G4 G5
H5
H4
H3
I4 I5
J3 J4 J5
EN1447
EN(TURBO)-280

Step
Check
Yes
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 (B84) No.4:
(E55) No. 2 (B84) No.5:

CHECK POOR CONTACT.
Check poor contact in tumble generator valve generator valve actuator con- contact in tumble
actuator connector.
nector.
generator valve
actuator connector.
EN(TURBO)-281
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.
valve assembly.
<Ref. to
FU(TURBO)-41,
Tumble Generator
Valve Assembly.>

CC:DTC P1095 TUMBLE GENERATOR VALVE CIRCUIT #1 (OVERCURRENT)

CAUTION:
WIRING DIAGRAM:
TUMBLE
GENERATOR VALVE
ACTUATOR RH
E55
E2
F61
RHD
: LHD
B21
: RHD
LHD
LHD
A2
A4
RHD
LHD
LHD
F76
B209
RHD
RHD
B84 ECM
E55
F61
: LHD
1 2
B21
: RHD
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
B84
B209
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
F5
G4 G5
H5
H4
H3
I4 I5
J3 J4 J5
EN1447
EN(TURBO)-282

Step
Check
CONNECTOR.
2)Disconnect the connector from tumble generator valve connector.
3)Measure the voltage between tumble generator valve actuator and chassis ground.
EN(TURBO)-283
Yes
valve assembly.
<Ref. to
FU(TURBO)-41,
Tumble Generator
Valve Assembly.>
No
Repair the battery
short circuit
between ECM and
tumble generator
valve actuator.

CD:DTC P1096 TUMBLE GENERATOR VALVE CIRCUIT #2 (OPEN CIRCUIT)

CAUTION:
WIRING DIAGRAM:
TUMBLE
GENERATOR VALVE
ACTUATOR LH
E51
E2
F61
RHD
: LHD
B21
: RHD
LHD
LHD
A5
B5
RHD
F76
LHD
LHD
B209
RHD
11
10
RHD
B84 ECM
E55
F61
: LHD
1 2
B21
: RHD
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
B84
B209
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
F5
G4 G5
H5
H4
H3
I4 I5
J3 J4 J5
EN1448
EN(TURBO)-284

Step
Check
Yes
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 (B84) No. 10:
(E51) No. 2 (B84) No. 11:

CHECK POOR CONTACT.
Check poor contact in tumble generator valve generator valve actuator con- contact in tumble
actuator connector.
nector.
generator valve
actuator connector.
EN(TURBO)-285
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.
valve assembly.
<Ref. to
FU(TURBO)-41,
Tumble Generator
Valve Assembly.>

CE:DTC P1097 TUMBLE GENERATOR VALVE CIRCUIT #2 (OVERCURRENT)

CAUTION:
WIRING DIAGRAM:
TUMBLE
GENERATOR VALVE
ACTUATOR LH
E51
E2
F61
RHD
: LHD
B21
: RHD
LHD
LHD
A5
B5
RHD
F76
LHD
LHD
B209
RHD
11
10
RHD
B84 ECM
E55
F61
: LHD
1 2
B21
: RHD
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
B84
B209
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
F5
G4 G5
H5
H4
H3
I4 I5
J3 J4 J5
EN1448
EN(TURBO)-286

Step
Check
CONNECTOR.
2)Disconnect the connector from tumble generator valve connector.
3)Measure the voltage between tumble generator valve actuator and chassis ground.
EN(TURBO)-287
Yes
valve assembly.
<Ref. to
FU(TURBO)-41,
Tumble Generator
Valve Assembly.>
No
Repair the battery
short circuit
between ECM and
tumble generator
valve actuator.

CF:DTC P1110 ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW INPUT

CAUTION:
Step
Check
Yes
No
to inspect DTC
indicate DTC P1110?
FU(TURBO)-49,
P1110.
Engine Control
Module.>
NOTE:
Atmospheric pressure sensor is built
into ECM.
CG:DTC P1111 ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH INPUT

CAUTION:
Step
Check
Yes
No
to inspect DTC
P1111.
indicate DTC P1111?
FU(TURBO)-49,
Engine Control
Module.>
NOTE:
into ECM.
EN(TURBO)-288

CH:DTC P1112 ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM

CAUTION:
Step
Check
EN(TURBO)-289
Yes
List of Diagnostic
Trouble Code
(DTC).<Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
No
Replace the ECM.
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
NOTE:
into ECM.

CI: DTC P1130 FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION

(OPEN CIRCUIT) [MT VEHICLES]
CAUTION:
WIRING DIAGRAM:
RHD
RHD
B18
MAIN RELAY
6
4
LHD
SBF-5
LHD
2
B61
1 2
3 4
BATTERY
F44
B47
5
3
2
2
4
6
F44
1 2 3 4
5 6 7 8
B18
4
FRONT OXYGEN
(A/F) SENSOR
F60
18
1
5
9
13
2
6
10
14
3
7
11
15
: LHD
: RHD
4
8
12
16
ECM
B137
8
9
RHD
LHD
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
A3
B209
F76
LHD
B209
E
RHD
B137
29
B22
19
B47
4
5
2
1
1
3
5
F60
: LHD
B22
: RHD
E3
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1433
EN(TURBO)-290

Step
Check
TOR.
(B137) No. 29 (B18) No. 3:
(B137) No. 19 (B18) No. 4:
CHECK POOR CONTACT.

tor?
EN(TURBO)-291
Yes
Go to step 2.
No
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
Repair the poor
Replace the front
contact in front
oxygen (A/F) senoxygen (A/F) sensor. <Ref. to
sor connector.
FU(TURBO)-44,
Front Oxygen (A/
F) Sensor.>

CJ: DTC P1131 FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION

(SHORT CIRCUIT) [MT VEHICLES]
CAUTION:
WIRING DIAGRAM:
RHD
RHD
B18
MAIN RELAY
6
4
LHD
SBF-5
LHD
2
B61
1 2
3 4
BATTERY
F44
B47
5
3
2
2
4
6
F44
1 2 3 4
5 6 7 8
B18
4
FRONT OXYGEN
(A/F) SENSOR
F60
18
1
5
9
13
2
6
10
14
3
7
11
15
: LHD
: RHD
4
8
12
16
ECM
B137
8
9
RHD
LHD
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
A3
B209
F76
LHD
B209
E
RHD
B137
29
B22
19
B47
4
5
2
1
1
3
5
F60
: LHD
B22
: RHD
E3
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1433
EN(TURBO)-292

Step
FRONT OXYGEN (A/F) SENSOR CONNECTOR.
and chassis ground.
Check
Yes
?
No
Repair the ground
ECM and front

?
Repair the ground

ECM and front
Go to step 5.

ECM and front
After repair,
replace the ECM.
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
Is the voltage more than 4.95 Go to step 6.
Measure the voltage between ECM connector V?
and chassis ground.
Repair the poor

contact in ECM
connector.
Replace the front

FU(TURBO)-44,
Front Oxygen (A/
F) Sensor.>
Is the voltage more than 10 V? Repair the battery Repair the poor
short circuit in harcontact in ECM
and chassis ground.
ness between
connector.
ECM and front
After repair,
replace the ECM.
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-293

CK:DTC P1134 FRONT OXYGEN (A/F) SENSOR MICRO-COMPUTER PROBLEM

CAUTION:
WIRING DIAGRAM:
RHD
RHD
B18
MAIN RELAY
6
4
LHD
SBF-5
LHD
2
B61
1 2
3 4
BATTERY
F44
B47
5
3
2
4
6
F44
1 2 3 4
5 6 7 8
B18
4
FRONT OXYGEN
(A/F) SENSOR
B47
2
1
1
3
5
F60
B137
18
29
19
4
5
B22
1
5
9
13
2
6
10
14
3
7
11
15
: LHD
: RHD
4
8
12
16
ECM
8
9
B137
RHD
LHD
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
A3
B209
F76
LHD
B209
RHD
F60
: LHD
B22
: RHD
E3
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1433
Step
Check
Yes
No
to inspect DTC
P1134.
indicate DTC P1134?
FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-294

EN(TURBO)-295

CL: DTC P1139 FRONT OXYGEN (A/F) SENSOR #1 HEATER CIRCUIT

RANGE/PERFORMANCE PROBLEM
CAUTION:
WIRING DIAGRAM:
RHD
RHD
B18
MAIN RELAY
6
4
LHD
SBF-5
LHD
2
B61
1 2
3 4
BATTERY
F44
B47
5
3
2
2
4
6
F44
1 2 3 4
5 6 7 8
B18
4
FRONT OXYGEN
(A/F) SENSOR
F60
18
1
5
9
13
2
6
10
14
3
7
11
15
: LHD
: RHD
4
8
12
16
ECM
B137
8
9
RHD
LHD
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
A3
B209
F76
LHD
B209
E
RHD
B137
29
B22
19
B47
4
5
2
1
1
3
5
F60
: LHD
B22
: RHD
E3
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1433
EN(TURBO)-296

Step
(B137) No. 5 (B18) No. 1:
(B137) No. 4 (B18) No. 1:
(B137) No. 19 (B18) No. 4:
(B137) No. 29 (B18) No. 3:
main relay and front oxygen (A/F) sensor connector.
(B47) No. 4 (B18) No. 2:
Measure the resistance between front oxygen
(A/F) sensor connector terminals.
Terminals
No. 2 No. 1:
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

FU(TURBO)-44,
Front Oxygen (A/
F) Sensor.>
Replace the front
CHECK POOR CONTACT.
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(TURBO)-44,
Front Oxygen (A/
F) Sensor.>
EN(TURBO)-297

CM:DTC P1141 MASS AIR FLOW SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (LOW INPUT)
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
RHD
RHD
MAIN RELAY
6
4
LHD
5
3
LHD
8
B61
BATTERY
SBF-5
F44
2
1
B47
MASS AIR FLOW AND

E13
B27
E7
5
E8
B3
B:
B135
* 12
*
*1
LHD : 3
RHD : 2
*2
LHD : 6
RHD : 1
B19
B83
E:
B3
1 2 3 4 5
E
ECM
B47
1
3
5
2
4
6
B84
E:
B : B135
B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B83
1 2 3
4 5 6
(LHD)
1 2 3 4 5 6
F44
(RHD)
1 2 3 4
5 6 7 8
EN0970
EN(TURBO)-298

Step
Check
Yes
Diagnostics Chart
with Trouble
Code <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P1141.
EN(TURBO)-299
No
Replace the mass
air flow and intake
air temperature
sensor.

CN:DTC P1142 THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT)
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
LHD model
THROTTLE
POSITION
SENSOR
E13
F61
1 2 3
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
1 2
1
3
2
E13
B83
1 2 3
4 5 6
20
19
18
E2
F61
A1
i2
G2
F76
B135
B209
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
1
6
B83
B209
9
7
19
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
B135 ECM
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1437
EN(TURBO)-300

RHD model
THROTTLE
POSITION
SENSOR
E13
1
3
2
1 2 3
E13
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
20
19
18
E2
B21
B83
3
1
1 2 3 4 5 6
B83
B135
9
7
19
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B135 ECM
EN0972
Step
Check
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P1142.
EN(TURBO)-301
No
<Ref. to
FU(TURBO)-33,
Throttle Position
Sensor.>

CO:DTC P1146 PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

CAUTION:
WIRING DIAGRAM:
LHD model
THROTTLE BODY
2
3
1
PRESSURE SENSOR
E21
18
20
16
E2
F61
G2
A1
F5
F76
B209
1
6
19
9
8
B83
B135 ECM
E21
1 2 3
B83
1 2 3
4 5 6
1 2
5
6
9 10
13
14
17 18
3 4
7
8
11 12
15
16
19 20
B209
B135
F61
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1435
EN(TURBO)-302

RHD model
THROTTLE BODY
2
3
1
PRESSURE SENSOR
E21
18
20
16
E2
B21
3
1
19
9
8
B83
B135 ECM
E21
B83
1 2 3
1 2 3 4 5 6
B21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
B135
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
EN0968
Step
Check
Yes
No
vant DTC using
List of Diagnostic
NOTE:
Trouble Code
In this case, it is not necessary to inspect DTC
(DTC). <Ref. to
P1146.
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
Go to step 3.
intake system.
intake system?
EN(TURBO)-303

Step
(140F).
N or P position.
Check
Is the value within the specifications?
Yes
Go to step 4.
NOTE:
Specification:
Ignition ON
73.3 106.6 kPa (550 800 mmHg,
21.65 31.50 inHg)
Idling
20.0 46.7 kPa (150 350 mmHg, 5.91
13.78 inHg)
Read the data of throttle position signal using equal to or less than 5% when
tool.
NOTE:
equal to or more than 85%
EN(TURBO)-304
Replace the intake

air temperature
and pressure sensor. <Ref. to
FU(TURBO)-35,
Pressure Sensor.>
No
Replace the intake
air temperature
to FU(TURBO)-35,
Pressure Sensor.>
Adjust or replace
to FU(TURBO)-33,
Throttle Position
Sensor.>

<Ref. to
FU(TURBO)-33,
Throttle Position
Sensor.>

EN(TURBO)-305

CP: DTC P1152 FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) [AT VEHICLES]
CAUTION:
WIRING DIAGRAM:
B18
1 2
3 4
BATTERY
MAIN RELAY
SBF-5
6
4
B47
5
3
2
2
4
6
FRONT OXYGEN
(A/F) SENSOR
B22
1
5
9
13
B18
1
2
6
10
14
3
7
11
15
4
8
12
16
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
ECM
B209
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
8
9
E
3
B137
29
B137
19
B47
4
5
2
1
1
3
5
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H5
H3 H4
I4 I5
J3 J4 J5
B22
E3
E
EN1449
EN(TURBO)-306

Step
Check
TOR.
(B137) No. 29 (B18) No. 3:
(B137) No. 19 (B18) No. 4:
CHECK POOR CONTACT.

tor?
EN(TURBO)-307
Yes
Go to step 2.
No
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
Repair the poor
Replace the front
contact in front
oxygen (A/F) senoxygen (A/F) sensor. <Ref. to
sor connector.
FU(TURBO)-44,
Front Oxygen (A/
F) Sensor.>

CQ: DTC P1153 FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) [AT VEHICLES]
CAUTION:
WIRING DIAGRAM:
B18
1 2
3 4
BATTERY
MAIN RELAY
SBF-5
6
4
B47
5
3
2
2
4
6
FRONT OXYGEN
(A/F) SENSOR
B22
1
5
9
13
B18
1
2
6
10
14
3
7
11
15
4
8
12
16
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
ECM
B209
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
8
9
E
3
B137
29
B137
19
B47
4
5
2
1
1
3
5
F1
G1G2
H1 H2
I1 I2
J1 J2
A4 A5
B4 B5
C4 C5
D4 D5
E5
F5
G4 G5
H5
H3 H4
I4 I5
J3 J4 J5
B22
E3
E
EN1449
EN(TURBO)-308

Step
and chassis ground.
Check
Yes
?
No
Repair the ground
ECM and front

?
Repair the ground

ECM and front
Go to step 5.

ECM and front
After repair,
replace the ECM.
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
Is the voltage more than 4.95 Go to step 6.
Measure the voltage between ECM connector V?
and chassis ground.
Repair the poor

contact in ECM
connector.
Replace the front

FU(TURBO)-44,
Front Oxygen (A/
F) Sensor.>
Is the voltage more than 10 V? Repair the battery Repair the poor
short circuit in harcontact in ECM
and chassis ground.
ness between
connector.
ECM and front
After repair,
replace the ECM.
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-309

CR:DTC P1230 FUEL PUMP CONTROLLER MALFUNCTION

*3
4
B97
RHD
RHD
CAUTION:
WIRING DIAGRAM:
LHD
F44
10
R1
LHD
8
B61
FUEL PUMP
RELAY
B46
BATTERY
SBF-5
FUEL PUMP
CONTROLLER
1
3
R15
9
8
*21
*
7
6
R122
R3
B99
A13
C16
2
1
R57
FUEL
PUMP
*1
LHD : 20
RHD : 15
*2
LHD : 19
RHD : 14
*3
LHD : 7
RHD : 5
ECM
R58
F44
B97
1 2 3 4
5 6 7 8
A : B134
1 2 3 4 5
6 7
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
A:
B134
C:
B136
B46
R122
1 2
3 4
1 2
3 4
5 6 7 8 9 10
B99
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
R58
1 2 3
4 5 6
C : B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
EN0991
EN(TURBO)-310

Step
Check
Yes
CHECK POWER SUPPLY CIRCUIT TO FUEL Is the voltage more than 10V? Go to step 2.
PUMP CONTROLLER.
controller.
4)Measure the voltage between fuel pump
controller and chassis ground.
CHECK GROUND CIRCUIT OF FUEL PUMP Is the resistance less than 5

CONTROLLER.
?
fuel pump controller and chassis ground.
Go to step 3.

?
Go to step 4.

CONTROLLER AND FUEL PUMP CONNECTOR.
fuel pump controller and fuel pump connector.
(R122) No. 7 (R58) No. 2:
(R122) No. 6 (R58) No. 1:
CONTROLLER AND FUEL PUMP CONNECTOR.
Is the resistance more than 1M Go to step 5.

?
EN(TURBO)-311
No
Repair the power
supply circuit.
NOTE:
In this case repair
the following:
Open or ground
pump relay and
fuel pump controller
Poor contact in
fuel pump controller connector
Poor contact in
fuel pump relay
connector
NOTE:
the following:
Open circuit
between fuel
pump controller
and chassis
ground
Poor contact in
fuel pump controller connector
Repair the open
circuit between
fuel pump controller and fuel pump.
Repair the ground

short circuit
between fuel
pump controller
and fuel pump.

Step
Check
CHECK HARNESS BETWEEN FUEL PUMP Is the resistance less than 1
?
CONTROLLER AND ECM CONNECTOR.
fuel pump controller and ECM connector.
(R122) No. 9 (B134) No. 13:
(R122) No. 8 (B136) No. 16:

CONTROLLER AND ECM CONNECTOR.
CHECK POOR CONTACT.
Check poor contact in ECM and fuel pump
controller connector.
Yes
Go to step 6.

?

and fuel pump controller connector.
EN(TURBO)-312
Repair the poor

contact in ECM
and fuel pump
controller.
No
NOTE:
the following:
Open circuit
between fuel
pump controller
and ECM
Poor contact in
fuel pump controller and ECM connector
Repair the ground
short circuit
between fuel
pump controller
and ECM.
Replace the fuel

pump controller.
<Ref. to
FU(TURBO)-52,
Fuel Pump Controller.>

EN(TURBO)-313

CS:DTC P1244 WASTEGATE CONTROL SOLENOID VALVE RANGE/PERFORMANCE PROBLEM (LOW INPUT) [MT VEHICLES]
CAUTION:
WIRING DIAGRAM:
5
3
RHD
6
4
RHD
MAIN RELAY
LHD
F44
LHD
8
B61
BATTERY
SBF-5
1 2 3 4
5 6 7 8
F44
2
1
B47
B47
1
3
5
B137
2
4
6
ECM
B137
24
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
B127
1 2
2
1
B127
WASTEGATE
CONTROL SOLENOID
VALVE
EN0974
EN(TURBO)-314

Step
Check
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P1244.
EN(TURBO)-315
No
Replace the
wastegate control
solenoid valve.
<Ref. to
FU(TURBO)-43,
Valve.>

CT:DTC P1245 WASTEGATE CONTROL SOLENOID VALVE MALFUNCTION

(FAIL-SAFE) [MT VEHICLES]
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(TURBO)-45, Operation.> and Inspection Mode <Ref. to EN(TURBO)-42, Inspection Mode.> .
WIRING DIAGRAM:
5
3
RHD
6
4
RHD
MAIN RELAY
LHD
F44
LHD
8
B61
BATTERY
SBF-5
1 2 3 4
5 6 7 8
F44
2
1
B47
B47
1
3
5
B137
2
4
6
ECM
B137
24
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
B127
1 2
2
1
B127
WASTEGATE
CONTROL SOLENOID
VALVE
EN0974
EN(TURBO)-316

Step
Check
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P1245.
EN(TURBO)-317
No
Replace the
wastegate control
solenoid valve.
<Ref. to
FU(TURBO)-43,
Valve.>

CU:DTC P1301 FIRE DUE TO INCREASED EXHAUST TEMPERATURE

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
B83
1 2 3
4 5 6
(LHD)
EXHAUST GAS
TEMPERATURE
SENSOR
1 2 3 4 5 6
1
2
(RHD)
B279
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
B279
1 2
5
LHD : 6
RHD : 1
16
19
B83
B136 ECM
EN0984
EN(TURBO)-318

Step
CHECK ANY OTHER DIAGNOSTIC TROUBLE CODE (DTC).
Conduct the troubleshooting for all DTC
P0301, P0302, P0303 and P0304. <Ref. to
Code (DTC).>
Check
Does failure for repair or
replacement exist?
EN(TURBO)-319
Yes
Repair or replace
the failure, then
replace precatalytic converter.
No
Contact with your
Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.

CV:DTC P1312 EXHAUST GAS TEMPERATURE CIRCUIT MALFUNCTION

CAUTION:
WIRING DIAGRAM:
B83
1 2 3
4 5 6
(LHD)
EXHAUST GAS
TEMPERATURE
SENSOR
1 2 3 4 5 6
1
2
(RHD)
B279
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
B279
1 2
5
LHD : 6
RHD : 1
16
19
B83
B136 ECM
EN0984
EN(TURBO)-320

Step
Check
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P1312.
EN(TURBO)-321
No
Replace the
<Ref. to
FU(TURBO)-48,

EN(TURBO)-322

CW:DTC P1480 COOLING FAN RELAY 1 CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
Overheating
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(TURBO)-45, Operation.> and Inspection Mode <Ref. to EN(TURBO)-42, Inspection Mode.> .
EN(TURBO)-323

WIRING DIAGRAM:
BATTERY
SBF-1
B72
IGNITION
SWITCH
No.18
SBF-4
*1
LHD : 2
RHD : 7
*2
LHD : 12
RHD : 17
17
28
* 12
*
F29
F28
1
3
2
1
3
2
F16
B72
1 2
3 4
(BLUE)
F27
SUB FAN
MOTOR
F28
F17
F29
4
3
MAIN FAN MAIN FAN

RELAY1
RELAY2
30A
SUB FAN
RELAY1
2
1
SUB FAN
RELAY2
30A
25
27
28
26
24
22
21
23
F45
8
6
5
7
B62
17
19
20
18
B137 ECM
No.17
MAIN FAN
MOTOR
F30
5 6 9 13 14 17 21 22 25
7
10
15
18
23
26
8 11 12 16 19 20 24 27 28
F66
29
30
F30
F66
F27
B137
F45
F16
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
(LHD)
F17
3 2 1
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
(RHD)
EN0981
EN(TURBO)-324

Step
driver's side).
4)While operating the radiator fan relay, measure the voltage between ECM and chassis
ground.
NOTE:
Check Mode.<Ref. to EN(TURBO)-46, Compulsory Valve Operation Check Mode.>
CHECK SHORT CIRCUIT IN RADIATOR FAN
RELAY CONTROL CIRCUIT.
2)Remove the main fan relay and sub fan
relay. (with A/C models)
chassis ground.
2)Remove the main fan relay 1 and 2.
relay terminals.
Terminal
No. 25 No. 26 (Main fan relay 1)
No. 23 No. 24 (Main fan relay 2)
1)Remove the sub fan relay.
relay terminals.
Terminal
No. 7 No. 8 (Sub fan relay 1)
No. 17 No. 18 (Sub fan relay 2)
CHECK POOR CONTACT.
Check
between 0 and 10 V?
Yes
No
up, the circuit has
this time. In this
case, repair the
poor contact in
ECM connector.

short circuit in radiator fan relay control circuit. After
repair, replace the
ECM. <Ref. to
FU(TURBO)-49,
Engine Control
Module.>

?
Replace the main

fan relay and
ECM. <Ref. to
FU(TURBO)-49,
Engine Control
Module.>
Go to step 4.

?
Replace the sub

fan relay and
ECM. <Ref. to
FU(TURBO)-49,
Engine Control
Module.>
Go to step 5.

connector?
Repair the poor

contact in ECM
connector.
Replace the ECM.

<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-325

CX:DTC P1507 IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE)

TROUBLE SYMPTOM:
Fuel is cut according to fail-safe function.
CAUTION:
WIRING DIAGRAM:
RHD
6
4
RHD
MAIN RELAY
LHD
5
3
B61
RHD
F44
B209
SBF-5
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
LHD
F44
LHD
2
1
BATTERY
B47
F1
G1G2
H1 H2
I1 I2
J1 J2
B61
LHD
F44
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2 3 4
5 6 7 8
B47
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
1
3
5
RHD
: LHD
B22
: RHD
F60
: LHD
B22
: RHD
F60
2
4
6
E3
2
1
5
9
13
2
6
10
14
IDLE
AIR CONTROL
SOLENOID
VALVE
3
7
11
15
4
8
12
16
E7
E7
1
3
1 2 3
LHD
: RHD
B136
12
RHD
B21
1 2
E2
B21
G5
: LHD
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
F76
B209
F61
10
12
F61
RHD
E2
LHD
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
B136 ECM
E
EN1444
EN(TURBO)-326

Step
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P1507.
Is there a fault in air intake sys- Repair the air suc- Go to step 3.
tem?
tion and leaks.

gasket
Adjust the throttle

Control Cable.>
Are foreign particles in by-pass Remove the forReplace the idle
air line?
by-pass air line.
valve. <Ref. to
FU(TURBO)-36,
Idle Air Control
Solenoid Valve.>
by-pass air line.
EN(TURBO)-327
Go to step 4.

CY:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-4
IGNITION
SWITCH
B72
P R N D 3
AT
MT
T3
T7
MT
B12
12
7
12
11
AT
B134 ECM
16
B14
STARTER
MOTOR
B72
1 2
3 4
B134
1 2 3 4 5
6 7
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
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
EN1428
EN(TURBO)-328

Step
Check
turned to START?
EN(TURBO)-329
Yes
No
Repair the harCheck the starter
ness and connec- motor circuit. <Ref.
tor.
to EN(TURBO)-60,
STARTER
NOTE:
In this case, repair MOTOR CIRCUIT, Diagnostics
the following:
Open or ground for Engine Startshort circuit in har- ing Failure.>
ness between
ECM and starter
motor connector
Poor contact in
ECM connector

CZ:DTC P1544 HIGH EXHAUST TEMPERATURE DETECTED

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B83
1 2 3
4 5 6
(LHD)
EXHAUST GAS
TEMPERATURE
SENSOR
1 2 3 4 5 6
1
2
(RHD)
B279
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
B279
1 2
5
LHD : 6
RHD : 1
16
19
B83
B136 ECM
EN0984
EN(TURBO)-330

Step

NOTE:
Loose installation of exhaust manifold
Cracks or hole of exhaust manifold
Loose installation of front oxygen (A/F) sensor
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P1544.
tem?
the failure, then
replace precatalytic converter.
EN(TURBO)-331
Contact with your

Subaru distributor
service.
NOTE:
Inspection by DTM
probable
parts.

DA:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

CAUTION:
WIRING DIAGRAM:
LHD model
MAIN RELAY
4
6
2
SBF-5
8
5
3
B61
F44
B72 IGNITION
SWITCH
2
1
BATTERY
No.11
SBF-4
B47
A2
D2
D3
D10
A14
SBF-1
A : B134
C : B136
ECM
D : B137
E:
D8
D9
A22
C17
C8
C18
A7
A15
E1
B84
C3
F1
D2
J3
A3
B209
15
13
14
16
F76
F60
E3
E
B72
B47
1
3
5
1 2
3 4
F1
G1G2
H1 H2
I1 I2
J1 J2
A : B134
F60
2
4
6
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
D : B137
B209
A1 A2 A3
B1 B2
C1 C2 C3
D1 D2
E1
A4 A5
B4 B5
C4 C5
D4 D5
E5
1 2 3 4 5
6 7
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
E:
1 2
3 4 5 6 7 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
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
F5
G4 G5
H3 H4 H5
I4 I5
J3 J4 J5
EN1429
EN1429
EN(TURBO)-332

RHD model
MAIN RELAY
DATA LINK CONNECTOR
4
6
SBF-5
5
3
2
1
B72
IGNITION
SWITCH
BATTERY
No.11
B47
SBF-4
1
A2
D2
D3
D10
A14
SBF-1
A:
B134
C : B136
ECM
D : B137
B84
13
14
16
15
D8
D9
A22
C17
C8
C18
A7
A15
E1
E:
B22
E3
E
B72
1 2
3 4
E
B47
1
3
5
2
4
6
A : B134
B22
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
E:
C : B136
D : B137
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 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 31
B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
EN0960
Step
Check
chassis ground.
MAIN FUSE BOX CONNECTOR.
?
EN(TURBO)-333
Yes
Repair the poor
contact in ECM
connector.
No
Go to step 2.

ECM connector
and battery terminal.

Step
CHECK FUSE SBF-5.
Check
Is the fuse blown?
Yes
Replace the fuse.
No
NOTE:
the following:
Open circuit in
harness between
ECM and battery
Poor contact in
ECM connector
Poor contact in
battery terminal
EN(TURBO)-334

EN(TURBO)-335

DB:DTC P1595 AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT LOW INPUT
CAUTION:
WIRING DIAGRAM:
TCM
20
21
B56
B135
B55
5 6
1 2 3 4
10 11 12 13 14 15
19 20 21
ECM
B135
8
9
7
16 17 18
22 23 24
7 6
5 4 3 2 1
15 14 13 12 11 10 9 8
22 21 20 19 18
17 16
B2M4371
EN(TURBO)-336

Step
TCM CONNECTOR.
chassis ground.
Check

TCM CONNECTOR.
TCM.
chassis ground.
CHECK TROUBLE CODE FOR AUTOMATIC
TRANSMISSION.
Read the DTC for automatic transmission.
<Ref. to AT-22, Read Diagnostic Trouble Code
(DTC).>

?
Yes
Go to step 2.
NOTE:
the following:
Poor contact in
ECM connector
Poor contact in
TCM connector
ECM and TCM
connector.
Go to step 4.
Does the DTC appear for auto- Inspect the DTC

matic transmission?
for automatic
transmission.
<Ref. to AT-42,
(DTC).>
EN(TURBO)-337
No
Even if MIL lights
up, the circuit has
this time.
Repair the poor

contact in ECM
connector.
Replace the TCM.

<Ref. to AT-46,
(TCM).>

DC:DTC P1596 AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT HIGH INPUT
CAUTION:
WIRING DIAGRAM:
TCM
20
21
B56
B135
B55
5 6
1 2 3 4
10 11 12 13 14 15
19 20 21
ECM
B135
8
9
7
16 17 18
22 23 24
7 6
5 4 3 2 1
15 14 13 12 11 10 9 8
22 21 20 19 18
17 16
B2M4371
EN(TURBO)-338

Step
TCM CONNECTOR.
chassis ground.

TCM CONNECTOR.
and chassis ground.
TCM CONNECTOR.
and chassis ground.
Check
Yes
No
ECM and TCM
connector. After
repair, replace the
ECM. <Ref. to
FU(TURBO)-49,
Engine Control
Module.>
Go to step 3.
Repair the poor

contact in ECM
connector.
Does the voltage change from Even if MIL lights

1 V to 4 V while monitoring the up, the circuit has
value with voltage meter?
this time.

TCM CONNECTOR.
CHECK POOR CONTACT.
connector?
EN(TURBO)-339
Go to step 4.
Contact with your

Subaru distributor
service.
NOTE:
Inspection by DTM
is required, beNOTE:
probable
In this case, repair cause
cause is deteriorathe following:
Poor contact in tion of multiple
parts.
ECM connector
Poor contact in
TCM connector
Go to step 6.
Repair the open
circuit in harness
between ECM and
TCM connector.
Repair the poor

contact in TCM
connector.
Check the TCM

power supply line
and grounding
line.

DD:DTC P1698 ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW INPUT
CAUTION:
WIRING DIAGRAM:
B55
14
10
TCM
B136
B55
1 2 3 4 5 6
10 11 12 13 14 15
19 20 21
ECM
B136
7 8 9
16 17 18
22 23 24
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
EN1169
EN(TURBO)-340

Step
chassis ground.
TCM CONNECTOR.
TCM.
TCM CONNECTOR.
(B136) No. 14 (B55) No. 20:
Check
Yes
Repair the poor
contact in ECM
connector.

?

ECM and TCM
connector.

?
Repair the poor

Repair the open
contact in ECM or circuit in harness
TCM connector.
between ECM and
TCM connector.
EN(TURBO)-341
No
Go to step 2.

DE:DTC P1699 ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH INPUT
CAUTION:
WIRING DIAGRAM:
B55
14
10
TCM
B136
B55
1 2 3 4 5 6
10 11 12 13 14 15
19 20 21
ECM
B136
7 8 9
16 17 18
22 23 24
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
EN1169
EN(TURBO)-342

Step
chassis ground.
TCM CONNECTOR.
chassis ground.
Check
No
Repair the battery
ECM and TCM
connector. After
repair, replace the
ECM. <Ref. to
FU(TURBO)-49,
Engine Control
Module.>
Does the voltage change more Repair the battery Contact with your
than 10 V by shaking harness short circuit in har- Subaru distributor
ness between
service.
monitoring the value with volt- ECM and TCM
NOTE:
age meter?
connector. After
Inspection by DTM
repair, replace the is required, beECM. <Ref. to
cause
probable
FU(TURBO)-49,
cause is deterioraEngine Control
tion of multiple
Module.>
parts.
EN(TURBO)-343
Yes
Go to step 2.

DF:DTC P1701 CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION

FOR AUTOMATIC TRANSMISSION
CAUTION:
WIRING DIAGRAM:
B94
11
CCM
B54
B94
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
TCM
B54
1 2 3 4 5 6
10 11 12 13 14 15
19 20 21
7 8 9
16 17 18
22 23 24
EN1170
EN(TURBO)-344

Step
CCM CONNECTOR.
CCM.
TCM and CCM connector.
(B55) No. 22 (B94) No. 3:
CCM CONNECTOR.
1)Connect the connector to TCM and CCM.
2)Lift-up the vehicle or set the vehicle on free
rollers.
CAUTION:
On AWD models, raise all wheels off
ground.
3)Start the engine.
4)Turn the cruise control main switch to ON.
MPH).
6)Turn the cruise control command switch to
ON.
chassis ground.
CHECK POOR CONTACT.
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and
CCM connector.

?
Go to step 3.
Repair the short
circuit in harness
between TCM and
CCM connector.
Is the resistance less than 1 V? Go to step 4.
Check the cruise

control command
switch circuit.
<Ref. to CC-6,
INSPECTION,
Cruise Control
Command
Switch.>

connector?
Replace the TCM.

<Ref. to AT-46,
(TCM).>
EN(TURBO)-345
Repair the poor

contact in TCM
connector.

DG:DTC P1711 ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT MALFUNCTION

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
TCM
19
B56
B134
B55
5 6
1 2 3 4
10 11 12 13 14 15
19 20 21
ECM
B134
8
9
7
16 17 18
22 23 24
7 6
5 4 3 2 1
15 14 13 12 11 10 9 8
22 21 20 19 18
17 16
B2M4374
EN(TURBO)-346

Step
chassis ground.
CHECK POOR CONTACT.

TCM CONNECTOR.
TCM.
(B135) No. 19 (B54) No. 13:
TCM CONNECTOR.
CHECK POOR CONTACT.
Check
Yes
No
Go to step 4.

ECM and TCM
connector.
Repair the poor
connector?
contact in ECM
connector.
Go to step 3.
Replace the ECM.

<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
Repair the open
circuit in harness
between ECM and
TCM connector.

?
Go to step 5.

?

ECM and TCM
connector.

connector?
Repair the poor

contact in TCM
connector.
EN(TURBO)-347
Replace the TCM.

<Ref. to AT-46,
(TCM).>

DH:DTC P1712 ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT MALFUNCTION

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
TCM
18
14
B56
B134
B55
5 6
1 2 3 4
10 11 12 13 14 15
19 20 21
ECM
B134
8
9
7
16 17 18
22 23 24
7 6
5 4 3 2 1
15 14 13 12 11 10 9 8
22 21 20 19 18
17 16
B2M4375
EN(TURBO)-348

Step
chassis ground.
CHECK POOR CONTACT.

TCM CONNECTOR.
TCM.
(B134) No. 18 (B56) No. 4:
TCM CONNECTOR.
CHECK POOR CONTACT.
Check
Yes
No
Go to step 4.

ECM and TCM
connector.
Repair the poor
connector?
contact in ECM
connector.
Go to step 3.
Replace the ECM.

<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
Repair the open
circuit in harness
between ECM and
TCM connector.

?
Go to step 5.

?

ECM and TCM
connector.

connector?
Repair the poor

contact in TCM
connector.
EN(TURBO)-349
Replace the TCM.

<Ref. to AT-46,
(TCM).>


A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(TURBO)-91, Engine Trouble in General.>
Symptom
1. Engine stalls during idling.
2. Rough idling
3. Engine does not return to idle.
4. Poor acceleration
5. Engine stalls or engine sags or hesitates at

acceleration.
Problem parts
2) Pressure sensor
3) Mass air flow and intake temperature sensor
2) Pressure sensor
6) Air intake system (*5)
11) Oxygen sensor
3) Accelerator cable (*6)
5) Pressure sensor
6) Mass air flow sensor
1) Pressure sensor
9) A/C switch and A/C cut relay
10) Engine torque control signal circuit
1) Pressure sensor
6) Purge control solenoid valve
EN(TURBO)-350

Symptom
6. Surge
7. Spark knock
8. After burning in exhaust system
Problem parts
1) Pressure sensor
1) Pressure sensor
4) Knock sensor
1) Pressure sensor
*1: Check ignition coil & ignitor assembly and spark plug.
*2: Indicate the symptom occurring only in cold temperatures.
*3: Ensure the secure installation.
*4: Check fuel injector, fuel pressure regulator and fuel filter.
*5: Inspect air leak in air intake system.
*6: Adjust accelerator cable.
EN(TURBO)-351

EN(TURBO)-352
TRANSMISSION SECTION

of SUBARU vehicles.
CONTROL SYSTEMS
CS
AUTOMATIC TRANSMISSION
AT
(DIAGNOSTICS)
AT
MANUAL TRANSMISSION AND

DIFFERENTIAL
MT
CLUTCH SYSTEM
CL

approval.
G1840GE4
CONTROL SYSTEMS
CS
1.
2.
3.
4.
5.
6.
7.
Page
Select Lever ................................................................................................7
Select Cable................................................................................................9
MT Gear Shift Lever..................................................................................12
MT Drive Select Lever...............................................................................18
Drive Select Cable ....................................................................................20
General Diagnostic....................................................................................21
GENERAL DESCRIPTION
CONTROL SYSTEMS
A: SPECIFICATIONS
Item
Vibration torque of rod against lever
Nm (kgf-m, ft-lb)
CS-2
Specification
0.7 (0.07, 0.5) or less
GENERAL DESCRIPTION
CONTROL SYSTEMS
B: COMPONENT
1. AT SELECT LEVER
(2)
(12)
(4)
(3)
(5)
T2
(13)
(22)
(1)
(14)
(6)
(15)
(8)
(22)
(7)
(9)
(16)
(10)
(11)
T4
(17)
(18)
(19)
T1
T3
(20)
(21)
TR0928
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Indicator light bulb

Detent arm
Detent spring
Select lever COMPL
Spring pin
Arm COMPL
Bush
Plate
Grommet
Packing
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Spacer
Grip
Indicator cover
Blind
Cushion plate
Guide plate
Snap pin
Washer
Select cable
Nut B
CS-3
(21)
(22)
Nut A
Clip

T1: 7.5 (0.76, 5.5)
T2: 13 (1.3, 9.4)
T3: 18 (1.8, 13.0)
T4: 33 (3.4, 25)
GENERAL DESCRIPTION
CONTROL SYSTEMS
2. MT GEAR SHIFT LEVER
TR0894
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Gear shift knob

Console boot
Plate COMPL
Lever
Bush
Bush
Lock wire
Boot
Snap ring
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
O-ring
O-ring
Bush A
Cushion rubber
Bush B
Joint
Rod
Bracket
Washer
CS-4
(19)
(20)
(21)
Stay
Spacer
Spring pin

T1: 7.5 (0.76, 5.5)
T2: 12 (1.2, 8.7)
T3: 18 (1.8, 13.0)
GENERAL DESCRIPTION
CONTROL SYSTEMS
3. DRIVE SELECT LEVER
(1)
T
T
(4)
(3)
(2)
(10)
(7)
(6)
(9)
(5)
(8)
T
TR0336
(1)
(2)
(3)
(4)
(5)
Knob
Cushion
Plate COMPL
Bush
Cable
(6)
(7)
(8)
(9)
(10)
Spring
Lever COMPL
Clip
Clevis pin
Snap pin
CS-5

T: 18 (1.8, 13.0)
GENERAL DESCRIPTION
CONTROL SYSTEMS
C: CAUTION
Use SUBARU genuine grease etc. or the equivalent. Do not mix 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 grease to avoid damage and deformation.
Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate,
or shop cloth between the part and the vise.
Before disconnecting electrical connectors, be
sure to disconnect the ground cable from battery.
CS-6
SELECT LEVER
CONTROL SYSTEMS
2. Select Lever
B: INSTALLATION
A: REMOVAL
1) Mount the select lever onto the vehicle body.

2) Tighten the four bolts to install the select lever to
vehicle body, then connect the connector.

3) Move the select lever to N position.
5) Remove the rear exhaust pipe and muffler.
Non-turbo model with OBD
<Ref. to EX-11, REMOVAL, Rear Exhaust Pipe.>,
<Ref. to EX-12, REMOVAL, Muffler.>
Non-turbo model without OBD
<Ref. to EX(w/oOBD)-13, REMOVAL, Rear Exhaust Pipe.>, <Ref. to EX(w/oOBD)-14, REMOVAL, Muffler.>
Turbo model
<Ref. to EX(TURBO)-13, REMOVAL, Rear Exhaust Pipe.>, <Ref. to EX(TURBO)-14, REMOVAL,
Muffler.>
6) Remove the heat shield cover. (If equipped)
7) Disconnect the cable from select lever, and then
remove the cable bracket.
B3M1795A
(A) Adjusting nuts

(B) Cable bracket

9) Remove the console box. <Ref. to EI-40, REMOVAL, Console Box.>
10) Disconnect the connectors, then remove the
four bolts to take out the select lever assembly from
body.
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
B3M1796
3) Install the console box. <Ref. to EI-38, INSTALLATION, Glove Box.>

4) Set the location of select lever at N position.
6) Set the location of range select lever to N position.
7) Insert the thread portion of the other inner cable
and into connector hole of the select lever, and fix
the other outer cable end to bracket.
Tightening torque:
18 Nm (1.8kgf-m, 13.0 ft-lb)
8) Adjust the select cable position. <Ref. to CS-10,
ADJUSTMENT, Select Cable.>
9) After completion of fitting, make sure that the select lever operates smoothly all across the operating range.
10) Inspect the following items. If the following inspection reveals problems, adjust the select cable
and inhibitor switch. <Ref. to CS-10, ADJUSTMENT, Select Cable.> and <Ref. to AT-28, ADJUSTMENT, Inhibitor Switch.>
(1) The engine starts operating when select lever is in position P, but not in other positions.
(2) The back-up light is lit when the select lever
is in position R, but not in other positions.
(3) Select lever and indicator positions are
matched.
11) Install the heat shield cover. (If equipped)
B3M1510
CS-7
SELECT LEVER
CONTROL SYSTEMS
12) Install the rear exhaust pipe and muffler.

<Ref. to EX-11, INSTALLATION, Rear Exhaust
Pipe.>, <Ref. to EX-12, INSTALLATION, Muffler.>
<Ref. to EX(w/oOBD)-13, INSTALLATION, Rear
Exhaust Pipe.>, <Ref. to EX(w/oOBD)-14, INSTALLATION, Muffler.>
Turbo model
<Ref. to EX(TURBO)-13, INSTALLATION, Rear
Exhaust Pipe.>, <Ref. to EX(TURBO)-14, INSTALLATION, Muffler.>
5) Remove the cap, and then extract the spring pin.
B3M1797A
C: DISASSEMBLY
1) Remove the grip.
2) Remove the indicator light, and then remove the
indicator cover.
NOTE:
Be careful not to break the indicator light during removal.
(A) Spring pin

(B) Arm COMPL
6) Remove the select lever lower, and then take

away the select lever upper from plate.
B3M1848A
(A) Select lever lower

(B) Select lever upper
(C) Plate
B3M1511A
(A) Grip
(B) Indicator cover
(C) Indicator light
D: ASSEMBLY
3) Remove the blind.

4) Remove the clips, and then remove the guide
plate.
1) Clean all parts before assembly.

2) Apply grease [NIGTIGHT LYW No. 2 or equivalent] to each parts. <Ref. to CS-3, AT Select Lever.>
3) Assembly is in the reverse order of disassembly.
4) After completion of fitting, transfer the select lever to range P 1, then check whether the indicator and select lever agree, whether the pointer
and position mark agree and what the operating
force is.
E: INSPECTION
B3M2177A
(A) Clips
(B) Guide plate
1) Inspect the removed parts by comparing with

new ones for deformation, damage and wear. Correct or replace if defective.
2) Confirm the following parts for operating condition before assembly. Moving condition of the selector lever upper, it should move smoothly.
CS-8
SELECT CABLE
CONTROL SYSTEMS
3. Select Cable
9) Disconnect the cable from select lever, and then

remove the cable bracket.
A: REMOVAL
3) Prior to removal, set the lever to N position.
5) Remove the front and center exhaust pipe.
<Ref. to EX-7, REMOVAL, Front Exhaust Pipe.>
Pipe.>
Turbo model
<Ref. to EX(w/oOBD)-12, REMOVAL, Center Exhaust Pipe.>
7) Remove the snap pin from range select lever.
B3M1795A
(A) Adjusting nuts

(B) Cable bracket
10) Remove the select cable from plate assembly.
B: INSTALLATION
1) Install the select cable to plate assembly.
Tightening torque:
32 Nm (3.3 kgf-m, 24 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)
TR0895
(A)
(B)
(C)
(D)
(E)
Range select lever

Snap pin
Select cable
Clamp
Washer
8) Remove the plate assembly from transmission

case.
B3M1030G
(A) Select cable

(B) Plate ASSY
B3M1030E
(A) Select cable

(B) Plate ASSY
(C) Clamp
CS-9
SELECT CABLE
CONTROL SYSTEMS
D: ADJUSTMENT
4) Install the snap pin to range select lever.

3) Set the lever to N position.
7) Loosen the adjusting nut on each side.
TR0895
(A)
(B)
(C)
(D)
(E)
Range select lever

Snap pin
Select cable
Clamp
Washer
5) Move the select lever to N position, then adjust

the select cable position. <Ref. to CS-10, ADJUSTMENT, Select Cable.>
7) Install the front and center exhaust pipe.
Pipe.>
<Ref. to EX(w/oOBD)-10, INSTALLATION, Front
Exhaust Pipe.>
Turbo model
Exhaust Pipe.>
B3M1792A
(A) Adjusting nut A

(B) Adjusting nut B
8) Turn the adjusting nut B until it lightly touches

the connector.
C: INSPECTION
Check the removed cable and replace if damaged,
rusty, or malfunctioning.
1) Check for smooth operation of the cable.
2) Check the inner cable for damage and rust.
3) Check the outer cable for damage, bends, and
cracks.
4) Check the boot for damage, cracks, and deterioration.
5) Move the select lever from P position to 1 position. You should be able to feel the detentes in
each position. If the detentes cannot be felt or the
position pointer is improperly aligned, adjust the cable.
CS-10
B3M1793A
(A)
(B)
(C)
(D)
(E)
(F)
Front side
Select lever
Connector
Adjusting nut B
Contact point
Adjusting nut A
SELECT CABLE
CONTROL SYSTEMS
9) While preventing the adjusting nut B from moving with a wrench, tighten the adjusting nut A.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
B3M1794A
(A) Adjusting nut A

(B) Adjusting nut B
10) After completion of fitting, make sure that the

select lever operates smoothly all across the operating range.
CS-11
MT GEAR SHIFT LEVER

CONTROL SYSTEMS
4. MT Gear Shift Lever
10) Remove the rod from joint.
A: REMOVAL
2) Remove the gear shift knob.
5) Remove the boot plate from body.
B3M1824A
(A) Stay
(B) Rod
11) Remove the cushion rubber from body.
B3M1822

<Ref. to EX-11, REMOVAL, Rear Exhaust Pipe.>,
<Ref. to EX-12, REMOVAL, Muffler.>
<Ref. to EX(w/oOBD)-13, REMOVAL, Rear Exhaust Pipe.>, <Ref. to EX(w/oOBD)-14, REMOVAL, Muffler.>
Turbo model
<Ref. to EX(TURBO)-13, REMOVAL, Rear Exhaust Pipe.>, <Ref. to EX(TURBO)-14, REMOVAL,
Muffler.>
9) Remove the stay from transmission bracket.
B3M1825A
(A) Stay
(B) Cushion rubber
12) Remove the joint, and then extract the spring

pin.
B3M1826A
(A) Joint
(B) Spring pin
B3M1823A
(A) Stay
(B) Transmission bracket
CS-12
MT GEAR SHIFT LEVER

CONTROL SYSTEMS
14) Remove the gear shift lever.
6) Mount the cushion rubber on the body.

Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
B3M1827
B: INSTALLATION
1) Install the joint to transmission and secure with
the spring pin.
2) Insert the gear shift lever from room side.
NOTE:
After inserting the rod and stay, temporarily put
them onto transmission mount.
B3M1825A
(A) Stay
(B) Cushion rubber
7) Connect the rod to the joint.

Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
B3M1827

4) Install the joint to shifter arm.
5) Insert the straight pin.
B3M1824A
(A) Stay
(B) Rod
8) Connect the stay to transmission bracket.

Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
B3M1826A
B3M1823A
(A) Stay
(B) Transmission bracket
CS-13
MT GEAR SHIFT LEVER

CONTROL SYSTEMS

<Ref. to EX-11, INSTALLATION, Rear Exhaust
Pipe.>, <Ref. to EX-12, INSTALLATION, Muffler.>
Exhaust Pipe.>, <Ref. to EX(w/oOBD)-14, INSTALLATION, Muffler.>
Turbo model
12) Install the boot plate to body.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
13) Install the console box. <Ref. to EI-40, INSTALLATION, Console Box.>
C: DISASSEMBLY
3) Remove the snap ring from bush B, then disconnect the stay.
B3M0619B
(A) Snap ring

(B) Bush B
(C) Boot
4) Remove the boot from gear shift lever.

5) Remove the bush and cushion rubber from stay.
1) Disassemble the lock wire.
B3M0830D
B3M0617C
(A) Bush
(B) Stay
(C) Cushion rubber
(A) Lock wire

(B) Stay
6) Remove the O-ring, then disconnect the bush B.
2) Remove the rod from lever.
B3M0620C
B3M1828A
(A) O-ring
(B) O-ring
(C) Bush B
(A) Rod
(B) Lever
(C) Stay
CS-14
MT GEAR SHIFT LEVER

CONTROL SYSTEMS
7) Draw out the spring pin, then remove the bush A

from gear shift lever.
3) Mount each part; boot, O-ring, bush A, spacer,

bush B, bush and spring pin on the gear shift lever.
NOTE:
Apply grease [DNIGTIGHT LYW No. 2 or equivalent] to the inner and side surfaces of the bush
when installing the spacer.
B3M0621B
(A) Spring pin

(B) Bush A
D: ASSEMBLY
B3M0623C
1) Clean all parts before assembly.

2) Mount the bush and cushion rubber on the stay.
B3M0830C
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
Boot
O-ring
Bush
Spacer
Bush A
Bush B
Spring pin
O-ring
4) Insert the gear shift lever into boot hole.

5) Install the snap ring and stay to bush B.
(A) Bush
(B) Cushion rubber
B3M0619C
(A) Snap ring

(B) Bush B
CS-15
MT GEAR SHIFT LEVER

CONTROL SYSTEMS
6) Tighten with lock wire to the extent that the boot

will not come off.
NOTE:
Always use a new lock wire.
9) Check the swing torque of the rod in relation to

gear shift lever.
If the torque exceeds specification, replace the
bush or retighten nuts.
Rocking torque:
0.7 Nm (0.07 kgf-m, 0.5 ft-lb) or less
B3M0617C
(A) Lock wire

(B) Stay
B3M1829C
(A) Center of rotation

(B) Swing torque
7) Insert the rod into boot hole.

8) Connect the rod to gear shift lever.
10) Check that there is no excessive play and that

parts move smoothly.
Tightening torque:
11.8 Nm (1.2 kgf-m, 8.7 ft-lb)
B3M1828A
(A) Rod
(B) Lever
(C) Stay
CS-16
MT GEAR SHIFT LEVER

CONTROL SYSTEMS
E: INSPECTION
1) Check each part (bush, cushion rubber, spacer,
boot, stay and rod, etc.) for deformation, damage
and wear. Repair or replace any defective part. Determine defective parts by comparing with new
parts.
2) Check the swing torque of the rod in relation of

gear shift lever.
If the torque exceeds specification, replace the
bush or retighten nuts.
Rocking torque:
0.7 Nm (0.07 kgf-m, 0.5 ft-lb) or less
B3M1829C
(A) Center of rotation

(B) Swing torque
B3M1765A
(A)
(B)
(C)
(D)
(E)
(F)
Bush
Cushion rubber
Spacer
Boot
Stay
Rod
CS-17
MT DRIVE SELECT LEVER

CONTROL SYSTEMS
5. MT Drive Select Lever
B: INSTALLATION
A: REMOVAL
1) Install the drive select lever.
1) Apply parking brake and place chocks to hold

the wheels.
3) Set the drive select lever to HI position.
4) Remove the knob.
5) Remove the console box. <Ref. to EI-40, Console Box.>
6) Remove the bolt installing drive select lever assembly on body.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
B3M1516A
(A) HI position
3) Be sure to insert the cable eye end bolt into lever

arm slit.
B3M0766
7) Remove the flange nut, clip and then disconnect

the cable from lever assembly.
B3M1517A
(A) Cable eye end bolt

(B) Lever arm
B3M1846A
(A) Flange nut

(B) Lever COMPL
(C) Clip
4) Tighten the nut where cable end bolt comes to a

stop.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
CS-18
MT DRIVE SELECT LEVER

CONTROL SYSTEMS
C: DISASSEMBLY
1) Remove the spring.
B3M2132A
(A) Spring
2) Remove the lever, cushion and bush.
B3M2133A
(A)
(B)
(C)
(D)
(E)
Washer
Bush
Plate COMPL
Cushion
Lever COMPL
D: ASSEMBLY
1) Assemble in the reverse order of disassembly.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
2) Make sure the select lever moves smoothly.
E: INSPECTION
1) Make sure the select lever moves smoothly. If it
does not move smoothly, repair or replace it.
2) Make sure the drive select lever is not damaged.
If it is damaged, repair or replace it.
CS-19
DRIVE SELECT CABLE

CONTROL SYSTEMS
6. Drive Select Cable
D: ADJUSTMENT
A: REMOVAL

2) Remove the drive select lever knob.
4) Loosen the nut.
5) Make sure the transmission is in HI position. If
isn't, pull on the cable to put transmission in HI position.
6) Tighten the nut in the location where cable end
bolt stops naturally.
1) Remove the drive select lever. <Ref. to CS-18,

REMOVAL, MT Drive Select Lever.>
2) Remove the intake duct. <Ref. to IN-7, Air Intake
Duct.>
3) Remove the air cleaner case. <Ref. to IN-6, Air
Cleaner Case.>
4) Remove the snap ring and clevis pin.
5) Loosen the nut and disconnect the cable from
cable bracket.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
7) Make sure to move the transmission to HI or LO
position by moving the drive select lever. If it
doesn't, readjust the cable.
S3M0641A
(A) Snap pin

(B) Clevis pin
(C) Nut
6) Remove the cable from the under side of vehicle.
B3M0769
B: INSTALLATION
2) Make sure the drive select lever operates properly.
C: INSPECTION
1) Make sure to move the transmission to HI or LO
position by moving the drive select lever. If it
doesn't, adjust the cable.<Ref. to CS-20, ADJUSTMENT, Drive Select Cable.>
2) Make sure the cable operates smoothly. If it
catches or fails to work properly, repair or replace
it.
3) Check the cable for damage.
CS-20
GENERAL DIAGNOSTIC
CONTROL SYSTEMS
7. General Diagnostic
A: INSPECTION
Symptom
1. Select lever
Possible cause
(1) Starter does not run.
(2) Back-up light does not light up.
CS-21
Remedy
Adjust the select cable and inhibitor switch, or
inspect circuit.
Adjust the select cable and inhibitor switch, or
inspect circuit.
GENERAL DIAGNOSTIC
CONTROL SYSTEMS
CS-22
AT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Page
Automatic Transmission Fluid .....................................................................9
Differential Gear Oil...................................................................................11
Road Test..................................................................................................12
Stall Test ...................................................................................................13
Time Lag Test ...........................................................................................15
Line Pressure Test ....................................................................................16
Transfer Clutch Pressure Test ..................................................................18
Automatic Transmission Assembly ...........................................................19
Transmission Mounting System ................................................................25
Extension Case Oil Seal ...........................................................................27
Inhibitor Switch..........................................................................................28
Front Vehicle Speed Sensor .....................................................................32
Rear Vehicle Speed Sensor......................................................................36
Torque Converter Turbine Speed Sensor .................................................37
Control Valve Body ...................................................................................38
Shift Solenoids, Duty Solenoids and ATF Temperature Sensor ...............40
ATF Filter ..................................................................................................45
Transmission Control Module (TCM) ........................................................46
ATF Cooler Pipe and Hose .......................................................................48
GENERAL DESCRIPTION
5. PLANETARY GEAR AND PLATE
A: SPECIFICATIONS
Model
1. TORQUE CONVERTER CLUTCH
Tooth number of front

sun gear
pinion
internal gear
Tooth number of rear
sun gear
pinion
internal gear
Drive &
driven plate
number of
high clutch
Drive &
driven plate
number of
low clutch
Drive &
driven plate
number of
reverse
clutch
Drive &
driven plate
number of 24 brake
Drive &
driven plate
number of
low &
reverse
brake
2.0 L
2.0 L
Model
1.6 L
Non2.5 L
Turbo
turbo
Symmetric, 3 element, single stage, 2 phase
Type
torque converter
Stall torque
1.85
2.2 2.4 2.0 2.2 1.9 2.1
ratio
2.15
Nominal
236 mm
246 mm (9.69 in)
diameter
(9.29 in)
2,200 2,000 2,100 2,600
Stall speed
2,700
2,500
2,600
3,300
(at sea level)
rpm
rpm
rpm
rpm
One-way
Sprague type one-way clutch
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
4. TRANSMISSION GEAR RATIO

1st
2nd
3rd
4th
Rev
Gear ratio
2.785
1.545
1.000
0.694
2.272
AT-2
2.0 L
Nonturbo
1.6 L
2.5 L
2.0 L
Turbo
33
21
75
42
17
75
GENERAL DESCRIPTION
6. SELECTOR POSITION
Transmission in neutral, output member
immovable, and engine start possible
P (Park)
R
(Reverse)
N (Neutral)
D (Drive)
3 (3rd)
2 (2nd)
1 (1st)
8. COOLING AND HARNESS
Inhibitor switch
Transmission harness
Transmission in reverse for backing

Transmission in neutral and engine start possible
Automatic gear change 1st
4th
2nd 3rd
9. TRANSFER
Model
Automatic gear change 1st 2nd 3rd

4th
Transfer
type
Automatic gear change 1st 2nd 3rd

4th
1st gear locked (Deceleration possible 1st
2nd 3rd 4th)
Control
method
Drive &
driven
plate number of
transfer
clutch
Control
method
Hydraulic remote control
7. HYDRAULIC CONTROL AND LUBRICATION

Electronic/hydraulic control
[Four forward speed
changes by electrical signals
of vehicle speed and accelerator (throttle) opening]
Dexron III type Automatic
transmission fluid
Type
Fluid
Fluid capacity
1.6 L and
2.0 L Nonturbo model
2.5 L and
2.0 L Turbo
model
Liquid-cooled cooler incorporated in radiator

12 poles
20 poles
Cooling system
1.6 L and
2.0 L Nonturbo
2.5 L
Multi-plate transfer (MPT)
2.0 L Turbo
Variable
torque distribution (VTD)
Electronic, hydraulic type
Lubricant
The same Automatic transmission fluid used

in automatic transmission
1st reduction gear

ratio
1.000 (53/53)
8.4 8.7 2 (8.9 9.2 US

qt, 7.4 7.7 Imp qt)
9.3 9.6 2 (9.8 10.1 US
qt, 8.2 8.4 Imp qt)
Lubrication system
Oil
Forced feed lubrication with

oil pump
Automatic transmission fluid
(above mentioned)
10.FINAL REDUCTION
Model
Front final gear ratio
EXCEPT 1.6 L
4.111 (37/9)
1.6 L
4.444 (40/9)
Lubrication oil
H3M1235A
Front differential oil capacity
1.1 1.3 2 (1.2 1.4 US qt, 1.0 1.1 Imp qt)
AT-3
GENERAL DESCRIPTION
B: COMPONENT
NOTE:
For information about other transmission mounting components, refer to AUTOMATIC TRANSMISSION
<Pub. No. G0864ZE> a separate publication.
1. TRANSMISSION MOUNTING
B2M3384A
(1)
(2)
(3)
(4)
Pitching stopper
Rear cushion rubber
Transmission rear crossmember
Stopper

T1: 35 (3.6, 26)
T2: 39 (4.0, 29)
T3: 50 (5.1, 37)
T4: 58 (5.9, 43)
T5: 70 (7.1, 51)
AT-4
GENERAL DESCRIPTION
C: CAUTION
Remove contamination including dirt and corrosion before removal, installation, and disassembly.
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, installation, disassembly and replacement.
When disassembling the case and other light alloy parts, use a plastic hammer to force it apart. Do
not pry it apart with a screwdriver or other tool.
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.
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.
Be careful not to incorrectly install or fail to install
O-rings, snap rings and other such parts.
Avoid damaging the mating surface of the case.
Before applying sealant, completely remove the
old seal.
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
398527700
DESCRIPTION
PULLER ASSY
REMARKS
Used for removing extension case oil seal.
INSTALLER
Used for installing extension oil seal.
B3M1977
498057300
B3M1972
AT-5
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
498575400
DESCRIPTION
OIL PRESSURE
GAUGE ASSY
REMARKS
Used for measuring oil pressure.
498897200
ADAPTER
Used oil pump housing when measuring reverse

clutch pressure and line pressure.
498545400
FILTER WRENCH
Used for removing and installing ATF filter.
498277200
STOPPER SET
Used for removing and installing automatic

transmission assembly to engine.
B3M2040
B3M2041
B3M2042
B3M2043
AT-6
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
499267300
DESCRIPTION
STOPPER PIN
REMARKS
Used for installing and adjusting inhibitor switch.
41099AA020
ENGINE SUPPORT
Used for supporting engine.
41099AA010
ENGINE SUPPORT
BRACKET
CRANK PULLEY
WRENCH
Used for stopping rotating of crankshaft pulley

bolts.
B3M2008
B3M1976
B3M1975
Except 2.5 L model

499977300
2.5 L model
499977100
B2M3870
AT-7
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
24082AA190
<Newly adopted
tool>
DESCRIPTION
CARTRIDGE
REMARKS
SELECT MONITOR
KIT

English:
22771AA030 (Without printer)
German:
French:
Spanish:
B2M3876
22771AA030
B2M3877

TOOL NAME
Circuit Tester
REMARKS
Used for measuring resistance, voltage and ampere.
AT-8
AUTOMATIC TRANSMISSION FLUID

2. Automatic Transmission Fluid

A: INSPECTION
1) Check the level of ATF.
(1) Raise the ATF temperature to 70 to 80C
(158 to 176F) from 20 to 30C (68 to 86F)
(when cold) by driving a distance of 5 to 10 km (3
to 6 miles).
NOTE:
The level of ATF varies with fluid temperature. Pay
attention to the fluid temperature when checking oil
level.
(4) Fluid temperature rising speed

By idling the engine
25 minutes
<Reference>
Time for temperature rise to 30C (86F) with atmospheric temperature of 0C (32F): Approx. 8 minutes
By running the vehicle
10 minutes
(5) Method for checking fluid level upon delivery
or at periodic inspection
Check fluid level after a warm-up run of approx.
10 minutes. During the warm-up period, the automatic transmission functions can also be
checked.
2) Check the fluid for leaks.
Check for leaks in the transmission. If there are
leaks, it is necessary to repair or replace gasket, oil
seals, plugs or other parts.
B: REPLACEMENT
B3M1020B

2) Drain the ATF completely.
(A) ATF level gauge

(B) Upper level
(C) Lower level
(2) Make sure the vehicle is level. After selecting all positions (P, R, N, D, 3, 2, 1), set the select lever in P range. Measure the fluid level
with the engine idling.
NOTE:
After running, idle the engine for one or two minutes before measurement.
(3) If the fluid level is below the center between
upper and lower marks, add the recommended
ATF until the fluid level is found within specified
range (above the center between upper and
lower marks). When the transmission is hot, the
level should be above the center of upper and
lower marks, and when it is cold, the level
should be found below the center of these two
marks.
NOTE:
Use care not to exceed the upper limit level.
ATF level varies with temperature. Remember
that the addition of fluid to the upper limit mark
when the transmission is cold will result in overfilling of fluid.
CAUTION:
Directly after the engine has been running, the
ATF is hot. Be careful not to burn yourself.
NOTE:
Tighten the ATF drain plug after draining the ATF.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
B3M1036B
(A) Oil pan

(B) Drain plug (ATF)
(C) Differential oil drain plug
AT-9
AUTOMATIC TRANSMISSION FLUID

4) Pour ATF into the oil charge pipe.

Recommended fluid:
Capacity:
Fill the same amount of fluid drained from
drain plug hole.
Capacity when transmission is overhauled:
1.6 L and 2.0 L Non-turbo models
8.4 8.7 2 (8.9 9.2 US qt, 7.4 7.7 Imp
qt)
2.5 L and 2.0 L Turbo models
9.3 9.6 2 (9.8 10.1 US qt, 8.2 8.4 Imp
qt)
5) Check the level and leaks of ATF.
<Ref. to AT-9, REPLACEMENT, Automatic Transmission Fluid.>
AT-10
DIFFERENTIAL GEAR OIL

3. Differential Gear Oil

4) Pour gear oil into the gauge hole.
A: INSPECTION
proper orientation.
4) Remove it again and note the reading. If the differential gear oil level is below the L line, add oil to
bring the level up to the F line.
5) To prevent overfilling the differential gear oil, do
not add oil above the F line.
Recommended fluid:
Use GL-5 or equivalent.
Gear oil capacity:
1.1 1.3 2 (1.2 1.4 US qt, 1.0 1.1 Imp qt)
5) Check the level of differential gear oil.
<Ref. to AT-11, INSPECTION, Differential Gear
Oil.>
S3M0478A
(A) Upper level

(B) Lower level
B: REPLACEMENT
2) Drain the differential gear oil completely.
CAUTION:
differential gear oil is hot. Be careful not to burn
yourself.
NOTE:
Tighten the differential gear oil drain plug after
draining the differential gear oil.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
B3M1036B
(A) Oil pan

(B) Drain plug
AT-11
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 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 3rd gear engine brake when shifting
between D 3rd range while driving in 4th gear of
D range [50 to 60 km/h (31 to 37 MPH)].
Check the 2nd gear engine brake when shifting
between 3 2 range while driving in the 3 range
3rd gear [40 to 50 km/h (25 to 31 MPH)].
Check the 1st gear engine brake when shifting
between 2 1 range while driving in the 2 range
2nd gear [20 to 30 km/h (12 to 19 MPH)].
6. LOCK-UP FUNCTION
Check that rpm does not change sharply when the
acclelerator pedal is lightly depressed when 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. UNUSUAL SOUNDS AND VIBRATION

Check for unusual sounds and vibration while driving and during shifting.
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.OIL LEAKS
After the driving test, inspect for oil leaks.
AT-12
STALL TEST
5. Stall Test
A: INSPECTION
1. GENERAL INFORMATION
The stall test is of extreme importance in diagnosing the condition of the automatic transmission and
the engine. It should be conducted to measure the
engine stall speeds in R and 2 ranges.
Purposes of the stall test:
1) To check the operation of the automatic transmission clutch.
2) To check the operation of the torque converter
clutch.
3) To check engine performance.
2. TEST METHODS
1) Preparations before test:
(1) Check that throttle valve opens fully.
(2) Check that engine oil level is correct.
(3) Check that coolant level is correct.
(4) Check that ATF level is correct.
(5) Check that differential gear oil level is correct.
(6) Increase ATF temperature to 50 to 80C
(122 to 176F) by idling the engine for approx.
30 minutes (with select lever set to N or P).
2) Install an engine tachometer at a location visible
from the driver's compartment and mark the stall
speed range on the tachometer scale.
3) Place the wheel chocks at the front and rear of
all wheels and engage the parking brake.
4) Move the manual linkage to ensure it operates
properly, and shift the select lever to the 2 range.
5) While forcibly depressing the foot brake pedal,
gradually depress the accelerator pedal until the
engine operates at full throttle.
9) If the stall speed in 2 range is higher than specifications, low clutch slipping and 2-4 brake slipping
may occur. To identify it, conduct the same test as
above in D range.
10) Perform the stall tests with the select lever in
R range.
NOTE:
Do not continue the stall test for MORE THAN 5
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 1
minute after each stall test with the select lever set
in the P or N range and with the idle speed lower
than 1,200 rpm.
If the stall speed is higher than the specified
range, attempt to finish the stall test in as short a
time as possible, in order to prevent the automatic
transmission from sustaining damage.
Stall speed (at sea level):
1.6 L model: 2,200 2,700 rpm
2.0 L Non-turbo model: 2,000 2,500 rpm
2.0 L Turbo model: 2,600 3,300 rpm
2.5 L model: 2,100 2,600 rpm
B3M1589B
(A) Brake pedal

(B) Accelerator pedal
6) When the engine speed is stabilized, read that

speed quickly and release the accelerator pedal.
7) Shift the select lever to N range, and cool down
the engine by idling it for more than one minute.
8) Record the stall speed.
AT-13
STALL TEST
3. EVALUATION
Stall speed (at sea level)
Less than specifications
Position
2,
R
D
Greater than specifications
Cause
Throttle valve not fully open
Erroneous engine operation
Torque converter clutch's one-way clutch slipping
Line pressure too low
Low clutch slipping
One-way clutch malfunctioning
Reverse clutch slipping
Low & reverse brake slipping
Low clutch slipping
2-4 brake slipping
AT-14
TIME LAG TEST

6. Time Lag Test

A: INSPECTION
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.
NOTE:
Perform the test at normal operating fluid temperature 60 to 80C (140 to 176F).
Be sure to allow a 1 minute interval between
tests.
Make three measurements and take the average
value.
2. TEST METHODS
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
4) In the same manner, measure the time lag for
N R.
Time lag: Less than 1.5 seconds
3. EVALUATION
1) If N D time lag is longer than specified:
Low clutch worn
One-way clutch not operating properly
2) If N R time lag is longer than specified:
Reverse clutch worn
Low & reverse brake worn
AT-15
LINE PRESSURE TEST

7. Line Pressure Test
2. TEST METHODS
A: MEASUREMENT
1) Temporarily attach the ST to a suitable place in

the driver's compartment, remove the blind plug located in front of the toe board and pass the hose of
the ST to engine compartment.
ST 498575400
OIL PRESSURE GAUGE
ASSY
If the clutch or the brake shows a sign of slippage or
shifting sensation is not correct, the line pressure
should be checked.
Excessive shocks during upshifting or shifting
takes place at a higher point than under normal circumstances, may be due to the line pressure being
too high.
Slippage or inability to operate the vehicle may,
in most cases, be due to loss of oil pressure for the
operation of the clutch, brake or control valve.
1) Line pressure measurement (under no load)
NOTE:
Before measuring the line pressure, jack-up all
wheels.
Maintain the temperature of ATF at approx. 50C
(122F) during measurement.
(ATF will reach the above temperature after idling
the engine for approx. 30 minutes with select lever
in N or P.)
2) Line pressure measurement (under heavy load)
NOTE:
Before measuring the line pressure, apply both
foot and parking brakes with all wheels chocked
(Same as for stall test conditions).
Measure the line pressure when select lever is in
R, 2 with engine under stall conditions.
Measure the line pressure within 5 seconds after
shifting the select lever to each position. (If line
pressure needs to be measured again, allow the
engine to idle and then stop. Wait for at least 1
minute before measurement.)
Maintain the temperature of ATF at approx. 50C
(122F) during measurement (ATF will reach the
above temperature after idling the engine for approx. 30 minutes with the select lever in N or P.)
B3M0568C
(A) Pressure gauge hose

(B) Hole in toe board (blank cap hole)
(C) Brake pedal
2) Remove the test plug and install the ST instead.

ST 498897200
OIL PRESSURE GAUGE
ADAPTER
B3M2264A
(A) Test plug
3) Connect the ST1 with ST2.

ST1 498897200 OIL PRESSURE GAUGE
ADAPTER
ST2 498575400 OIL PRESSURE GAUGE
ASSY
AT-16
LINE PRESSURE TEST

4) Check for duty ratio changes by opening and

closing the throttle valve using Subaru Select Monitor.
(1) Insert the cartridge to Subaru Select Monitor. <Ref. to AT-5, PREPARATION TOOL, General Description.>
S2M0286

link connector.
5) Check the line pressure in accordance with the
following chart.
3. EVALUATION
Range
position
2
R
D
Standard line pressure

Line presLine pressure
Throttle
sure duty
position
kPa (kg/cm2, psi)
ratio (%)
1,128 1,304
5
Full open
(11.5 13.3,
164 189)
1,520 1,716
5
Full open
(15.5 17.5,
220 249)
304 412
95
Full closed
(3.1 4.2, 44 60)
AT-17
TRANSFER CLUTCH PRESSURE TEST

8. Transfer Clutch Pressure

Test
2. EVALUATION
A: INSPECTION
NOTE:
If oil pressure is not produced or if it does not
change in the AWD mode, the transfer duty solenoid or transfer valve assembly may be malfunctioning. If oil pressure is produced in the FWD
mode, the problem is similar to that in the AWD
mode.
MPT model
1. TEST METHODS
MPT model
Check the transfer clutch pressure in accordance
with the following chart in the same manner as with
line pressure. <Ref. to AT-16, Line Pressure Test.>
ST 498897700
OIL PRESSURE ADAPTER
SET
ST 498575400
OIL PRESSURE GAUGE
ASSY
AWD mode: D range
FWD mode: P range, engine speed 2,000 rpm
Standard transfer clutch pressure kPa (kg/cm2, psi)

ON Duty
Throttle
FWD
AWD mode
ratio
position
mode
(%)
932 1,089
95
Full open
(9.5 11.1,
135 158)
2/3
216 294
60
throttle
(2.2 3.0, 31 43)
Full
5
0 (0, 0)
closed
NOTE:
Before setting in FWD mode, install the spare fuse
on FWD mode switch.
VTD model
B3M1047C
(A) Test plug
VTD model
Check the transfer clutch pressure in accordance
with the following chart in the same manner as with
line pressure.
ST 498897700
OIL PRESSURE ADAPTER
SET
ST 498575400
OIL PRESSURE GAUGE
ASSY
H3M1840B
(A) Test plug
AT-18
OFF Duty
ratio
(%)
Throttle
position
95
Full open
40
2/3 throttle
Standard transfer clutch pressure kPa (kg/cm2, psi)

932 1,089
(9.5 11.1, 135 158)
216 294
(2.2 3.0, 31 43)
AUTOMATIC TRANSMISSION ASSEMBLY

9. Automatic Transmission Assembly

A: REMOVAL
2) Open the front hood fully, and support with stay.
4) Remove the air intake duct. (Non-turbo model)
<Ref. to IN-7, REMOVAL, Air Intake Duct.>
5) Remove the air cleaner case. (Non-turbo model)
6) Remove the air cleaner case stay. (Non-turbo
model)

plate.
(3) While rotating the engine, remove the other
bolts using ST.
CAUTION:
Be careful not to drop bolts into torque converter clutch housing.
Except 2.5 L model
ST 499977300
CRANK PULLEY WRENCH
2.5 L model
ST 499977100
CRANK PULLEY WRENCH
S2M0901
7) Remove the intercooler. (Turbo model)

<Ref. to IN(TURBO)-10, REMOVAL, Intercooler.>
8) Disconnect the following connectors.
(1) Transmission harness connector
S2M0207

ST 498277200
STOPPER SET
H2M1961A
S2M0212
(2) Transmission ground cable

9) Remove the starter.
<Ref. to SC-5, REMOVAL, Starter.>
13) Remove the ATF level gauge.

NOTE:
Plug the opening to prevent entry of foreign particles into transmission fluid.
S2M0908
H3M1839
AT-19

14) Set the ST.
21) Drain the ATF to remove the ATF drain plug.
NOTE:
Also the ENGINE SUPPORT BRACKET
41099AA010 can be used.
ST 41099AA020 ENGINE SUPPORT ASSY
B3M1036C
(A) Oil pan

(B) Drain plug
G2M0313
15) Remove the bolt which holds right upper side of

22) Disconnect the ATF cooler hoses from pipes of

transmission side, and remove the ATF level gauge
guide.
B3M2191
B3M2044

18) Remove the front, center, rear exhaust pipe
and muffler. (Non-turbo model) <Ref. to EX(w/
oOBD)-9, REMOVAL, Front Exhaust Pipe.>, <Ref.
to EX(w/oOBD)-13, REMOVAL, Rear Exhaust
Pipe.> and <Ref. to EX(w/oOBD)-14, REMOVAL,
Muffler.> or <Ref. to EX-7, REMOVAL, Front Exhaust Pipe.>, <Ref. to EX-11, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX-12, REMOVAL,
Muffler.>
19) Remove the center, rear exhaust pipe and muffler. (Turbo model)
<Ref. to EX(TURBO)-8, REMOVAL, Center Exhaust Pipe.>, <Ref. to EX(TURBO)-13, REMOVAL,
Rear Exhaust Pipe.> and <Ref. to EX(TURBO)-14,
REMOVAL, Muffler.>
23) Remove the propeller shaft. <Ref. to DS-15,

REMOVAL, Propeller Shaft.>
24) Remove the shift select cable. <Ref. to CS-9,
REMOVAL, Select Cable.>
25) Disconnect the stabilizer link from transverse
link.
AT-20

26) Remove the bolt securing ball joint of transverse link to housing.
Except sedan turbo MODEL
29) Place the transmission jack under transmission.

NOTE:
Make sure that the support plates of transmission
jack don't touch the oil pan.
30) Remove the transmission rear crossmember
from vehicle.
S4M0090
Sedan turbo MODEL
S2M0221
31) Remove the transmission.

CAUTION:
Move the transmission and torque converter as
a unit away from engine.
TR0090
27) Remove the spring pins and separate the front

drive shafts from each side of transmission.
B3M0035
32) Separate the transmission assembly and rear

cushion rubber.
B: INSTALLATION
1) Install the rear cushion rubber to transmission
assembly.
G2M0325

Tightening torque:
39 Nm (4.0 kgf-m, 29 ft-lb)
ST 498277200
STOPPER SET
B3M2047
H2M1961A
AT-21

3) Install the transmission onto engine.

(1) Gradually raise the transmission with transmission jack.
8) Connect the engine and transmission.

(1) Remove the ST from torque converter clutch
case.
NOTE:
clutch case when removing the ST.
ST 498277200
STOPPER SET
(2) Install the starter.
<Ref. to SC-6, INSTALLATION, Starter.>
(3) Tighten the bolt which holds right upper side
of transmission to engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
B2M0035
(2) Engage them at splines.

4) 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)
B3M2044
9) Install the torque converter clutch to drive plate.

(2) Tighten the other bolts while rotating the engine by using ST.
S2M0021A
5) Take off the transmission jack.

6) Tighten the nuts and bolts which hold lower side
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
NOTE:
Be careful not to drop bolts into torque converter
clutch housing.
Except 2.5 L model
ST 499977300
CRANK PULLEY WRENCH
2.5 L model
ST 499977100
CRANK PULLEY WRENCH
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
B3M2047

S2M0207
(3) Clog the plug onto service hole.
AT-22

10) Remove the ST.
14) Tighten the installing bolts.

Tightening torque:
49 Nm (5.0 kgf-m, 36 ft-lb)
G2M0313

B2M3402A
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 37 ft-lb)
T2: 58 Nm (5.9 kgf-m, 43 ft-lb)
(A) Transverse link

(B) Ball joint
15) Install the stabilizer link from transverse link.

Tightening torque:
30 Nm (3.1 kgf-m, 22.1 ft-lb)
H3M1839A

Install the front drive shafts into transmission.
(1) Lift-up the vehicle.
(2) Install the front drive shaft into transmission.
(3) Drive a new spring pin into chamfered hole
of drive shaft.
TR0089
Sedan turbo MODEL

Tightening torque:
45 Nm (4.6 kgf-m, 33.2 ft-lb)
G2M0325
13) Connect the ball joint into housing.

TR0090
16) Install the shift select cable onto select lever.

<Ref. to CS-9, INSTALLATION, Select Cable.>
AT-23

17) Install the ATF level gauge guide, and connect

the ATF cooler hoses to pipe.
B3M2191
18) Install the propeller shaft. <Ref. to DS-16, INSTALLATION, Propeller Shaft.>
20) Install the rear exhaust pipe and muffler assembly.
Non-turbo model
Exhaust Pipe.> and <Ref. to EX(w/oOBD)-14, INSTALLATION, Muffler.> or <Ref. to EX-11, INSTALLATION, Rear Exhaust Pipe.> and <Ref. to
EX-12, INSTALLATION, Muffler.>
Turbo model
21) Install the front and center exhaust pipe. (Nonturbo model) <Ref. to EX(w/oOBD)-10, INSTALLATION, Front Exhaust Pipe.> or <Ref. to EX-8, INSTALLATION, Front Exhaust Pipe.>
22) Install the center exhaust pipe. (Turbo model)
Exhaust Pipe.>
25) Install the ATF level gauge.
28) Install the air cleaner case stay. (Non-turbo

model)
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
29) Install the air cleaner case and intake duct.
(Non-turbo model) <Ref. to IN-6, INSTALLATION,
Air Cleaner Case.>, <Ref. to IN-7, INSTALLATION,
Air Intake Duct.>
30) Install the intercooler. (Turbo model)
<Ref. to IN(TURBO)-11, INSTALLATION, Intercooler.>
level gauge by using the gauge hole. <Ref. to AT-9,
Automatic Transmission Fluid.>
34) Check the select lever operation.
<Ref. to AT-28, INSPECTION, Inhibitor Switch.>
35) Check the ATF level. <Ref. to AT-9, Automatic
Transmission Fluid.>
36) Check the vehicle on the road tester. <Ref. to
AT-12, Road Test.>
S2M0214
26) Connect the following connectors.

(1) Transmission harness connectors
27) Connect the following cables.
(1) Cruise control cable (With cruise control vehicles)
AT-24
TRANSMISSION MOUNTING SYSTEM

10.Transmission Mounting System
7) Remove the transmission rear crossmember.
A: REMOVAL
1. PITCHING STOPPER
S2M0221
8) Remove the rear cushion rubber.
B: INSTALLATION
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)
TR0072
2. CROSSMEMBER AND CUSHION RUBBER

2) Jack-up the vehicle and support it with sturdy
racks.
3) Remove the front, center, rear exhaust pipes
and muffler. (Non-turbo model) <Ref. to EX(w/
oOBD)-9, REMOVAL, Front Exhaust Pipe.>, <Ref.
to EX(w/oOBD)-13, REMOVAL, Rear Exhaust
Pipe.> and <Ref. to EX(w/oOBD)-14, REMOVAL,
Muffler.> or <Ref. to EX-7, REMOVAL, Front Exhaust Pipe.>, <Ref. to EX-11, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX-12, REMOVAL,
Muffler.>
REMOVAL, Muffler.>
6) Set the transmission jack under the transmission.
T1
T2
TR0086
2) Install the air cleaner case. (Non-turbo model)

3) Install the intercooler. (Turbo model).
CAUTION:
Make sure that the support plates of transmission jack don't touch the oil pan.
AT-25

C: INSPECTION
Repair or replace parts if the results of the inspection below are not satisfactory.
1) Install the rear cushion rubber.
1. PITCHING STOPPER
Tightening torque:
39 Nm (4.0 kgf-m, 29 ft-lb)
2) Install the crossmember.
Make sure that the pitching stopper is not bent or

damaged. Make sure that the rubber is not stiff,
cracked, or otherwise damaged.
Tightening torque:
T1: 35 Nm (3.6 kgf-m, 26 ft-lb)
T2: 70 Nm (7.1 kgf-m, 51 ft-lb)

Make sure that the crossmember is not bent or
damaged. Make sure that the cushion rubber is not
stiff, cracked, or otherwise damaged.
S2M0221A
3) Remove the transmission jack.

5) Install the front, center, rear exhaust pipes and
the muffler. (Non-turbo model) <Ref. to EX(w/
oOBD)-10, INSTALLATION, Front Exhaust Pipe.>,
Exhaust Pipe.> and <Ref. to EX(w/oOBD)-14, INSTALLATION, Muffler.> or <Ref. to EX-8, INSTALLATION, Front Exhaust Pipe.>, <Ref. to EX-11,
INSTALLATION, Rear Exhaust Pipe.> and <Ref. to
6) Install the center, rear exhaust pipe and muffler.
(Turbo model)
Exhaust Pipe.>, <Ref. to EX(TURBO)-13, INSTALLATION, Rear Exhaust Pipe.> and <Ref. to
EX(TURBO)-14, INSTALLATION, Muffler.>
AT-26
EXTENSION CASE OIL SEAL

11.Extension Case Oil Seal

A: INSPECTION
Make sure the ATF does not leak from the joint of
transmission and propeller shaft. If so, replace the
oil seal. <Ref. to AT-27, REPLACEMENT, Extension Case Oil Seal.>
B: REPLACEMENT
1) Clean the transmission exterior.
NOTE:

Non-turbo model
Exhaust Pipe.> and <Ref. to EX(w/oOBD)-14, INSTALLATION, Muffler.> or <Ref. to EX-11, INSTALLATION, Rear Exhaust Pipe.> and <Ref. to
Turbo model
<Ref. to EX(TURBO)-13, Installation, Rear Exhaust Pipe.> and <Ref. to EX(TURBO)-14, INSTALLATION, Muffler.>
11) Pour ATF and check the ATF level. <Ref. to
AT-9, Automatic Transmission Fluid.>
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
B3M1036B
(A) Oil pan

(B) Drain plug

Non-turbo model
<Ref. to EX(w/oOBD)-13, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(w/oOBD)-14, REMOVAL, Muffler.> or <Ref. to EX-11, REMOVAL,
Rear Exhaust Pipe.> and <Ref. to EX-12, REMOVAL, Muffler.>
Turbo model
<Ref. to EX(TURBO)-13, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(TURBO)-14, REMOVAL, Muffler.>
5) Remove the propeller shaft. <Ref. to DS-15, REMOVAL, Propeller Shaft.>
6) Using the ST, remove the oil seal.
ST 398527700
PULLER ASSY
7) Using the ST, install the oil seal.
ST 498057300
INSTALLER
AT-27
INHIBITOR SWITCH
12.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.
3) Check if there is continuity at equal points when

the select lever is turned 1.5 in both directions
from N range.
If there is continuity in one direction and the continuity in the other or if there is continuity at unequal
points, adjust the inhibitor switch. <Ref. to AT-28,
ADJUSTMENT, Inhibitor Switch.>
NOTE:
Also check that continuity in ignition circuit does not
exist when the select lever is in R, D, 3, 2 and
1 ranges.
NOTE:
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
Position
P
R
N
D
3
2
1
P/N
R
Pin No.
43
42
41
48
47
46
45
12 11
10 9
B3M1586A
(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-10, ADJUSTMENT, Select Cable.>
B: ADJUSTMENT
1) Shift 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 inhibitor switch lever and switch body.
ST 499267300
STOPPER PIN
B3H0016B
B3M1027A
4) Tighten the three inhibitor switch bolts.

Tightening torque:
3.5 Nm (0.35 kgf-m, 2.5 ft-lb)
5) Repeat the above checks. If the inhibitor switch
is determined to be faulty, replace it.
AT-28
INHIBITOR SWITCH
C: REMOVAL
1) Set up the vehicle on a lift.
2) Move the select lever to N range.
5) Disconnect the inhibitor switch connector.
10) Remove the plate assembly from transmission

case.
B3M1030H
(A) Select cable

(B) Plate ASSY
11) Remove the bolts.

B3M1028B
(A) Inhibitor switch
6) Remove the inhibitor switch connector from stay.

Pipe.> or <Ref. to EX-7, REMOVAL, Front Exhaust
Pipe.>
9) Remove the snap pin and washer from range select lever.
B3M1031B
12) Move the range select lever to parking position

(left side).
TR0908
(A)
(B)
(C)
(D)
Snap pin
Select cable
Range select lever
Washer
B3M1032B
(A) Range select lever
AT-29
INHIBITOR SWITCH
13) Remove the inhibitor switch from transmission.
6) Install the plate assembly to transmission.

Tightening torque:
T: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
B3M1033B

B3M1030I
14) Disconnect the inhibitor switch harness connector from inhibitor switch.
(A) Select cable

(B) Plate ASSY
D: INSTALLATION
1) Connect the inhibitor switch harness connector
to inhibitor switch.
2) Install the inhibitor switch to transmission case.
7) Install the washer and snap pin to range select

lever.
TR0908
B3M1033B
(A)
(B)
(C)
(D)
3) Move the range select lever to neutral position.

4) Using the ST, tighten the bolts of inhibitor switch.
ST 499267300
STOPPER PIN
Tightening torque:
3.5 Nm (0.36 kgf-m, 2.6 ft-lb)
Snap ring
Select cable
Range select lever
Washer
8) Install the front and center exhaust pipes. (Nonturbo model)

Except 3.0 L model
Exhaust Pipe.> or <Ref. to EX-8, INSTALLATION,
Front Exhaust Pipe.>
Exhaust Pipe.>
11) Install the inhibitor switch connector from stay.
B3M1034B

(B) Range select lever
5) Install the select cable to range select lever.
AT-30
INHIBITOR SWITCH
12) Connect the inhibitor switch connector.
B3M1028B

15) Inspect the inhibitor switch. <Ref. to AT-28, INSPECTION, Inhibitor Switch.>
AT-31
FRONT VEHICLE SPEED SENSOR

13.Front Vehicle Speed Sensor
A: REMOVAL
NOTE:
1) Set up the vehicle on a lift.

Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
G6M0095
B3M1036B

5) Disconnect the transmission connector.
S3M0039B
(A) Transmission connector
6) Remove the pitching stopper. <Ref. to AT-25,

REMOVAL, Transmission Mounting System.>
7) Remove the transmission connector from stay.
(A) Oil pan

(B) Drain plug
11) Remove the front, center, exhaust pipes and

muffler. (Non-turbo model)
Pipe.>, <Ref. to EX(w/oOBD)-13, REMOVAL, Rear
Exhaust Pipe.> and <Ref. to EX(w/oOBD)-14, REMOVAL, Muffler.> or <Ref. to EX-7, REMOVAL,
Front Exhaust Pipe.>, <Ref. to EX-11, REMOVAL,
REMOVAL, Muffler.>
13) Remove the shield cover. (If equipped)
NOTE:
Make sure that the support plates of transmission
jack don't touch the crossmember.
AT-32


bolts.
21) Disconnect the duty solenoids and ATF temperature sensor connectors. Remove the connectors from clip and disconnect the connectors.
TR0544
B3M2263I
17) Lower the AT jack.

NOTE:
Do not separate the AT jack and transmission.
18) Remove the oil cooler inlet and outlet pipe.
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
(J)
NOTE:
When removing the outlet pipe, be careful not to
lose balls and springs used with retaining screws.
19) Remove the front and rear vehicle speed sensor and torque converter turbine speed sensor.
Front vehicle speed sensor and torque
converter turbine speed sensor
Lock-up duty solenoid (Blue)

Low clutch timing solenoid (Gray)
Line pressure duty solenoid (Red)
Shift solenoid 2 (Yellow)
Shift solenoid 1 (Green)
2-4 brake timing solenoid (Black)
2-4 brake duty solenoid (Red)
Transfer duty solenoid (Brown)
Transmission ground
22) Remove the harness assembly.
B: INSTALLATION
1) Pass the harness assembly through the hole in
the transmission case.
B3M1066B
(A) Front vehicle speed sensor

(B) Torque converter turbine speed sensor
B3M1067
B3M1056B
(A) Rear vehicle speed sensor

(B) Front vehicle speed sensor
20) Remove the oil pan.
AT-33

2) Connect the harness connectors.

Connect the connectors of same color, and secure
the connectors to valve body using clips.
Tightening torque (Transmission ground cable)
8 Nm (0.8 kgf-m, 5.8 ft-lb)
4) Apply liquid gasket fully to three holes other than

screw holes on transmission case.
Fluid packing:
THREE BOND 1217B
B3M2265
B2M22631
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
(J)
5) Install the oil pan.

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
6) Install the front and rear vehicle speed sensor,
and also the torque converter turbine speed sensor, and then fasten the harness.

Transmission ground
Tightening torque:
7 Nm (0.7 kgf-m, 5.1 ft-lb)
7) Install the oil cooler pipes.
NOTE:
Be sure to use a new aluminum washer.
3) Apply proper amount of liquid gasket to the entire oil pan mating surface.
Fluid packing:
THREE BOND 1217B
Tightening torque:
T1: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
T2: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
B3M2059A
B3M1040
8) Install the transmission rear crossmember bolts.

Tightening torque:
70 Nm (7.1 kgf-m, 51 ft-lb)
AT-34


10) Install the shield cover. (If equipped)
11) Install the front, center, rear exhaust pipes and
muffler. (Non-turbo model)
Exhaust Pipe.>, <Ref. to EX(w/oOBD)-13, INSTALLATION, Rear Exhaust Pipe.> and <Ref. to
EX(w/oOBD)-14, INSTALLATION, Muffler.> or
Pipe.>, <Ref. to EX-11, INSTALLATION, Rear Exhaust Pipe.> and <Ref. to EX-12, INSTALLATION,
Muffler.>
12) Install the center, rear exhaust pipes and muffler. (Turbo model)
14) Install the transmission connector to the stay.
15) Install the pitching stopper. <Ref. to AT-25, INSTALLATION, Transmission Mounting System.>
AT-35
REAR VEHICLE SPEED SENSOR

14.Rear Vehicle Speed Sensor

A: REMOVAL
When removing the rear vehicle speed sensor, refer to Front Vehicle Speed Sensor. <Ref. to AT32, REMOVAL, Front Vehicle Speed Sensor.>
B: INSTALLATION
When installing the rear vehicle speed sensor, refer
to Front Vehicle Speed Sensor. <Ref. to AT-33,
INSTALLATION, Front Vehicle Speed Sensor.>
AT-36
TORQUE CONVERTER TURBINE SPEED SENSOR

15.Torque Converter Turbine

Speed Sensor
A: REMOVAL
When removing the torque converter turbine speed
sensor, refer to Front Vehicle Speed Sensor.
<Ref. to AT-32, REMOVAL, Front Vehicle Speed
Sensor.>
B: INSTALLATION
When installing the torque converter turbine speed
sensor, refer to Front Vehicle Speed Sensor.
<Ref. to AT-33, INSTALLATION, Front Vehicle
Speed Sensor.>
AT-37
CONTROL VALVE BODY

16.Control Valve Body
5) Disconnect the duty solenoids and ATF temperature sensor connectors. Remove the connectors
from clip and disconnect the connectors.
A: REMOVAL
NOTE:
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
B2M2263I
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
(J)
B3M1036B
(A) Oil pan

(B) Drain plug

Transmission ground
6) Remove the control valve.

NOTE:
Remove and clean the magnet.
Remove the old gasket on the oil pan and transmission case completely.
NOTE:
When removing the control valve body, be careful
not to interfere with transfer duty solenoid wiring.
B3M1037
AT-38
CONTROL VALVE BODY

B: INSTALLATION
1) Set the range select lever in N range.
2) Install the control valve and ground connectors.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
Fluid packing:
THREE BOND 1217B
B3M1040
B3M1037A
(A) Short bolts

(B) Long bolts

Fluid packing:
THREE BOND 1217B
3) Connect all connectors.
B3M2265
B3M2263I
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
(J)

Transmission ground

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
8) Pour ATF into the oil charge pipe.
Recommended fluid:
4) Attach the magnet at the specified position.
Fluid capacity:
Fill the same amount of fluid drained from
drain plug hole.
9) Check the level of ATF.
<Ref. to AT-9, Automatic Transmission Fluid.>
C: DISASSEMBLY
Refer to AUTOMATIC TRANSMISSION <Pub.
No. G0864ZE> a separate publication.
D: ASSEMBLY
E: INSPECTION
B3M1105
AT-39
SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR

17.Shift Solenoids, Duty Solenoids and ATF Temperature

Sensor
6) Remove the solenoids, duty solenoids and ATF

temperature sensor.
A: REMOVAL
NOTE:
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
B3M1039A
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
1. TRANSFER DUTY SOLENOID AND

TRANSFER VALVE BODY
B3M1036C
(A) Oil pan

(B) Drain plug

5) Disconnect the solenoid and sensor connectors.
Remove the connectors from clip and disconnect
the connectors.

B2M2263J
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)


H3M1839
6) Remove the front exhaust pipe with center exhaust pipe. (Non-turbo model)
Pipe.> or <Ref. to EX-7, REMOVAL, Front Exhaust
Pipe.>
7) Remove the center exhaust pipe. (Turbo model)
<Ref. to EX(TURBO)-8, REMOVAL, Center Exhaust Pipe.>
AT-40


Non-turbo model
<Ref. to EX(w/oOBD)-13, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(w/oOBD)-14, REMOVAL, Muffler.> or <Ref. to EX-11, REMOVAL,
Turbo model
9) Raise the vehicle and drain the ATF.
13) Remove the rear vehicle speed sensor.
B3M1043
14) Remove the select cable nut.
B3M1036B
B3M0308
(A) Oil pan

(B) Drain plug
(C) Deferential oil drain plug
10) Remove the heat shield cover.

12) Remove the transmission rear crossmember.
(1) Support the transmission using a transmission jack and raise slightly.
(2) Remove the bolts and nuts as shown in the
figure.
15) Move the gear select cable so that extension

bolts can be removed.
16) Remove the bolts.
17) Remove the extension case.
NOTE:
Use a container to catch oil flowing from extension.
B3M1044
18) Disconnect the transfer duty solenoid connector.

S2M0221
AT-41

19) Remove the transfer duty solenoid and transfer

valve body.
2) Connect the harness connectors.

Connect the connectors of same color, and secure
the connectors to valve body using clips.
B3M1045F
B2M2263J
(A) Transfer valve body

(B) Transfer duty solenoid connector
(C) Transfer duty solenoid
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
B: INSTALLATION
1) Install the solenoids and ATF temperature sensor.
Tightening torque:
T: 8 Nm (0.8 kgf-m, 5.8 ft-lb)

Fluid packing:
THREE BOND 1217B
B3M1039B
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)

B3M1040

Fluid packing:
THREE BOND 1217B
B3M2265
AT-42

2) Install the extension case to transmission case.

(1) Tighten eleven bolts.

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(2) Adjust the select cable. <Ref. to CS-10, ADJUSTMENT, Select Cable.>
3) Install the rear vehicle speed sensor.
Tightening torque:
T: 7 Nm (0.7 kgf-m, 5.1 ft-lb)
B3M1036C
(A) Oil pan

(B) Drain plug

1. TRANSFER DUTY SOLENOID AND

TRANSFER VALVE BODY
1) Install the transfer duty solenoid and transfer
valve body.
(1) Install the transfer duty solenoid and transfer valve body.
B3M1043A

(1) Tighten the bolts.
Tightening torque:
T1: 35 Nm (3.6 kgf-m, 26 ft-lb)
T2: 70 Nm (7.1 kgf-m, 51 ft-lb)
Tightening torque:
T: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
(2) Connect the transfer duty solenoid connector.
S2M0221B
B3M1045G
(A) Transfer valve body

(B) Transfer duty solenoid connector
(C) Transfer duty solenoid
(2) Lower and remove the transmission jack.

6) Install the front, center rear exhaust pipe and
muffler. (Turbo model) <Ref. to EX(w/oOBD)-10,
INSTALLATION, Front Exhaust Pipe.>, <Ref. to
EX(w/oOBD)-13, INSTALLATION, Rear Exhaust
Pipe.> and <Ref. to EX(w/oOBD)-14, INSTALLATION, Muffler.> or <Ref. to EX-8, INSTALLATION,
Front Exhaust Pipe.>, <Ref. to EX-11, INSTALLATION, Rear Exhaust Pipe.> and <Ref. to EX-12, INSTALLATION, Muffler.>
7) Install the center, rear exhaust pipes and muffler. (Turbo model)
AT-43

8) Lower and remove the jack.

9) Connect the transmission harness connector.
S2M0212

Tightening torque:
T1: 50 Nm (5.1 kgf-m, 37 ft-lb)
T2: 58 Nm (5.9 kgf-m, 43 ft-lb)
H3M1839A
11) Install the air cleaner case. <Ref. to IN-6, INSTALLATION, Air Cleaner Case.>
AT-44
ATF FILTER
18.ATF Filter
A: REMOVAL
NOTE:
The ATF filter is maintenance free.
2) Using the ST, remove the ATF filter.
ST 498545400
OIL FILTER WRENCH
B3M1665B
(A) ATF filter
3) Use a new ATF filter and apply a thin coat of ATF

to the oil seal.
B: INSTALLATION
1) Install the ATF filter. Turn it by hand, being careful not to damage the oil seal.
2) Using the ST, tighten the ATF filter to transmission case.
Calculate the ATF filter torque specifications using
the 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 0.078 m (3.07 in)
L2: Torque wrench length
Example:
Torque wrench length
mm (in)
100 (3.94)
150 (5.91)
200 (7.87)
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
ATF filter.
ST 498545400
OIL FILTER WRENCH
3) Add ATF.
4) Inspect the level of ATF. <Ref. to AT-9, Automatic Transmission Fluid.>
AT-45
TRANSMISSION CONTROL MODULE (TCM)

19.Transmission Control Module (TCM)
3) Disconnect the connectors from transmission

control module.
LHD MODEL
A: REMOVAL
B3M1592A
(A) Transmission control module

(B) Brake pedal bracket
G6M0095
2) Remove the lower cover and then disconnect

the connector.
RHD MODEL
B3M1593A
B3M1591

(B) Column shaft
4) Remove the transmission control module.
AT-46
TRANSMISSION CONTROL MODULE (TCM)

B: INSTALLATION
1) Install the transmission control module.
Tightening torque:
LHD model
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
RHD model
25 Nm (2.5 kgf-m, 18.1 ft-lb)
LHD MODEL
B3M1592A

(B) Brake pedal bracket
RHD MODEL
B3M1648A

(B) Column shaft
2) Connect the connectors to transmission control

module.
AT-47
ATF COOLER PIPE AND HOSE

20.ATF Cooler Pipe and Hose
7) Remove the ATF cooler pipe from frame.
A: REMOVAL
2) Remove the battery and washer tank.
5) Disconnect the ATF cooler hose from radiator.
NOTE:
Do not remove with a screwdriver or other pointed tools.
When the hose is difficult to remove, wrap a shop
cloth around the hose to protect it. Turn it with pliers, and then pull directly out with your hand.
B3M2054
8) Remove the oil cooler inlet and outlet pipes.

B3M2052
6) Disconnect the ATF cooler hoses from pipes.

NOTE:
Do not remove with a screwdriver or other pointed tools.
When the hose is difficult to remove, wrap a shop
cloth around the hose to protect it. Turn it with pliers, and then pull directly out with your hand.
NOTE:
When removing the outlet pipe, be careful not to
lose ball and spring used with retaining screw.
B3M2059B
(A) Inlet pipe

(B) Outlet pipe
B3M2191
AT-48

B: INSTALLATION
1) Install the oil cooler outlet and inlet pipes.
NOTE:
Be sure to use a new aluminum washer.
Tightening torque:
T1: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
T2: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
3) Connect the ATF cooler hose to pipe transmission side.

NOTE:
Install so that the hose is not folded over, excessively bent, or twisted.
Be careful to insert the hose to the specified position.
B3M2191
B3M2059A
2) Install the ATF cooler pipe to frame.
4) Connect the ATF cooler hose to the pipe of radiator side.

NOTE:
Install so that the hose is not folded over, excessively bent, or twisted.
Be careful to insert the hose to the specified position.
B3M2052

6) Install the battery and washer tank.
7) Fill ATF. <Ref. to AT-9, Automatic Transmission
Fluid.>
B3M2054
NOTE:
Make sure there are no ATF leaks in joints between
the transmission, radiator, pipes, and hoses.
AT-49

C: INSPECTION
Repair or replace any defective hoses, pipes,
clamps, and washers found from the inspection below.
1) Check for ATF leaks in joints between the transmission, radiator, pipes, and hoses.
2) Check for deformed clamps.
3) Lightly bend the hose and check for cracks in the
surface and other damage.
4) Pinch the hose with your fingers and check for
poor elasticity. Also check for poor elasticity in the
parts where the clamp was by pressing with your
fingernail.
5) Check for peeling, cracks, and deformation at
the tip of the hose.
AT-50
(DIAGNOSTICS)
AT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Page
Inspection Mode........................................................................................24
POWER Indicator Light Display ................................................................26
Diagnostic Procedure for POWER Indicator Light ....................................28
Diagnostic Procedure for Select Monitor Communication.........................37
Diagnostic Procedure for No-diagnostic Trouble Code (DTC) ................105
Symptom Related Diagnostic..................................................................133

AUTOMATIC TRANSMISSION (DIAGNOSTICS)

A: PROCEDURE
1
2
3
Step
CHECK PRE-INSPECTION.
occurred using interview checklist. <Ref. to
AT-4, Check List for Interview.>
2)Before performing the diagnosis, inspect following items which might influence the AT
problems.
General inspection <Ref. to AT-5, INSPECTION, General Description.>
Oil leak
Stall speed test <Ref. to AT-13, Stall Test.>
Line pressure test <Ref. to AT-16, Line Pressure Test.>
Transfer clutch pressure test <Ref. to AT-18,
Transfer Clutch Pressure Test.>
Time lag test <Ref. to AT-15, Time Lag Test.>
Road test <Ref. to AT-12, Road Test.>
Inhibitor switch <Ref. to AT-28, Inhibitor
Switch.>
CHECK POWER INDICATOR LIGHT.
Turn the ignition switch to ON.
2)Repair the POWER indicator light circuit or
power supply and ground line circuit.
<Ref. to AT-28, Diagnostic Procedure for
POWER Indicator Light.>
TROUBLE CODE (DTC).
Calling up the DTC.
Without SUBARU SELECT MONITOR
<Ref. to AT-22, WITHOUT SUBARU SELECT
MONITOR, Read Diagnostic Trouble Code
(DTC).>
With SUBARU SELECT MONITOR
<Ref. to AT-23, WITH SUBARU SELECT
(DTC).>
Check
Yes
Is the unit that might influence Go to step 2.
AT problem normal?
No
Repair or replace
each item.
Does not the POWER indicator Go to step 3.

light up?
Is the POWER indicator light
Go to step 4.
flashing?
Go to step 4.
Is the DTC displayed?
Go to step 6.
NOTE:
Record all DTC.
NOTE:
If the communication function of select monitor
cannot be executed normally, check the communication circuit. <Ref. to AT-37, COMMUNICATION FOR INITIALIZING IMPOSSIBLE,
Diagnostic Procedure for Select Monitor Communication.>
AT-2
Go to step 5.
Go to step 5.

Step
Check
PERFORM THE GENERAL DIAGNOSTICS. Is the DTC displayed?
1)Inspect using Diagnostic Procedure for Nodiagnostic trouble code (DTC).<Ref. to AT105, Diagnostic Procedure for No-diagnostic
2)Inspect using Symptom Related Diagnostic. <Ref. to AT-133, Symptom Related Diagnostic.>
3)Perform the clear memory mode.
MONITOR, Clear Memory Mode.>
4)Perform the inspection mode. <Ref. to AT24, Inspection Mode.>
Calling up the DTC.
(DTC).>
MONITOR, OPERATION, Read Diagnostic
Is the DTC displayed?
1)Inspect using Diagnostics Chart with Diagnostic Trouble Code (DTC).<Ref. to AT-42,
Code (DTC).>
NOTE:
For trouble code table, refer to List of Diagnostic Trouble Code (DTC).<Ref. to AT-27, List of
2)Repair the trouble cause.
MONITOR, OPERATION, Clear Memory
Mode.>
4)Perform the inspection mode. <Ref. to AT24, Inspection Mode.>
5)Calling up the DTC.
AT-3
Yes
Complete the
diagnosis.
No
Go to step 6.
Complete the
diagnosis.
Inspect using
Diagnostics Chart
with Diagnostic
Connector. <Ref.
to AT-42, Diagnostic Procedure with


A: CHECK
NOTE:
Customer's name
Data vehicle brought in
Data of repair
Trans. model
Odometer reading
Frequency
Weather
Place
Outdoor temperature
Vehicle speed
Malfunction indicator lamp (MIL)
Select lever position
Driving condition
POWER switch
HOLD switch
Symptoms
TRANSMISSION
VIN
km/h or mile
Continuous Intermittent (
times a day)
Fine Cloudy Rainy Snowy
Various/Others
(
)
High Suburbs Inner city Uphill Rough road
Others
(
)
Hot Warm Cool Cold
km/h (MPH)
Continuously lit
P R N D
Not affected
At racing
While decelerating
Not lit
3 2 1
At starting
While accelerating
While turning ( RH/
LH)
ON OFF
ON OFF
No up-shift
No down-shift
No kick down
Vehicle does not move ( Any position
Lock-up malfunction
Noise or vibration
Shift shock or slip
Select lever does not move
Others
(
)
AT-4
While idling
While cruising
Particular position)
GENERAL DESCRIPTION
3. ATF LEVEL
A: CAUTION
Make sure that ATF level is in the specification.

<Ref. to AT-9, INSPECTION, Automatic Transmission Fluid.>
Supplemental Restraint System Airbag

The airbag system wiring harness is routed near
the transmission control module (TCM).
CAUTION:
All airbag system wiring harness and connectors are colored yellow. Do not use an electrical test equipment on these circuit.
wiring harness when performing diagnostics
and servicing the TCM.
Measurement
When measuring the voltage and resistance of
ECM, TCM or each sensor, use a tapered pin with
diameter of less than 0.64 mm (0.025 in) in order to
avoid poor contact. Do not insert the pin more than
6.5 mm (0.256 in).
B: INSPECTION
1. BATTERY
Measure the battery voltage and specific gravity of
electrolyte.
B3M0173B
(A) Upper level

(B) Lower level
4. FRONT DIFFERENTIAL OIL LEVEL

Make sure that front differential oil level is in the
specification. <Ref. to AT-11, INSPECTION, Differential Gear Oil.>
Standard voltage: 12V or more

2. TRANSMISSION GROUND
Make sure that the ground terminal bolt is tightened
securely.
Chassis side
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
B3M0174B
(A) 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.
WARNING:
Stop the engine while checking operation of selector lever.
TR0373
B3M1747
AT-5
GENERAL DESCRIPTION
6. POWER SWITCH
7. HOLD SWITCH
Make sure that the POWER indicator light in combination meter comes ON, when turning the power
switch to ON.
Make sure that the HOLD indicator light in combination meter comes ON, when turning the hold
switch to ON.
TR0378
TR0377
C: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
24082AA190
CARTRIDGE
REMARKS
B2M3876
22771AA030
SELECT MONITOR
KIT

English:
German:
French:
Spanish:
B2M3877

TOOL NAME
Circuit Tester
Oscilloscope
REMARKS
Used for measuring sensor.
AT-6
GENERAL DESCRIPTION
AT-7


A: LOCATION
1. CONTROL MODULE
(1)
(3)
(2)
(4)
TR0379
(3)
(2)
(4)
(1)
TR0521
(1)
(2)

POWER indicator light (AT diagnostic indicator light)
(3)
(4)
AT-8
Transmission control module (TCM)

Data link connector

(2)
B3M1575A
TR0383
B3M1592B
B3M1652A
(4)
TR0382
AT-9

2. SENSOR
(1)
(3)
(5)
(6)
(2)
(4)
TR0385
(1)
(2)
(3)

Inhibitor switch
(4)
(5)

Torque converter turbine speed
sensor
AT-10
(6)

Non-turbo model
(2)
(4)
S2M0262B
TR0387
Turbo model
(2)
(4)
(3)
TR0592
TR0388
(5)
(6)
TR0390
AT-11
TR0389

3. SOLENOID
B3M1186A
(1)
(2)
(3)
Solenoid 1
Solenoid 2
(4)
(5)
(6)

B2M2263D
AT-12
(7)
(8)

B2M2264E

AT-13


to B54
9
18
24
8
17
23
7
16
22
6 5
15 14
to B55
9
18
24
4 3 2 1
13 12 11 10
21 20 19
8
17
23
7
16
22
6 5
15 14
4 3 2 1
13 12 11 10
21 20 19
to B56
9
18
24
8
17
23
7
16
22
6 5
15 14
4 3 2 1
13 12 11 10
21 20 19
TR0532

Content
P range
switch
Inhibitor
switch
Brake switch
Connector
No.
B56
B54
B54
B55
Terminal No.
Voltage (V)
1
23
24
Ignition switch OFF
10 13
Resistance
to body
(ohms)

engine OFF)
10 13
N range
switch
B55
14
R range
switch
B55
D range
switch
B55
3 range
switch
B55
2 range
switch
B55
1 range
switch
B55
B55
12

Select lever in any other
than P range (except N
range)
than N range (except P
range)
than R range
than D range
than 3 range
than 2 range
than 1 range
AT-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
Less than 1
More than 8
Less than 1
More than 8
Less than 1
More than 8
More than 10.5
Less than 1

Connector
No.
Terminal No.
Kick-down switch
B55
11
AT OIL TEMP warning light
B56
10
B54

power supply
B54
B54
11
Content
B55
24
B55
18

speed sensor
B55
B56
Engine speed signal
Cruise set signal
B55
B55
17
17
22
B56
B56
14

Intake manifold pressure
signal (Non-turbo model)
Mass air flow signal (Turbo
model)
B55
10
B54
B54
Shift solenoid 1
B54
22
Shift solenoid 2
B54
Voltage (V)
Throttle fully opened.

Light ON
Light OFF
engine OFF)
ATF temperature 20C
(68F)
ATF temperature 80C
(176F)
Vehicle stopped.
km/h (12 MPH)
Vehicle stopped.
km/h (12 MPH)
Engine idling after warmup. (D range)
Engine idling after warmup. (N range)
km/h (6 MPH)
engine OFF)
engine ON)
(SET lamp ON)
set. (SET lamp OFF)
engine ON)
engine ON)
Ignition switch ON
Engine idling after warmup.
Engine idling after warmup.
1st or 4th gear
2nd or 3rd gear
1st or 2nd gear
3rd or 4th gear
Less than 1
More than 6.5
Less than 1
More than 9
0.2 1.0
4.2 4.7
AT-15
Resistance
to body
(ohms)
4.8 5.3
1.6 2.0
2.1 k 2.9 k
0.4 0.9
275 375
0
450 650
0
450 650
0
450 650
Less than 1
More than 4
More than 10.5
8 11
Less than 1
More than 6.5

More than 4
More than 4
0.4 1.6
0.9 1.4
More than 9
Less than 1
More than 9
Less than 1
10 16
10 16

Content
Connector
No.
B54
Terminal No.
B54

(Non-turbo model)
B54

(Turbo model)
B56
B54
18
engine OFF)
warm-up.
engine OFF)
warm-up.
Fuse on FWD switch
open and with select lever
in 1st gear).
engine OFF) after warmup.
engine OFF) after warmup.
1st gear
3rd gear
2nd gear
4th gear
Hold switch ON
Hold switch OFF
Power switch ON
Power switch OFF
Light ON
Light OFF
Fuse removed.
Fuse installed.
Fused ON FWD switch
switch.
ABS switch ON
ABS switch OFF
B54
16
B54
15
Hold switch
B55
16
Power switch
B55
23
Power indicator light
B56
11
FWD switch
B55
20
FWD indicator light
B56
ABS signal
B55
21


B54
B55
B56
B54
B54
B54
20
9
19
21
10
19
AT diagnosis signal
B56
21
Ignition switch ON

Select Monitor)
B56
15
System ground line
AT-16
Voltage (V)
Resistance
to body
(ohms)
1.5 4.0
2.0 4.5
Less than 0.5
More than 8.5
Less than 0.5
More than 8.5
Less than 0.5
More than 8.5
Less than 0.5
10 17
10 17
10 17
1.5 5.0
2.0 4.5
Less than 0.5
Less than 1
More than 9
Less than 1
More than 9
Less than 1
More than 8
Less than 1
More than 10
Less than 1
More than 9
6 9.1
Less than 1
Less than 1
10 16
10 16
More than 9
Less than 1
6.5 15
0
0
Less than 1
Less than 1
Less than 1
0
0
Less than 1
More than 4
Less than 1
Less than 1

AT-17

B: SCHEMATIC
(2)
(31)
(3)
(32)
(33)
(4)
(34)
(35)
(39)
(36)
(5)
(37)
(6)
(38)
(7)
(40)
(1)
(8)
(9)
(41)
(10)
(11)
(42)
(12)
(13)
(43)
(14)
(44)
(15)
(45)
(17)
(16)
(46)
(19)
(18)
(47)
(21)
(20)
(48)
(23)
(22)
(49)
(25)
(24)
(50)
(27)
(26)
(51)
(29)
(28)
(30)
TR0395
AT-18

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

Cruise control module
ABS control module
Ignition switch
Brake switch
Brake light
Battery
Combination meter (Speedometer circuit)
(9)
(10)
AT OIL TEMP light

FWD indicator light (Non-turbo
model)
(11)
(12)
(13)
(14)
(15)
(16)
(17)

FWD switch (Non-turbo model)
Power switch
Kick-down switch
Hold indicator light
Hold switch
P range indicator light
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
P range switch
R range indicator light
R range switch
N range indicator light
N range switch
D range indicator light
D range switch
3 range indicator light
3 range switch
2 range switch
1 range switch
Data link connector
Engine speed signal
AT-19
(37)
Non-turbo model:
Turbo model:
Mass air flow signal
(38)
(39)
(40)
(41)
AT diagnostics signal
Engine control module
Torque converter turbine speed
sensor
(42)
(43)
(44)
(45)
(46)
(47)
(48)
(49)
(50)
(51)

Shift solenoid 1
Shift solenoid 2


A: OPERATION
S2M0288C
(A) Power switch

S2M0285

Monitor.
<Ref. to AT-6, PREPARATION TOOL, General Description.>
S2M0286

connector.
(1) Data link connector located in the lower portion of instrument panel (on driver's side).

screen, select the {Transmission Control System}
and press [YES] key.
8) Press the [YES] key after displayed information
of transmission type.
9) On the Transmission Diagnosis display
screen, select the {Diagnostic Code(s) Display}
screen, select the {Latest Diagnostic Code(s)} or
{Memorized Diagnostic Code(s)} and press [YES]
key.
NOTE:
For detailed concerning the diagnostic trouble
codes (DTC), refer to the DIAGNOSTIC TROUBLE
CODE LIST. <Ref. to AT-27, List of Diagnostic
2. READ CURRENT DATA
EN0768

connector.
NOTE:
Do not connect scan tools except for Subaru Select
Monitor and OBD-II general scan tool.

screen, select the {Current Data Display & Save}
6) Using the scroll key, move the display screen up
or down until desired data is shown.
A list of the support data is shown in the following
table.
AT-20

Contents
Battery voltage
Engine speed signal
Gear position
Mass air flow sensor signal (Turbo model)
Intake manifold pressure sensor voltage (Non-turbo model)
2 wheel drive switch signal (Non-turbo model)
Parking range signal
Neutral range signal
Drive range signal
3rd range signal
2nd range signal
1st range signal
Power mode switch signal
Hold mode switch signal
Kick down switch signal
Automatic transmission fluid temperature lamp
Display
Battery Voltage
Rear Wheel Speed
Front Wheel Speed
Engine Speed
ATF Temp.
Gear Position
Lock Up Duty Ratio
Transfer Duty Ratio
Turbine Revolution Speed
Brake Clutch Duty Ratio
Mani. Pressure Voltage
FWD Switch
Stop Light Switch
ABS Signal
P Range Signal
N Range Signal
R Range Signal
D Range Signal
3rd Range Signal
2nd Range Signal
1st Range Signal
Shift Solenoid #1
Shift Solenoid #2
Torque Control Signal 1
Torque Control Signal 2
Diagnosis Lamp
Power Mode Switch
Hold Mode Switch
Kick Down Switch
ATF Temperature Lamp
NOTE:
3. CLEAR MEMORY MODE

Unit of measure
V
km/h or MPH
km/h or MPH
rpm
C or F
V
%
%
%
V
rpm
%
V
V
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF

screen, select the {Clear Memory} and press [YES]
key.
5) When the `Done' and `Turn Ignition Switch OFF'
are shown on display screen, turn the Subaru Select Monitor and ignition switch to OFF.
NOTE:
AT-21


A: OPERATION
Step
PERFORM READ DIAGNOSTIC TROUBLE
CODE.
1)Warm-up the engine.
4)Start the engine.
5)Drive the vehicle at speeds greater than 20
km/h (12 MPH).
6)Stop the vehicle.
7)The brake pedal depressed and move select
lever to 1 range.
10)Move the select lever 2 range.
14)Move the select lever D range.
CHECK INDICATOR LIGHT.
Check
Does the indicator light blink at
4 Hz intervals? NOTE: Blinks
every 0.125 (1/8) seconds
(until the ignition switch is
turned OFF).
Yes
No
Repair the power Go to step 2.
supply and ground
circuit.<Ref. to AT34, CHECK
POWER SUPPLY
AND GROUND
LINE, Diagnostic
Procedure for
POWER Indicator
Light.>
Does the indicator light blink at The AT system is

2 Hz intervals? NOTE: Blinks normal.
every 0.25 (1/4) seconds (until
ignition switch is turned to
OFF).
Is the DTC outputted?
Inspect the problem corresponding with DTC.
Go to step 3.
Go to step 4.
NOTE:
Record all DTCs.
Does the indicator light remain Repair the power Calling up the DTC
illuminated?
indicator light cir- again.
cuit <Ref. to AT28, Diagnostic
Procedure for
POWER Indicator
Light.>, or Inspect
inhibitor switch,
wiring, TCM, etc.
AT-22

The power indicator light flashes the code corresponding to faulty part.
The long segment (1.2 sec on) indicates a ten, and the short segment (0.2 sec on) signifies a one.
B3M1199B

Refer to SUBARU SELECT MONITOR for information about how to obtain and understand diagnostic
trouble codes (DTC). <Ref. to AT-20, OPERATION, Subaru Select Monitor.>
AT-23
INSPECTION MODE
8. Inspection Mode
A: OPERATION
WARNING:
brake is applied.
safety stand.
blocks or similar items between safety stands
and the vehicle.
B2M2969C
(A) Safety stand

(B) Free rollers
AT-24
CLEAR MEMORY MODE


A: OPERATION
Current diagnostic trouble codes (DTC) shown on
display are cleared by turning the ignition switch to
OFF after conducting on-board diagnostics operation. Previous diagnostic trouble codes (DTC),
however, cannot be cleared since they are stored
in the TCM memory which is operating on back-up
power supply. These diagnostic trouble codes
(DTC) can be cleared by removing the specified
fuse (located under light or left lower position of the
instrument panel).
CLEAR MEMORY:
Removal of No. 4 fuse (for at least one
minute)
The No. 4 fuse is located in the line to memory
back-up power supply of TCM. Removal of this
fuse clears the previous diagnostic trouble codes
(DTC) stored in TCM memory.
Be sure to remove the No. 4 fuse for at least the
specified length of time. Otherwise, the diagnostic
trouble codes (DTC) may not be cleared.

Refer to SUBARU SELECT MONITOR for information about how to clear trouble codes.
<Ref. to AT-21, CLEAR MEMORY MODE, OPERATION, Subaru Select Monitor.>
AT-25
POWER INDICATOR LIGHT DISPLAY

10.POWER Indicator Light Display

A: INSPECTION
When any on-board diagnostics item is malfunctioning, the display on POWER indicator light blinks
from the time malfunction is detected after starting
the engine until ignition switch is turned to OFF.
The malfunctioning part or unit can be determined
by a diagnostic trouble code (DTC) during on-board

diagnostics operation. Problems which occurred
previously can also be identified through the memory function. If the POWER indicator does not show
a problem (although a problem is occurring), the
problem can be determined by checking the performance characteristics of each sensor using select
monitor. The indicator signal is as shown in the figure.
S3M0062F
AT-26


A: LIST
DTC No.
Item
Content of diagnosis
11
Engine speed signal
Detects open or shorted input

signal circuit.
23
Mass air flow signal

(Turbo model)

signal circuit.
27

signal circuit.
31

signal circuit.
33
Front vehicle speed

sensor

signal circuit.
36
Torque converter turbine speed sensor

signal circuit.
38
Torque control signal

signal circuit.
45

(Non-turbo model)

signal circuit.
71
Shift solenoid 1
Detects open or shorted output signal circuit.
72
Shift solenoid 2
73
74
75
Line pressure duty sole- Detects open or shorted outnoid

put signal circuit.
76
77
79
93
Rear vehicle speed

sensor

signal circuit.
AT-27
Index
<Ref. to AT-42, DTC 11 ENGINE SPEED SIGNAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to AT-44, DTC 23 MASS AIR FLOW SIGNAL (TURBO MODEL), Diagnostic Procedure
<Ref. to AT-50, DTC 31 THROTTLE POSITION
<Ref. to AT-62, DTC 36 TORQUE CONVERTER
TURBINE SPEED SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to AT-66, DTC 38 TORQUE CONTROL
SIGNAL, Diagnostic Procedure with Diagnostic
<Ref. to AT-68, DTC 45 INTAKE MANIFOLD
PRESSURE SIGNAL (NON-TURBO MODEL),
Code (DTC).>
<Ref. to AT-70, DTC 71 SHIFT SOLENOID 1,
Code (DTC).>
<Ref. to AT-74, DTC 72 SHIFT SOLENOID 2,
Code (DTC).>
<Ref. to AT-78, DTC 73 LOW CLUTCH TIMING
SOLENOID, Diagnostic Procedure with Diagnostic
<Ref. to AT-82, DTC 74 2-4 BRAKE TIMING
<Ref. to AT-86, DTC 75 LINE PRESSURE DUTY
<Ref. to AT-90, DTC 76 2-4 BRAKE DUTY SOLENOID, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to AT-94, DTC 77 LOCK-UP DUTY SOLENOID, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to AT-98, DTC 79 TRANSFER DUTY
<Ref. to AT-102, DTC 93 REAR VEHICLE SPEED
DIAGNOSTIC PROCEDURE FOR POWER INDICATOR LIGHT

12.Diagnostic Procedure for POWER Indicator Light

A: POWER INDICATOR LIGHT DOES NOT COME ON OR GO OFF
DIAGNOSIS:
The POWER Indicator light circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), POWER indicator light does not illuminate.
When the on-board diagnostics is performed, POWER indicator light remains illuminated.
AT-28

WIRING DIAGRAM:
LHD MODEL
IGNITION
SBF-1
SWITCH
BATTERY
SBF-4
No.13
COMBINATION
METER
A:
i10
B:
i11
B36
i1
POWER
A7
23
B16
INHIBITOR SWITCH
1
9
10
11
B:
C:
B55
B56
C11
B12
T3
B7
T7
B1
B3
B14
B4
B5
B6
TRANSMISSION
CONTROL MODULE
T7
B12
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4
5 6 7 8
9 10 11 12
B56
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
7 8 9 10 11
1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
A:
8
9
7
16 17 18
22 23 24
B55
B36
B:
i10
1 2 3 4 5 6
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
7 8 9 10
8
9
7
16 17 18
22 23 24
i11
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
TR0400
AT-29

RHD MODEL
IGNITION
SWITCH
SBF-4
BATTERY
SBF-1
No.13
COMBINATION
METER
POWER
A:
i10
B:
i11
B38
i3
A7
22
B16
INHIBITOR SWITCH
1
3
2
10
11
4
T7
B12
B7
T3
B:
B55
C:
B56
C11
9
8
B1
B3
B14
B4
B5
B6
TRANSMISSION
CONTROL MODULE
B12
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4
5 6 7 8
9 10 11 12
A:
i10
1 2 3 4 5 6
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
B:
7 8 9 10
B56
B55
T7
8
9
7
16 17 18
22 23 24
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
8
9
7
16 17 18
22 23 24
i3
i11
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
TR0401
AT-30

1
2
Step
Turn the ignition switch to ON (engine OFF).
3)Remove the POWER indicator light bulb
from combination meter.
Perform Read Diagnostic Trouble Code
(DTC). <Ref. to AT-22, Read Diagnostic Trouble Code (DTC).>
Check
Does the POWER indicator
light illuminate?
bulb OK?
Does the POWER indicator

light blink?
Yes
Go to step 3.
No
Go to step 2.
Go to step 4.
Replace the
POWER indicator
light bulb.
A temporary poor Go to step 9.

contact of the connector or harness
may be the cause.
Repair the harness or connector
in TCM, inhibitor
switch and combination meter.
Is the fuse (No. 13) blown out? Replace the fuse Go to step 5.
CHECK FUSE (No. 13).
Remove the fuse (No. 13).
(No. 13). If
replaced fuse (No.
13) is blown out
easily, repair short
circuit in harness
between fuse (No.
13) and combination meter.
Repair the open
CHECK HARNESS CONNECTOR BETWEEN Is the voltage more than 9 V? Go to step 6.
circuit in harness
COMBINATION METER AND IGNITION
between combinaSWITCH.
tion meter and bat1)Turn the ignition switch to ON (engine OFF).
tery.
Repair the combi- Go to step 7.
nation meter.
Measure the voltage between combination
<Ref. to IDI-15,
Combination
Meter Assembly.>
CHECK OPEN CIRCUIT OF HARNESS.
Go to step 8.
Repair the open
?
circuit in harness
between TCM and
meter connector.
combination
meter, and poor
combination meter.
contact in couConnector & terminal
pling connector.
(B56) No. 11 (i11) No. 16:
Even if the
Replace the TCM.
1)Connect the connector to TCM and combinaPOWER indicator <Ref. to AT-46,
tion meter.
lights up, the cir- Transmission Con2)Turn the ignition switch to ON (engine OFF).
cuit has returned trol Module
3)Measure the voltage between TCM connecto a normal condi- (TCM).>
tion at this time. A
temporary poor
may be the cause.
in TCM.
AT-31

10
Step
Check
Yes
When each range is selected, Go to step 10.
1)Connect the Subaru Select Monitor to data does the LED of Subaru Select
link connector.
Monitor light up?
3)Turn the Subaru Select Monitor to ON.
4)Read the data of range switch using Subaru
Select Monitor.
Range switch is indicated in ON OFF.
CHECK SHORT CIRCUIT OF HARNESS.
M?
meter.
4)Measure the resistance of harness connector between TCM and chassis ground.
Connector & terminal/specified resistance
AT-32
No
Check the inhibitor switch circuit.
<Ref. to AT-119,
CHECK INHIBITOR SWITCH.,
Diagnostic Procedure for No-diagnostic Trouble
Code (DTC).>
Replace the TCM. Repair the short
<Ref. to AT-46,
circuit in harness
Transmission Con- between combinatrol Module
tion meter connec(TCM).>
tor and TCM
connector.

AT-33

B: CHECK POWER SUPPLY AND GROUND LINE

WIRING DIAGRAM:
SBF-1
BATTERY
SBF-5
LHD
RHD
NO.4
GENERATOR
SBF-4
F44
RHD
B61
LHD
RHD
B40
1
LHD
10
21
IGNITION
F45
SWITCH
DATA LINK
CONNECTOR
12
B62
B300
LHD
NO.11
4
2
13
LINE END
CHECK
CONNECTOR
B22
16
RHD
C:
B56
TCM
C19
A21
A: B54
C24
C15
A24
C1
A23
E3
16
B11
T4
LHD
: LHD MODEL
RHD : RHD MODEL
B11
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
TRANSMISSION
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
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
B22
F45
1
5
9
13
B56
B54
B40
2
6
10
14
3
7
11
15
4
8
12
16
8
9
7
16 17 18
22 23 24
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
F44
B300
1 2 3 4
5 6 7 8
1 2 3
4 5 6
8
9
7
16 17 18
22 23 24
TR0914
AT-34

1
2
Step
CHECK IGNITION SWITCH.
Check
Yes
Is the ignition switch turned to Go to step 2.
ON?
Is the voltage between 10 and Go to step 3.
15 V?
CHECK GENERATOR.
1)Start the engine.
2)Idle the engine.
3)Measure the voltage between generator and
chassis ground.
Terminal
ground ():
Is there poor contact at battery Repair or tighten
terminal?
the battery terminal.
CHECK POWER SUPPLY OF TCM.
13 V?
3)Measure the voltage between TCM connector and chassis ground.
CHECK FUSE (NO. 4).
Is the fuse (No. 4) blown out? Replace the fuse
(No. 4). If replaced
fuse (No. 4) has
blown out easily,
repair short circuit
in harness
between fuse (No.
4) and TCM.
CHECK IGNITION POWER SUPPLY CIR13 V?
CUIT.
1)Turn the ignition switch to ON (engine OFF).
2)Measure the ignition power supply voltage
between TCM connector and chassis ground.
CHECK FUSE (NO. 11).
Is the fuse (No. 11) blown out? Replace the fuse
(No. 11). If
replaced fuse (No.
11) has blown out
easily, repair short
circuit in harness
between fuse (No.
11) and TCM.
Go to step 9.
CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1
?
TCM AND TRANSMISSION.
2)Disconnect the connector from TCM and
transmission.
TCM and transmission connector.
(B56) No. 19 (B11) No. 16:
(B54) No. 21 (B11) No. 16:
AT-35
No
Turn the ignition
switch to ON.
Go to step 4.
Go to step 5.
Repair the open

circuit in harness
between fuse (No.
4) and TCM, or
fuse (No. 4) and
battery, and poor
contact in coupling connector.
Go to step 7.
Repair the open

circuit in harness
between fuse (No.
4) and TCM, or
fuse (No. 4) and
battery, and poor
Repair the open
circuit in harness
between TCM,
transmission harness connector,
and poor contact
in coupling connector.

10
Step
Check
Yes
Go to step 10.
TRANSMISSION AND TRANSMISSION
?
GROUND.
transmission and transmission ground.
(T4) No. 16 Transmission ground:
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in control Repair the conmodule power supply, ground nector.
line and data link connector?
AT-36
No
Repair the open
circuit in harness
between transmission and transmission ground.
Replace the TCM.

<Ref. to AT-46,
(TCM).>
DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION

13.Diagnostic Procedure for Select Monitor Communication

A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DIAGNOSIS:
Faulty harness connector
TROUBLE SYMPTOM:
Select monitor communication failure
AT-37

WIRING DIAGRAM:
SBF-1
BATTERY
SBF-5
LHD
RHD
NO.4
GENERATOR
SBF-4
F44
RHD
B61
LHD
RHD
B40
1
LHD
10
21
IGNITION
F45
SWITCH
DATA LINK
CONNECTOR
12
B62
B300
LHD
NO.11
4
2
13
LINE END
CHECK
CONNECTOR
B22
16
RHD
C:
B56
TCM
C19
A21
A: B54
C24
C15
A24
C1
A23
E3
16
B11
T4
LHD
: LHD MODEL
RHD : RHD MODEL
B11
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
TRANSMISSION
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
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
B22
F45
1
5
9
13
B56
B54
B40
2
6
10
14
3
7
11
15
4
8
12
16
8
9
7
16 17 18
22 23 24
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
F44
B300
1 2 3 4
5 6 7 8
1 2 3
4 5 6
8
9
7
16 17 18
22 23 24
TR0914
AT-38

Step
Check
Yes
CHECK SUBARU SELECT MONITOR POW- Is the voltage more than 10V? Go to step 2.
ER SUPPLY CIRCUIT.
Measure the voltage between data link connector and chassis ground.
CHECK SUBARU SELECT MONITOR

GROUND CIRCUIT.
data link connector and chassis ground.
CHECK COMMUNICATION OF SELECT

MONITOR.
2)Using the Subaru Select Monitor, check
whether communication to engine systems can
be executed normally.
MONITOR.
2)Disconnect the TCM connector.
3)Check whether communication to engine
systems can be executed normally.
MONITOR.
2)Connect the TCM connector.
3)Disconnect the ECM connector.
4)Check whether communication to transmission systems can be executed normally.
EACH CONTROL MODULE AND DATA LINK
CONNECTOR.
2)Disconnect the TCM, ECM, ABSCM&H/U,
cruise control module and immobilizer control
module connectors.
3)Measure the resistance between TCM connector and chassis ground.
CHECK OUTPUT SIGNAL FOR TCM.
chassis ground.
CHECK HARNESS/CONNECTOR BETWEEN
TCM AND DATA LINK CONNECTOR.
Measure the resistance between TCM connector and data link connector.
(B56) No. 15 (B40) No. 10:
Are the name and year of sys- Go to step 8.

tem displayed on Subaru
Select Monitor?
No
Repair the harness 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
ground terminal,
and poor contact
Go to step 4.

Select Monitor?
Go to step 5.
Are the name and year of sys- Inspect the ECM.

Select Monitor?
Go to step 6.

?
Repair the harness and connector between each

control module
and data link connector.

ness and connector between each
control module
Is the resistance less than 0.5 Go to step 9.

?
AT-39
Repair the harness and connector between TCM


10
11
Step
TCM AND DATA LINK CONNECTOR.
Measure the resistance between TCM and
(B56) No. 24 (B40) No. 6:
CHECK INSTALLATION OF TCM CONNECTOR.
CHECK POOR CONTACT IN CONNECTORS.
Check
Yes
?
No
Repair the harness and connector between TCM
Is the TCM connector inserted Go to step 11.

into TCM?
Insert the TCM

connector into
TCM.
Replace the TCM.
<Ref. to AT-46,
(TCM).>
Is there poor contact in control Repair the poor

module and data link connec- contact.
tor?
AT-40

AT-41


A: DTC 11 ENGINE SPEED SIGNAL
DIAGNOSIS:
The engine speed input signal circuit is open or shorted.
TROUBLE SYMPTOM:
No lock-up (after engine warm-up).
The POWER indicator light remains on when vehicle speed is 0.
WIRING DIAGRAM:
TCM
NA
TB
: B134
ECM
8
9
7
16 17 18
22 23 24
NA
: NON TURBO MODEL
TB
: TURBO MODEL
: B136
B134 : NA
B55
5 6
1 2 3 4
10 11 12 13 14 15
19 20 21
30
NA TB
19
17
B55
5 6
7 8
1 2
3 4
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
30 31 32 33
34 35
24 25
26 27 28 29
B136 : TB
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
TR0915
AT-42

3
4
6
7
Step
TCM AND ECM.
ECM.
TCM and ECM connector.
Non-turbo model
(B55) No. 17 (B134) No. 30:
Turbo model
(B55) No. 17 (B136) No. 9:
TCM AND ECM.
TCM connector and chassis ground.
PREPARE SUBARU SELECT MONITOR.
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.
Do you have a Subaru Select

Monitor?
V?
Go to step 5.
Go to step 4.
Even if the
Go to step 6.
POWER indicator
lights up, the circuit has returned
to a normal condition at this time. A
temporary poor
may be the cause.
in TCM and ECM.
CHECK INPUT SIGNAL FOR TCM USING
Is the revolution value same as Even if the
Go to step 6.
SUBARU SELECT MONITOR.
tachometer reading shown on POWER indicator
1)Connect the connectors to TCM and ECM. combination meter?
lights up, the cir2)Connect the Subaru Select Monitor to data
cuit has returned
link connector.
to a normal condi3)Start the engine and turn Subaru Select
Monitor switch to ON.
temporary poor
contact of the contemperature is above 80C (176F).
nector or harness
5)Idle the engine.
may be the cause.
6)Read the data of engine speed using Subaru
Repair the harSelect Monitor.
ness or connector
Display shows the engine speed signal value
in TCM and ECM.
sent from ECM.
CHECK POOR CONTACT.
Is there poor contact in engine Repair the poor
Go to step 7.
speed signal circuit?
contact.
CONFIRM DTC 11.
Replace the ECM with a new Replace the TCM. Replace the ECM.
one. Does the DTC appear
<Ref. to AT-46,
again, after memory has been Transmission Concleared?
trol Module
(TCM).>

1)Connect the connectors to TCM and ECM.
AT-43

B: DTC 23 MASS AIR FLOW SIGNAL (TURBO MODEL)

DIAGNOSIS:
The input signal circuit of TCM from ECM is open or shorted.
TROUBLE SYMPTOM:
Excessive shift shock.
WIRING DIAGRAM:
28
B135 ECM
B54
B135
B54
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
TCM
8
9
7
16 17 18
22 23 24
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
TR0573
Step
CHECK ENGINE GROUND TERMINALS AND
GROUND CIRCUIT OF ECM.
<Ref. to AT-50, DTC 31 THROTTLE POSITION SENSOR, Diagnostic Procedure with
TCM AND ECM.
ECM.
(B54) No. 1 (B135) No. 28:
TCM AND ECM.
Check
Is there any trouble?
Yes
No
terminal and/or
ground circuit of
ECM.

?
Go to step 3.
Repair the open

circuit in harness
between TCM and
ECM connector.

M?
Go to step 4.
Repair the short

circuit in harness
between TCM and
ECM connector.

Monitor?
Go to step 6.
Go to step 5.
AT-44

Step
2)Start the engine and warm-up the transmission until ATF temperature is above 80C
(176F).
Check
Yes
No
Is the voltage between 0.9 and Even if the AT OIL Go to step 7.
1.4 V?
TEMP warning
NOTE:
temporary poor
If ambient temperature is below 0C (32F),
contact of the condrive the vehicle until ATF reaches its operating
nector or harness
temperature.
may be the cause.
3)Idle the engine.
Repair harness or
4)Measure the voltage between TCM connecconnector in the
TCM and ECM.
Is the value voltage between
0.9 and 1.4 V?
2)Connect the Subaru Select Monitor to data
link connector.
3)Start the engine and turn the Subaru Select
temperature is above 80C (176F).
5)Idle the engine.
Display shows the mass air flow sensor signal
value sent from ECM.
CHECK POOR CONTACT.
Is there poor contact in intake
manifold pressure signal circuit?
AT-45
Even if the AT OIL Go to step 7.

TEMP warning
temporary poor
may be the cause.
Repair harness or
connector in the
TCM and ECM.
Repair the poor
contact.
Replace the TCM.

<Ref. to AT-46,
(TCM).>

C: DTC 27 ATF TEMPERATURE SENSOR

DIAGNOSIS:
The input signal circuit of TCM to ATF temperature sensor is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
TCM
20
11
B54
12
11
B11
AT1
ATF TEMPERATURE
SENSOR
T4
TRANSMISSION
AT1
B11
2 1
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
1 2
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
S3M0626
Step
Check
TCM AND ATF TEMPERATURE SENSOR.
?
and TCM.
(B54) No. 20 (B11) No. 12:
AT-46
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and
transmission connector.

7
8
Step
(B54) No. 11 (B11) No. 11:
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 ATF temperature reaches to 80C (176F).
NOTE:
drive the vehicle until ATF reaches its operating
temperature.
5)Disconnect the connector from transmission.
6)Measure the resistance between transmission connector terminals.
(T4) No. 11 No. 12:
CHECK ATF TEMPERATURE SENSOR.
2)Measure the resistance between transmission connector terminals.
(T4) No. 11 No. 12:
1)Connect the connector to transmission.
2)Warm-up the transmission until ATF temperature is about 80C (176F).
NOTE:
temperature.
3)Measure the voltage between TCM connector terminal.
(B54) No. 11 (+) No. 20 ():
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

M?
Go to step 5.
Repair the short

circuit in harness
between TCM and

and 375 ?
Go to step 11.
Does the resistance value

increase while ATF temperature decreases?
Go to step 11.
Go to step 7.
Do you have a Subaru Select Go to step 9.

Go to step 8.
Monitor?
Is the voltage between 0.4 and Even if the
Go to step 10.
0.9 V?
POWER indicator
to a normal condition at this time.
Temporary poor
may be the cause.
Repair the harness or contact in
ATF temperature
sensor and transmission connector.
AT-47

Step
Check
Does the ATF temperature
gradually decrease?
1)Connect the connector to transmission.
10
CHECK POOR CONTACT.
Is there poor contact in ATF

11

TRANSMISSION AND ATF TEMPERATURE ?
SENSOR.
3)Remove the transmission connector from
bracket.
4)Lift-up the vehicle and place safety stand.
Yes
No
Even if the
Go to step 10.
POWER indicator
to a normal condition at this time.
Temporary poor
may be the cause.
ATF temperature
sensor and transmission connector.
Repair the poor
Replace the TCM.
contact.
<Ref. to AT-46,
(TCM).>
Go to step 12.
Repair the open
circuit in harness
between ATF temperature sensor
and transmission
connector.
NOTE:
On AWD models, raise all wheels off ground.
5)Drain the ATF.
12
13
CAUTION:
Do not drain the ATF until it cools down.
6)Remove the oil pan, and disconnect the connector from ATF temperature sensor connector.
ATF temperature sensor and transmission
connector.
(T4) No. 11 (AT1) No. 2:
TRANSMISSION AND ATF TEMPERATURE
SENSOR.
ATF temperature sensor and transmission
connector.
(T4) No. 12 (AT1) No. 1:
TRANSMISSION AND ATF TEMPERATURE
SENSOR.
transmission connector and transmission
ground.

?
Go to step 13.
Repair the open

circuit in harness
and transmission
connector.

M?
Go to step 14.
Repair the short

circuit in harness
and transmission
connector.
AT-48

14
Step
Check
CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1
TRANSMISSION AND ATF TEMPERATURE M?
SENSOR.
ground.
AT-49
Yes
Replace the ATF
temperature sensor. <Ref. to AT40, Shift Solenoids, Duty Solenoids and ATF
No
Repair the short
circuit in harness
and transmission
connector.

D: DTC 31 THROTTLE POSITION SENSOR

DIAGNOSIS:
The input signal circuit of throttle position sensor is open or shorted.
TROUBLE SYMPTOM:
Shift point too high or too low; excessive shift shock; excessive tight corner braking.
AT-50

WIRING DIAGRAM:
NON-TURBO MODEL
B21
B22
14
16
13
15
LHD
12
11
9
RHD
E2
WO OO
B6 B6
A27 A27
C21 C21
ECM
C22 C22
C: B136
A35
A8 A8
C17 C17
C15 C15
C16 C16
B: B135
A7 A7
A34
A: B134
TCM
2
3
B54
E3
WO
LHD
OO
RHD
E13
OO : WITHOUT OBD MODEL
THROTTLE
POSITION SENSOR
B83
B83
SHIELD AND
SENSOR GROUND
JOINT CONNECTOR
B122
SHIELD AND
SENSOR GROUND
JOINT CONNECTOR
: WO
E13
1 2 3 4
OO WO
4
3
1
1
WO OO
2
5
4
1
4
3
2
WO : WITH OBD MODEL
B83
: OO
1 2 3 4 5 6 7 8 9 10 11 12
B136
4 5
6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
29 30
23 24 25
26 27 28
21 22
B22
B21
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
8
6 7
9 10
11 12
14 15
16
13
17 18
19 20
1
B134
B54
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
B122
8
9
7
16 17 18
22 23 24
1 2 3
4 5 6
B135
5 6
7 8
1 2
3 4
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
32
33
34 35
30 31
24 25
26 27 28 29
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
22 23
24 25 26
20 21
27 28
TR0916
AT-51

TURBO MODEL
A: B134
B: B135
C: B136
D: B137
E:
B84
E1
A7
A15
D8
C18
D9
2
3
C8
B7
B9
B19
TCM
C17
A22
ECM
B54
16
14
15
13
B22
E3
20
19
18
B21
E2
1
3
2
E13
B83
3
1
SHIELD AND
SENSOR GROUND
JOINT CONNECTOR
THROTTLE
POSITION SENSOR
E13
B134
B136
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
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
1 2 3 4 5 6
B21
B22
B83
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
3 4
8
6 7
9 10
11 12
14 15
16
13
17 18
19 20
1
B137
B54
1 2 3 4
5 6
10 11 12 13 14 15
19 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 31
B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
B135
8
9
7
16 17 18
22 23 24
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
TR0917
AT-52

1
2
Step
CHECK ENGINE GROUND TERMINALS.
NON-TURBO MODEL WITH OBD MODEL
NON-TURBO MODEL WITHOUT OBD
MODEL
TURBO MODEL
CHECK THROTTLE POSITION SENSOR.
2)Measure the resistance between throttle
position sensor connector receptacle's terminals.
Terminals
NON-TURBO MODEL
No. 4 No. 2:
TURBO MODEL
No. 1 No. 2:
CHECK THROTTLE POSITION SENSOR.
Measure the resistance between throttle position sensor connector receptacle's terminals.
Terminals
No. 2 No. 3:
TCM AND THROTTLE POSITION SENSOR.
TCM and throttle position sensor connector.
(B55) No. 3 (E13) No. 3:
Check
Yes
Have engine ground terminals Go to step 2.
been tightened?
Go to step 3.
?
No
Tighten the engine
ground terminals.
Repair the open
circuit in harness
between ECM
connector and
engine grounding
terminal.

and 4.2 k?
Go to step 4.

and 0.5 k?

?
Repair the open

circuit in harness
between TCM and
throttle position
sensor connector,
and poor contact
AT-53
Go to step 6.

10
11
12
13
Step
TCM and throttle position sensor connector.
NON-TURBO MODEL
(B54) No. 2 (E13) No. 4:
TURBO MODEL
(B54) No. 2 (E12) No. 1:
TCM AND ECM.
NON-TURBO MODEL
(B54) No. 3 (B136) No. 17:
TURBO MODEL
(B54) No. 3 (B135) No. 7:
TCM AND ECM.
NON-TURBO MODEL
(B54) No. 2 (B136) No. 15:
TURBO MODEL
(B54) No. 2 (B135) No. 9:
Check
?
Yes
Go to step 7.
No
Repair the open
circuit in harness
between TCM and
throttle position
sensor connector,
and poor contact

M?
Go to step 8.
Repair the short

circuit in harness
between TCM and
throttle position
sensor connector.

M?
Go to step 9.
Repair the short

circuit in harness
between TCM and
throttle position
sensor connector.

?
Go to step 10.
Repair the open

circuit in harness
between TCM and
ECM connector.

?
Go to step 11.
Repair the open

circuit in harness
between TCM and
ECM connector.

Monitor?
1.0 V in throttle fully closed?

1)Connect the connectors to TCM, throttle
position sensor and ECM.
3)Close the throttle completely.
1)Open the throttle completely.
4.7 V with throttle fully open?
AT-54
Go to step 12.
Go to step 18.
Go to step 18.

14
15
16
17
18
Step
1)Connect the connectors to TCM, throttle
position sensor and ECM.
link connector.
4)Turn the Subaru Select Monitor switch to
ON.
5)Throttle fully closed.
6)Read the data of throttle position sensor
Throttle position sensor input signal is indicated.
Check
0.2 and 1.0 V?
Yes
Go to step 15.
No
Go to step 18.

4.2 and 4.7 V?
Go to step 18.
Go to step 17.
NOTE:
Must be changed correspondingly with the accelerator pedal operation (from released to
depressed position).
CHECK INPUT SIGNAL FOR TCM (THROT- Is the voltage between 4.8 and
TLE POSITION SENSOR POWER SUPPLY). 5.3 V?
Measure the voltage between TCM connector
and chassis ground.
Even if the
POWER indicator
temporary poor
may be the cause.
in throttle position
sensor circuit.
Even if the
SUBARU SELECT MONITOR (THROTTLE
4.8 and 5.3 V?
POWER indicator
POSITION SENSOR POWER SUPPLY).
lights up, the cirRead the data of throttle position sensor power
cuit has returned
supply using Subaru Select Monitor.
to a normal condiThrottle position sensor power supply voltage
is indicated.
temporary poor
may be the cause.
in throttle position
sensor circuit.
CHECK POOR CONTACT.
contact.
AT-55
Go to step 18.
Go to step 18.
Replace the TCM.

<Ref. to AT-46,
(TCM).>

AT-56

E: DTC 33 FRONT VEHICLE SPEED SENSOR

DIAGNOSIS:
The vehicle speed signal is abnormal.
The circuit in combination meter is faulty.
The harness connector between TCM and vehicle speed sensor is in short or open.
TROUBLE SYMPTOM:
Erroneous idling.
Engine stalls.
Poor driving performance.
AT-57

WIRING DIAGRAM:
TCM
B54
B:
B55
C:
B56
C17
B18
A10
A:
SHIELD AND
SENSOR GROUND
JOINT CONNECTOR
RT RN LH
3
6
6
4
1
4
5
2
5
B37
B11
17
18
*1
B53
i2
LH
: LHD MODEL
RN
: RHD NON-TURBO MODEL
RT
: RHD TURBO MODEL
T4
: LHD : 9
: RHD : 7
COMBINATON
SPEEDOMETER
B53
LH
RN
1 2 3 4 5 6 7 8 9 10 11 12
METER
FRONT
VEHICLE SPEED
i10
SENSOR
B53
1 2 3
: RT
i10
B11
3 4
8
6 7
9 10
11 12
14 15
16
13
17 18
19 20
1
4 5 6
1 2 3 4 5 6
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
8
9
7
16 17 18
22 23 24
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
7 8 9 10
B56
B55
B54
8
9
7
16 17 18
22 23 24
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
: LH
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
i2
8
9
7
16 17 18
22 23 24
RN
RT
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
TR0918
AT-58

6
7
8
Step
transmission.
(B55) No. 18 (B11) No. 17:
(B54) No. 10 (B11) No. 18:
CHECK FRONT VEHICLE SPEED SENSOR.
connector receptacle's terminals.
(T4) No. 17 No. 18:
PREPARE OSCILLOSCOPE.
2)Lift-up or raise the vehicle and place safety
stands.
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
transmission connector, and poor
Repair the short
circuit in harness
between TCM and

M?
Go to step 5.

and 650 ?
Do you have an oscilloscope?

Monitor?
Is the voltage more than AC 1
V?
NOTE:
On AWD models, raise all wheels off floor.
3)Start the engine and set vehicle in 20 km/h
(12 MPH) condition.
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-22, Clear Memory
Mode.>
4)Measure the voltage between TCM connector terminals.
(B55) No. 18 (+) (B54) No. 10 ():
AT-59
Go to step 9.
Go to step 10.
Repair the short

circuit in harness
between TCM and
Replace the front
vehicle speed sensor. <Ref. to AT32, Front Vehicle
Speed Sensor.>
Go to step 7.
Go to step 8.
Even if the
Go to step 11.
POWER indicator
temporary poor
contact or harness may be the
cause. Repair the
harness or connector in the front
vehicle speed sensor circuit.

10
Step
USING OSCILLOSCOPE.
Check
Yes
No
Is the voltage more than AC 4 Even if the
Go to step 11.
V?
POWER indicator
to a normal condiNOTE:
temporary poor
3)Set the oscilloscope to TCM connector termicontact or harnals.
ness may be the
cause. Repair the
Positive probe; (B55) No. 18
harness or conEarth lead; (B54) No. 10
nector in front
1)Start the engine, and drive the wheels
vehicle speed senslowly.
sor circuit.
NOTE:
indicates no malfunctions. When AT control diagnosis is finished, perform the ABS memory
<Ref. to ABS-22, Clear Memory Mode.>
oscilloscope.
Does the speedometer indica- Even if the
Go to step 11.
tion increase as Subaru Select POWER indicator
Monitor data increases?
lights up, the cir2)Connect the Subaru Select Monitor to data
cuit has returned
link connector.
to a normal condi3)Lift-up or raise the vehicle and place safety
stands.
temporary poor
connector or harNOTE:
ness may be the
cause. Repair the
4)Turn the ignition switch to ON and turn Subharness or conaru Select Monitor switch to ON.
nector in front
5)Start the engine.
vehicle speed sen6)Read the data of vehicle speed using Subaru
sor circuit.
Select Monitor.
Compare the speedometer with Subaru
Select Monitor indications.
Vehicle speed is indicated in km/h or MPH.
7)Slowly increase the vehicle speed to 60 km/h
or 37 MPH.
11
NOTE:
Mode.>
CHECK POOR CONTACT.
AT-60
Repair the poor

contact.
Replace the TCM.

<Ref. to AT-46,
(TCM).>

AT-61

F: DTC 36 TORQUE CONVERTER TURBINE SPEED SENSOR

DIAGNOSIS:
The input signal circuit of TCM is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
TCM
8
9
B55
SHIELD
9
3
3
1
7
1
8
2
2
LH RN RT
JOINT
CONNECTOR
B53
14
15
B11
LH
: LHD MODEL
RN
RT
: RHD TURBO MODEL
T4
TORQUE
CONVERTER
TURBINE SPEED
SENSOR
B11
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
B53
B55
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
LH
1 2 3 4 5 6 7 8 9 10 11 12
8
9
7
16 17 18
22 23 24
B53
RT
RN
1 2 3 4 5 6
TR0919
AT-62

Step
SPEED SENSOR.
3)Measure the resistance between transmission connector receptacle's terminals.
(T4) No. 14 No. 15:
(B55) No. 8 (B11) No. 14:
(B55) No. 9 (B11) No. 15:
6
7

1)Connect the connectors to TCM and transmission.
2)Start the engine and move select lever to P
or N range.
(B55) No. 8 (+) No. 9 ():
Check
Yes
and 650 ?
No
Replace the turbine speed sensor. <Ref. to AT37, Torque Converter Turbine
Speed Sensor.>

?
Go to step 3.
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
Repair the short
circuit in harness
between TCM and

M?
Go to step 6.

Monitor?
V?
Go to step 10.
Go to step 9.
AT-63
Repair the short

circuit in harness
between TCM and
Go to step 7.
Go to step 8.
Even if the
Go to step 11.
POWER indicator
temporary poor
may be the cause.
in TCM and transmission.

10
11
Step
link connector.
3)Turn the ignition switch to ON and turn Subaru Select Monitor switch to ON.
4)Start the engine.
5)Move 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.
OSCILLOSCOPE.
2)Set the oscilloscope to TCM connector terminals.
Earth lead; (B55) No. 9
3)Start the engine and move select lever to P
or N range.
CHECK POOR CONTACT.
Check
Yes
Is the revolution value same as Even if the
the tachometer reading shown POWER indicator
on the combination meter?
temporary poor
may be the cause.
Is the signal voltage more than Even if the
AC 1 V?
POWER indicator
temporary poor
may be the cause.
Is there poor contact in torque Repair the poor
converter turbine speed sensor contact.
circuit?
AT-64
No
Go to step 11.
Go to step 11.
Replace the TCM.

<Ref. to AT-46,
(TCM).>

AT-65

G: DTC 38 TORQUE CONTROL SIGNAL

DIAGNOSIS:
The signal circuit is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
TCM
14
5
B56
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
B135
TB
B134
B135
8
9
7
16 17 18
22 23 24
: NON-TURBO MODEL
TB
: TURBO MODEL
TB NA
17
16
18
19
B56
NA
NA
ECM
B134
NA
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21
22 23
24 25 26
27 28
TB
1 2 3 4 5
6 7
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
TR0920
Step
TCM AND ECM.
ECM.
NON-TURBO MODEL
(B56) No. 14 (B135) No. 17:
(B56) No. 5 (B135) No. 16:
TURBO MODEL
(B56) No. 14 (B134) No. 18:
(B56) No. 5 (B134) No. 19:
TCM AND ECM.
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.
AT-66

4
5
Step
Check
CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage more than 4.8 V?
TCM.
Yes
No
Even if the
Go to step 4.
POWER indicator
temporary poor
may be the cause.
in TCM and ECM.
CHECK POOR CONTACT.
Is there poor contact in torque Repair the poor
Go to step 5.
control signal circuit?
contact.
CHECK GROUND LINE BETWEEN TRANS- Is there any dirt or rust at the Remove dirt and Go to step 6.
MISSION AND BODY.
ground line installing point?
rust.
Check installing condition of the ground line in
transmission and body.
CHECK GROUND LINE BETWEEN TRANS- Is the tightening torque value Go to step 7.
Tighten to the
MISSION AND BODY.
within specification?
specified torque.
Check installing condition of the ground line in
transmission and body.
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
CHECK GROUND LINE INSIDE TRANSMIS- Is the tightening torque value Go to step 9.
Tighten to the
SION.
within specification?
specified torque.
1)Drain the ATF and remove oil pan.
2)Check the tightening torque value of ground
line installing bolt.
Tightening torque:
T: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
terminal and/or
ground circuit of
ECM.
Is each voltage more than 4 V? Replace the TCM. Replace the ECM.
RECHECK OUTPUT SIGNAL EMITTED
<Ref. to AT-46,
FROM TCM.
Transmission ConMeasure the voltage between TCM connector
trol Module
and chassis ground.
(TCM).>
AT-67

H: DTC 45 INTAKE MANIFOLD PRESSURE SIGNAL (NON-TURBO MODEL)

DIAGNOSIS:
The input signal circuit of TCM from ECM is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
11
B136 ECM
B54
B136
B54
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
TCM
8
9
7
16 17 18
22 23 24
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
26 27
21 22
23 24 25
28 29 30
TR0921
Step
CHECK ENGINE GROUND TERMINALS AND
GROUND CIRCUIT OF ECM
TCM AND ECM.
ECM.
(B54) No. 1 (B136) No. 11:
TCM AND ECM.
Check
Yes
No
terminal and/or
ground circuit of
ECM.

?
Go to step 3.
Repair the open

circuit in harness
between TCM and
ECM connector.

M?
Go to step 4.
Repair the short

circuit in harness
between TCM and
ECM connector.

Monitor?
Go to step 6.
Go to step 5.
AT-68

Step
Check
Is the voltage between 0.4 and
1)Connect the connectors to TCM and ECM. 1.6 V?
2)Start the engine, and warm-up the transmission until ATF temperature is above 80C
(176F).
NOTE:
temperature.
3)Idle the engine.
0.4 and 1.6 V?
link connector.
3)Start the engine, and turn Subaru Select
temperature is above 80C (176F).
5)Idle the engine.
signal using Subaru Select Monitor.
Display shows the intake manifold pressure
signal value sent from ECM.
CHECK POOR CONTACT.
Is there poor contact in intake
manifold pressure signal circuit?
AT-69
Yes
No
Even if the
Go to step 7.
POWER indicator
temporary poor
may be the cause.
in TCM and ECM.
Even if the
Go to step 7.
POWER indicator
temporary poor
may be the cause.
in TCM and ECM.
Repair the poor
contact.
Replace the TCM.

<Ref. to AT-46,
(TCM).>

I:
DTC 71 SHIFT SOLENOID 1
DIAGNOSIS:
The output signal circuit of shift solenoid 1 is open or shorted.
TROUBLE SYMPTOM:
Does not shift.
WIRING DIAGRAM:
TCM
22
B54
B11
T4
AT5
SHIFT
SOLENOID 1
TRANSMISSION
B11
1 2
B54
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
TR0410
Step
Check
?
transmission.
TCM and shift solenoid 1 connector.
(B54) No. 22 (B11) No. 1:
AT-70
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

Step
CHECK SHIFT SOLENOID 1.
connector terminals.
(T4) No. 1 No. 16:
CHECK OUTPUT SIGNAL EMITTED FROM
TCM.
3)Move the select lever to D range.
TCM.
1)Turn the HOLD mode switch to ON.
Check
M?
Yes
Go to step 3.
No
Repair the short
circuit in harness
between TCM and

and 16 ?
Go to step 4.
Go to step 7.
Is the voltage more than 9V?
Go to step 5.
Go to step 6.
Is the voltage less than 1V?
Even if the
Go to step 6.
POWER indicator
temporary poor
may be the cause.
TCM.
Repair poor con- Replace the TCM.
tact.
<Ref. to AT-46,
(TCM).>
Go to step 8.
Replace the shift
solenoid 1. <Ref.
to AT-40, Shift
Solenoids, Duty
Solenoids and
ATF Temperature
Sensor.>
CHECK POOR CONTACT.
Is there poor contact in shift

solenoid 1 circuit?
CHECK SHIFT SOLENOID 1 (IN TRANSMIS- Is the resistance between 10

and 16 ?
SION).
bracket.
2)Lift-up or raise the vehicle and support with
safety stand.
NOTE:
3)Drain the ATF.
CAUTION:
4)Remove the oil pan, and disconnect connector from shift solenoid 1.
5)Measure the resistance between shift solenoid 1 connector and transmission ground.
Terminal
No. 1 Transmission ground:
AT-71

Step
SHIFT SOLENOID 1 AND TRANSMISSION.
shift solenoid 1 and transmission connector.
(AT5) No. 1 (T4) No. 1:
shift solenoid 1 connector and transmission
ground.
Check
?
Yes
Go to step 9.
No
Repair the open
circuit in harness
between shift solenoid 1 and transmission connector.

M?
Even if the
POWER indicator
temporary poor
may be the cause.
in shift solenoid 1
and transmission.
Repair the short

circuit harness
AT-72

AT-73

J: DTC 72 SHIFT SOLENOID 2

DIAGNOSIS:
The output signal circuit of shift solenoid 2 is open or shorted.
TROUBLE SYMPTOM:
Does not shift.
WIRING DIAGRAM:
B54 TCM
B11
T4
AT6
SHIFT
SOLENOID 2
TRANSMISSION
B11
1 2
3
6 7
9 10
11
13
14 15
17 18
19
5
B54
4
8
12
16
20
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7 8
16 17
22 23
9
18
24
TR0411
Step
Check
?
transmission.
TCM and shift solenoid 2 connector.
(B54) No. 5 (B11) No. 2:
AT-74
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

Step
TCM connector and transmission ground.
CHECK SHIFT SOLENOID 2.
(T4) No. 2 No. 16:
TCM.
safety stand.
Check
M?
Yes
Go to step 3.
No
Repair the short
circuit in harness
between TCM and

and 16 ?
Go to step 4.
Go to step 6.
Even if the
Go to step 5.
POWER indicator
temporary poor
may be the cause.
NOTE:
(176F).
NOTE:
temperature.
4)Move the selector lever to D range, and
MPH).
NOTE:
Mode.>
CHECK POOR CONTACT.
Is there poor contact in shift
solenoid 2 circuit?
CHECK SHIFT SOLENOID 2 (IN TRANSMIS- Is the resistance between 10

SION).
and 16 ?
bracket.
2)Drain the ATF.
CAUTION:
3)Remove the oil pan, and disconnect connector from shift solenoid 2.
4)Measure the resistance between shift solenoid 2 connector and transmission ground.
AT-75
Repair the poor

contact.
Go to step 7.
Replace the TCM.

<Ref. to AT-46,
(TCM).>
Replace the shift
solenoid 2 assembly. <Ref. to AT40, Shift Solenoids, Duty Solenoids and ATF

Step
shift solenoid 2 and transmission connector.
(AT6) No. 1 (T4) No. 2:
shift solenoid 2 connector and transmission
ground.
Check
?
Yes
Go to step 8.
No
Repair the open
circuit in harness

M?
Even if the
POWER indicator
temporary poor
may be the cause.
in shift solenoid 2
and transmission.
Repair the short

circuit harness
AT-76

AT-77

K: DTC 73 LOW CLUTCH TIMING SOLENOID

DIAGNOSIS:
The output signal circuit of low clutch timing solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
15
B54 TCM
B11
T4
AT9
LOW CLUTCH
TIMING
SOLENOID
TRANSMISSION
B11
1 2
B54
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7 8
16 17
22 23
9
18
24
TR0412
Step
Check
?
transmission.
(B54) No. 15 (B11) No. 3:
AT-78
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

Step
CHECK LOW CLUTCH TIMING SOLENOID.
(T4) No. 3 No. 16:
TCM.
3)Move the select lever to D range.
TCM.
1)Turn the HOLD mode switch to ON.
Check
M?
Yes
Go to step 3.
No
Repair the short
circuit in harness
between TCM and

and 16 ?
Go to step 4.
Go to step 7.
Go to step 5.
Go to step 6.
Even if the
Go to step 6.
POWER indicator
temporary poor
may be the cause.
TCM and transmission.
Repair the poor
Replace the TCM.
contact.
<Ref. to AT-46,
(TCM).>
Go to step 8.
Replace the low
clutch timing solenoid. <Ref. to AT40, Shift Solenoids, Duty Solenoids and ATF
CHECK POOR CONTACT.
Is there poor contact in low

clutch timing solenoid circuit?
CHECK LOW CLUTCH TIMING SOLENOID

(IN TRANSMISSION).
bracket.
safety stand.

and 16 ?
NOTE:
3)Drain the ATF.
CAUTION:
4)Remove the oil pan, and disconnect connector from low clutch timing solenoid.
5)Measure the resistance between low clutch
timing solenoid connector and transmission
ground.
Terminal
AT-79

Step
LOW CLUTCH TIMING SOLENOID AND
TRANSMISSION.
low clutch timing solenoid and transmission
connector.
(AT9) No. 1 (T4) No. 3:
LOW CLUTCH TIMING SOLENOID AND
TRANSMISSION.
low clutch timing solenoid connector and transmission ground.
Check
?
Yes
Go to step 9.
No
Repair the open
circuit in harness
between low
clutch timing solenoid and transmission connector.

M?
Even if the
POWER indicator
temporary poor
may be the cause.
in low clutch timing
solenoid and
transmission.
Repair the short

circuit harness
between low
clutch timing solenoid and transmission connector.
AT-80

AT-81

L: DTC 74 2-4 BRAKE TIMING SOLENOID

DIAGNOSIS:
The output signal circuit of 2-4 brake timing solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
16
B54 TCM
B11
T4
AT8
2-4 BRAKE
TIMING
SOLENOID
TRANSMISSION
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7 8
16 17
22 23
9
18
24
TR0413
Step
Check
?
transmission.
(B54) No. 16 (B11) No. 4:
AT-82
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

Step
(B54) No. 16 Transmission ground:
CHECK 2-4 BRAKE TIMING SOLENOID.
(T4) No. 4 No. 16:
TCM.
safety stand.
Check
M?
Yes
Go to step 3.
No
Repair the short
circuit in harness
between TCM and

and 16 ?
Go to step 4.
Go to step 7.
Go to step 5.
Go to step 6.
NOTE:
(176F).
NOTE:
temperature.
4)Move the selector lever to 1 range, and
MPH).
NOTE:
Mode.>
CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage more than 9 V?
TCM.
1)Move the selector lever to D range, and
MPH).
NOTE:
Mode.>
AT-83
Even if the
Go to step 6.
POWER indicator
temporary poor
may be the cause.
transmission.

Step
CHECK POOR CONTACT.
Check
Is there poor contact in 2-4
brake timing solenoid circuit?
Yes
Repair the poor
contact.
CHECK 2-4 BRAKE TIMING SOLENOID (IN

TRANSMISSION).
bracket.
safety stand.

and 16 ?
Go to step 8.

?
Go to step 9.
Repair the open

circuit in harness
between 2-4 brake
timing solenoid
and transmission
connector.

M?
Even if the
POWER indicator
temporary poor
may be the cause.
in 2-4 brake timing solenoid and
transmission.
Repair the short

circuit harness
between 2-4 brake
timing solenoid
and transmission
connector.
NOTE:
3)Drain the ATF.
CAUTION:
4)Remove the oil pan, and disconnect connector from 2-4 brake timing solenoid.
5)Measure the resistance between 2-4 brake
timing solenoid connector and transmission
ground.
Terminal
2-4 BRAKE TIMING SOLENOID AND
TRANSMISSION.
Measure the resistance of harness between 24 brake timing solenoid and transmission connector.
(AT8) No. 1 (T4) No. 4:
2-4 BRAKE TIMING SOLENOID AND
TRANSMISSION.
Measure the resistance of harness between 24 brake timing solenoid connector and transmission ground.
AT-84
No
Replace the TCM.
<Ref. to AT-46,
(TCM).>
Replace the 2-4
brake timing solenoid. <Ref. to AT40, Shift Solenoids, Duty Solenoids and ATF

AT-85

M: DTC 75 LINE PRESSURE DUTY SOLENOID

DIAGNOSIS:
The output signal circuit of line pressure duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
TCM
B54
B11
T4
AT2
LINE
PRESSURE
DUTY
SOLENOID
TRANSMISSION
B11
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
B54
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
8
9
7
16 17 18
22 23 24
TR0414
Step
and TCM.
(B54) No. 9 (B11) No. 5:
TCM AND CHASSIS GROUND.
CHECK LINE PRESSURE DUTY SOLENOID.
Terminal
(T4) No. 5 No. 16:
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

and 4.5 ?
Go to step 4.
Go to step 10.

Monitor?
Go to step 7.
Go to step 5.
AT-86

Step
TCM.
(176F).
Check
Yes
5.0 V with throttle fully closed?
NOTE:
temperature.
4)Move the select lever to N range.
CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage less than 1 V
TCM.
with throttle fully open?
and chassis ground.
CHECK OUTPUT SIGNAL EMITTED FROM Is the value 100 %?

TCM USING SUBARU SELECT MONITOR.
link connector.
3)Start the engine and turn Subaru Select
4)Warm-up the transmission until ATF temperature is above 80C (176F).
NOTE:
temperature.
ON (engine OFF).
7)Read the data of line pressure duty solenoid
Line pressure duty solenoid is indicated in
%.
8)Throttle is fully closed.
AT-87
No
Go to step 9.
Even if the
Go to step 9.
POWER indicator
temporary poor
may be the cause.
in transmission.
Go to step 8.
Go to step 9.

10
11
12
Step
Check
CHECK OUTPUT SIGNAL EMITTED FROM Is the value less than 25 %?
2)Throttle is fully open.
Yes
No
Even if the
Go to step 9.
POWER indicator
temporary poor
may be the cause.
in transmission.
CHECK POOR CONTACT.
Is there poor contact in line
Repair the poor
Replace the TCM.
pressure duty solenoid circuit? contact.
<Ref. to AT-46,
(TCM).>
CHECK LINE PRESSURE DUTY SOLENOID Is the resistance between 2.0 Go to step 11.
Replace the line
(IN TRANSMISSION).
and 4.5 ?
pressure duty
solenoid. <Ref. to
bracket.
AT-40, Shift Sole2)Drain the ATF.
noids, Duty Solenoids and ATF
CAUTION:
Temperature SenDo not drain the ATF until it cools down.
sor.>
3)Remove the oil pan, and disconnect connector from line pressure duty solenoid.
4)Measure the resistance between line pressure duty solenoid connector and transmission
ground.
Terminal
Go to step 12.
Repair the open
TRANSMISSION AND LINE PRESSURE
?
circuit in harness
DUTY SOLENOID.
between line presMeasure the resistance of harness between
sure duty solenoid
line pressure duty solenoid and transmission
and transmission
connector.
connector.
(T4) No. 5 (AT2) No. 1:
CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Even if the
Repair the short
TRANSMISSION AND LINE PRESSURE
M?
POWER indicator circuit in harness
DUTY SOLENOID.
lights up, the cir- between line presMeasure the resistance of harness between
cuit has returned sure duty solenoid
to a normal condi- and transmission
ground.
tion at this time. A connector.
temporary poor
may be the cause.
in line pressure
duty solenoid and
transmission.
AT-88

AT-89

N: DTC 76 2-4 BRAKE DUTY SOLENOID

DIAGNOSIS:
The output signal circuit of 2-4 brake duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
TCM
18
B54
B11
T4
AT7
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
B54
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
8
9
7
16 17 18
22 23 24
Step
and TCM.
(B54) No. 18 (B11) No. 9:
TCM AND CHASSIS GROUND.
CHECK 2-4 BRAKE DUTY SOLENOID.
Terminal
(T4) No. 16 No. 9:
TR0415
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

and 4.5 ?
Go to step 4.
Go to step 10.

Monitor?
Go to step 7.
Go to step 5.
AT-90

Step
TCM.
(176F).
Check
Yes
5.0 V with throttle fully closed?
NOTE:
temperature.
CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage less than 1 V
TCM.
with throttle fully open?
and chassis ground.

link connector.
4)Warm-up the transmission until ATF temperature is above 80C (176F).
NOTE:
temperature.
ON (engine OFF).
7)Read the data of 2-4 brake duty solenoid
2-4 brake duty solenoid is indicated in %.
AT-91
No
Go to step 9.
Even if the
Go to step 9.
POWER indicator
temporary poor
may be the cause.
Go to step 8.
Go to step 9.

Step
Check
CHECK OUTPUT SIGNAL EMITTED FROM Is the value less than 25 %?
2)Throttle is fully open.
CHECK POOR CONTACT.
Is there poor contact in 2-4

brake duty solenoid circuit?
10
CHECK 2-4 BRAKE DUTY SOLENOID (IN

TRANSMISSION).
bracket.
2)Drain the ATF.

and 4.5 ?
11
12
CAUTION:
3)Remove the oil pan, and disconnect connector from 2-4 brake duty solenoid.
4)Measure the resistance between 2-4 brake
duty solenoid connector and transmission
ground.
Terminal
TRANSMISSION AND 2-4 BRAKE DUTY SOLENOID.
Measure the resistance of harness between 24 brake duty solenoid and transmission connector.
(T4) No. 9 (AT7) No. 1:
TRANSMISSION AND 2-4 BRAKE DUTY SOLENOID.
ground.
Yes
No
Even if the
Go to step 9.
POWER indicator
temporary poor
may be the cause.
Repair the poor
Replace the TCM.
contact.
<Ref. to AT-46,
(TCM).>
Go to step 11.
Replace the 2-4
brake duty solenoid. <Ref. to AT40, Shift Solenoids, Duty Solenoids and ATF

?
Go to step 12.
Repair the open

circuit in harness
between 2-4 brake
duty solenoid and

M?
Even if the
POWER indicator
temporary poor
may be the cause.
in line pressure
duty solenoid and
transmission.
Repair the short

circuit in harness
between 2-4 brake
duty solenoid and
AT-92

AT-93

O: DTC 77 LOCK-UP DUTY SOLENOID

DIAGNOSIS:
The output signal circuit of lock-up duty solenoid is open or shorted.
TROUBLE SYMPTOM:
No lock-up (after engine warm-up).
WIRING DIAGRAM:
13
B54 TCM
B11
T4
AT3
LOCK-UP
DUTY
SOLENOID
TRANSMISSION
B11
1 2
3
6 7
9 10
11
13
14 15
17 18
19
5
B54
4
8
12
16
20
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8 9
17 18
23 24
TR0416
Step
(DTC).
Check
Do multiple DTCs appear in
the on-board diagnostics test
mode?
AT-94
Yes
Go to another
DTC.
No
Go to step 2.

5
6
Step
transmission.
(B54) No. 7 (B11) No. 13:
between TCM and chassis ground.
CHECK LOCK-UP DUTY SOLENOID.
(T4) No. 13 No. 16:
TCM.
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

and 17 ?
Go to step 5.
Go to step 11.

Monitor?
NOTE:
(176F).
NOTE:
temperature.
MPH). Wheels will lock-up.
NOTE:
Mode.>
AT-95
Go to step 6.
Go to step 10.

Step
Check
CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage less than 0.5 V?
TCM.
1)Return the engine to idling speed and move
select lever to N range.

Is the value 95 %?
Yes
No
Even if the
Go to step 10.
POWER indicator
temporary poor
may be the cause.
Go to step 9.
Go to step 10.
NOTE:
link connector.
(176F).
NOTE:
temperature.
6)Read the data of lock-up duty solenoid using
Lock-up duty solenoid is indicated in %.
MPH). Wheels will lock-up.
NOTE:
Mode.>
Return the engine to idling speed and move
selector lever to N range.
NOTE:
Mode.>
AT-96
Even if the
Go to step 10.
POWER indicator
temporary poor
may be the cause.

10
11
12
13
Step
CHECK POOR CONTACT.
Check
Yes
Is there poor contact in lock-up Repair poor conduty solenoid circuit?
tact.
CHECK LOCK-UP DUTY SOLENOID (IN

TRANSMISSION).
bracket.
2)Drain the ATF.

and 17 ?
Go to step 12.

?
Go to step 13.
Repair the open

circuit in harness
between TCM and

M?
Even if the
POWER indicator
temporary poor
may be the cause.
in lock-up duty
solenoid and
transmission.
Repair the short

circuit in harness
between lock-up
duty solenoid and
CAUTION:
3)Remove the oil pan and disconnect connector from lock-up duty solenoid.
4)Measure the resistance between lock-up
ground.
Terminal
LOCK-UP DUTY SOLENOID AND TRANSMISSION.
lock-up duty solenoid and transmission connector.
(T4) No. 13 (AT3) No. 1:
LOCK-UP DUTY SOLENOID AND TRANSMISSION.
ground.
AT-97
No
Replace the TCM.
<Ref. to AT-46,
(TCM).>
Replace the lockup duty solenoid.
<Ref. to AT-40,
Shift Solenoids,
Duty Solenoids
and ATF Temperature Sensor.>

P: DTC 79 TRANSFER DUTY SOLENOID

DIAGNOSIS:
The output signal circuit of transfer duty solenoid is open or shorted.
TROUBLE SYMPTOM:
Excessive braking in tight corners.
WIRING DIAGRAM:
TCM
B54
B11
T4
AT4
TRANSFER
DUTY
SOLENOID
TRANSMISSION
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
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
TR0417
Step
Check
?
transmission.
(B54) No. 6 (B11) No. 6:
AT-98
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

4
5
Step
Measure the resistance harness connector
CHECK TRANSFER DUTY SOLENOID.
connector and transmission terminals.
(T4) No. 6 No. 16:
Check
M?
Yes
Go to step 3.
No
Repair the short
circuit in harness
between TCM and

and 17 ?
Go to step 4.
Go to step 13.

Monitor?
P range?
Go to step 8.
Go to step 5.
Go to step 6.
Go to step 12.

TCM.
CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage more than 8.5 V
TCM.
in D range?
and chassis ground.
CHECK VEHICLE

link connector.
3)Turn the ignition switch to ON (engine OFF)
and turn Subaru Select Monitor switch to ON.
4)Move the select lever to D range with throttle fully open (vehicle speed 0 km/h or 0 MPH).
5)Read data of transfer duty solenoid using
Transfer duty solenoid is indicated in %.
Even if the
Go to step 12.
POWER indicator
temporary poor
may be the cause.
Go to step 8.
Go to step 10.
Is the target Non-turbo vehicle?

Is the value between 5 and 10 Go to step 9.
%?
AT-99
Go to step 12.

10
11
12
Step
Check
CHECK OUTPUT SIGNAL EMITTED FROM Is the value between approx.
TCM USING SUBARU SELECT MONITOR. 60 % and approx. 70 %?
1)Move the select lever to N range with throttle fully closed (vehicle speed 0 km/h or 0
MPH).
2)Read the data of transfer duty solenoid using
Yes
No
Even if the
Go to step 12.
POWER indicator
temporary poor
may be the cause.
Is the value between 80 and 95 Go to step 11.
Go to step 12.
%?

link connector.
3)Turn the ignition switch to ON (engine OFF)
and turn Subaru Select Monitor switch to ON.
4)Move the select lever to D range with throttle fully open (vehicle speed 0 km/h or 0 MPH).
CHECK OUTPUT SIGNAL EMITTED FROM Is the value approx. 40 %?
1)Move the select lever to N range with throttle fully close (vehicle speed 0 km/h or 0 MPH).
CHECK POOR CONTACT.
Even if the AT OIL Go to step 12.

TEMP warning
temporary poor
may be the cause.
in transfer duty
solenoid and TCM
connector.
Is there poor contact in transfer Repair the poor
Replace the TCM.
contact.
<Ref. to AT-46,
(TCM).>
AT-100

13
Step
CHECK TRANSFER DUTY SOLENOID (IN
TRANSMISSION).
Check
and 17 ?
Yes
Go to step 14.
No
Replace the transfer duty solenoid.

?
Go to step 15.
Repair the open

circuit in harness
between transfer
duty solenoid and

M?
Even if the
POWER indicator
temporary poor
may be the cause.
transfer duty solenoid and transmission.
Repair the short

circuit in harness
between transfer
duty solenoid and
NOTE:
2)Drain the automatic transmission fluid.
14
15
CAUTION:
Do not drain the automatic transmission fluid until it cools down.
3)Remove the extension case and disconnect
connector from transfer duty solenoid.
4)Measure the resistance between transfer
ground.
(AT4) No. 1 Transmission ground:
TRANSFER DUTY SOLENOID AND TRANSMISSION.
transfer duty solenoid and transmission connector.
(T4) No. 6 (AT4) No. 1:
TRANSFER DUTY SOLENOID AND TRANSMISSION.
ground.
AT-101

Q: DTC 93 REAR VEHICLE SPEED SENSOR

DIAGNOSIS:
The input signal circuit of TCM is open or shorted.
TROUBLE SYMPTOM:
No lock-up or excessive tight corner braking.
WIRING DIAGRAM:
A:
B54
B:
B55
B24
A19
TCM
SHIELD AND
SENSOR GROUND
JOINT CONNECTOR
6
3
9
1
7
4
2
8
5
LH RN RT
B53
19
20
B11
T4
LH
: LHD MODEL
RN
RT
: RHD TURBO MODEL
REAR VEHICLE
SPEED SENSOR
B53
LH
1 2 3 4 5 6 7 8 9 10 11 12
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
B53
RT
B54
B55
B11
RN
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
8
9
7
16 17 18
22 23 24
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
8
9
7
16 17 18
22 23 24
1 2 3 4 5 6
TR0922
AT-102

6
7
8
Step
transmission.
(B55) No. 24 (B11) No. 19:
(B54) No. 19 (B11) No. 20:
CHECK REAR VEHICLE SPEED SENSOR.
(T4) No. 19 No. 20:
stands.
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
transmission, and
poor contact in
coupling connector.
Repair the short
circuit in harness
between TCM and

M?
Go to step 5.
Repair the short

circuit in harness
between TCM and

and 650 ?
Replace the rear

vehicle speed sensor. <Ref. to AT36, Rear Vehicle
Speed Sensor.>
Go to step 7.
Go to step 8.

Monitor?
V?
NOTE:
(12 MPH) condition.
NOTE:
Mode.>
(B55) No. 24 (+) (B54) No. 19 ():
AT-103
Go to step 10.
Go to step 9.
Even if the
Go to step 11.
POWER indicator
temporary poor
may be the cause.

10
Step
link connector.
stands.
Check
Yes
No
Does the speedometer indica- Even if the
Go to step 11.
tion increase as the Subaru
POWER indicator
Select Monitor data increases? lights up, the circuit has returned
temporary poor
NOTE:
may be the cause.
Repair the har4)Turn the ignition switch to ON and turn Subness or connector
aru Select Monitor switch to ON.
in TCM and trans5)Start the engine.
mission.
6)Read the data of vehicle speed using Subaru
Select Monitor.
Compare the speedometer with Subaru
Select Monitor indications.
Vehicle speed is indicated in km/h or MPH.
7)Slowly increase the vehicle speed to 60 km/h
or 37 MPH.
NOTE:
Mode.>
Is the signal voltage more than
OSCILLOSCOPE.
AC 1 V?
stands.
NOTE:
3)Set the oscilloscope to TCM connector terminals.
Earth lead; (B54) No. 19
(12 MPH) condition.
11
NOTE:
Mode.>
oscilloscope.
CHECK POOR CONTACT.
Is there poor contact in rear
AT-104
Even if the
Go to step 11.
POWER indicator
temporary poor
may be the cause.
Repair the poor

contact.
Replace the TCM.

<Ref. to AT-46,
(TCM).>
DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)

15.Diagnostic Procedure for No-diagnostic Trouble Code (DTC)

A: CHECK GEAR POSITION.
1
Step
CHECK GEAR POSITION.
NOTE:
2)Start the engine.
3)Move the select lever to D range and drive
vehicle.
4)Read the data of gear position using Subaru
Select Monitor.
Gear position is indicated.
Check
Does the transmission gear
correspond to the gear which
is shown on display?
NOTE:
Mode.>
CHECK VEHICLE.
Is the target Non-turbo vehicle?
AT-105
Yes
Go to step 2.
No
Check the shift
solenoid 1 and
shift solenoid 2
signal circuit.
<Ref. to AT-70,
DTC 71 SHIFT
SOLENOID 1,
(DTC).> and <Ref.
to AT-74, DTC 72
SHIFT SOLENOID 2, Diagnostic Procedure with
Go to step CHECK
FWD
SWITCH.<Ref. to
AT-106, CHECK
FWD SWITCH.,
Code (DTC).>
Go to step CHECK
BRAKE SWITCH.
<Ref. to AT-110,
CHECK BRAKE
SWITCH., Diagnostic Procedure
for No-diagnostic
Trouble Code
(DTC).>

B: CHECK FWD SWITCH.

DIAGNOSIS:
The LED does not come on even if FWD switch is ON.
The FWD switch circuit is open or short.
AT-106

WIRING DIAGRAM:
LHD MODEL
BATTERY
SBF-4
SBF-1
IGNITION
SWITCH
E
COMBINATION
METER
FWD
A:
i10
B:
i11
30
29
No.13
FWD SWITCH
A7
B4
F67
F45
17
23
i1
B36
C2
B20
B62
B:
B55
C: B56
TCM
B56
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
B:
F45
B55
8
9
7
16 17 18
22 23 24
i11
1 2 3 4 5 6 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
10 11 12 13 14 15
19 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
8
9
7
16 17 18
22 23 24
A:
B36
i10
1 2 3 4 5 6
7 8 9 10
TR0419
AT-107

RHD MODEL
BATTERY
SBF-4
SBF-1
IGNITION
SWITCH
COMBINATION
FWD SWITCH
No.13
METER
i10
B:
i11
30
29
A:
F67
A7
B4
FWD
F45
15
22
i3
B38
C2
B20
B62
B:
B55
C: B56
TCM
B56
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
B:
B55
8
9
7
16 17 18
22 23 24
F45
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
8
9
7
16 17 18
22 23 24
i3
1 2 3 4 5 6 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:
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
i11
i10
1 2 3 4 5 6
7 8 9 10
TR0420
AT-108

Step
CHECK FWD SWITCH.
Check
When the fuse is inserted to
FWD switch, does LED light
up?
Yes
No
Go to step CHECK Go to step 2.
BRAKE
SWITCH.<Ref. to
AT-110, CHECK
BRAKE SWITCH.,
Code (DTC).>
Is the FWD indicator light bulb Go to step 3.
Replace the FWD
CHECK FWD INDICATOR LIGHT.
OK?
indicator light bulb.
<Ref. to IDI-15,
3)Remove the FWD indicator light bulb from
Combination
combination meter.
Meter Assembly.>
Go to step 4.
Repair the open
TCM AND FWD SWITCH.
?
circuit in harness
between TCM and
FWD switch conFWD switch.
nector.
TCM and FWD switch connector.
(B55) No. 20 (F67) No. 30:
Go to step 5.
Repair the open
FWD SWITCH AND CHASSIS GROUND.
?
circuit in harness
between FWD
FWD switch and chassis ground.
switch connector
and chassis
ground.
Repair the short
CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Go to step 6.
M?
circuit in harness
TCM AND FWD SWITCH.
between TCM and
between TCM and body to make sure that cirFWD switch concuit does not short.
nector.
Is the voltage less than 1 V in Go to step 7.
Go to step 11.
FWD switch while installing?
2)Connect the connector to TCM and FWD
switch.
4)Measure the signal voltage for TCM while
installing the fuse to FWD switch connector.
Replace the TCM.
Measure the signal voltage for TCM while
9.1 V in FWD switch while
<Ref. to AT-46,
removing the fuse from FWD switch connector. removing?
Transmission ConConnector & terminal
trol Module
(TCM).>
Go to step 9.
Repair the open
?
circuit in harness
TCM AND COMBINATION METER.
between TCM and
combination meter
combination meter.
and poor contact
in coupling conTCM and diagnosis connector.
nector.
(B56) No. 2 (i11) No. 4:
AT-109

10
11
12
Step
between TCM and chassis ground to make
sure that circuit does not short.
TCM.
2)Connect the connector to TCM and combination meter.
installing and removing the fuse to FWD switch
connector.
TCM.
Measure the signal voltage for TCM while
removing the fuse from FWD switch connector.
CHECK POOR CONTACT.
Check
M?
Yes
Go to step 10.
No
Repair the short
circuit in harness
between TCM and
combination meter
connector.

FWD switch while installing?
Go to step 11.
Go to step 12.
Is the voltage between 6 and

9.1 V in FWD switch while
removing?
Go to step 12.
Replace the TCM.

<Ref. to AT-46,
(TCM).>
Is there poor contact in FWD

switch circuit?
Repair the poor

contact.
Replace the TCM.

<Ref. to AT-46,
(TCM).>
C: CHECK BRAKE SWITCH.

1
Step
CHECK BRAKE SWITCH.
Check
Yes
When the brake pedal is
Go to step CHECK
depressed, does LED light up? ABS SWITCH.
<Ref. to AT-111,
CHECK ABS
for No-diagnostic
Trouble Code
(DTC).>
AT-110
No
Check the brake
switch circuit.
<Ref. to EN-224,
DTC P0703
BRAKE SWITCH
INPUT MALFUNCTION ,
(DTC).>

D: CHECK ABS SWITCH.

1
Step
CHECK ABS SWITCH.
Check
Does the LED of ABS switch
light up?
Yes
Check the ABS
switch circuit.
<Ref. to ABS-136,
DTC 44 ABSAT CONTROL
(NON CONTROLLED) ,
Diagnostics Chart
with Subaru Select
Monitor.> and
<Ref. to ABS-138,
DTC 44 ABSAT CONTROL
(CONTROLLED)
, Diagnostics
Chart with Subaru
Select Monitor.>
No
Go to step CHECK
CRUISE CONTROL SWITCH.
<Ref. to AT-111,
CHECK CRUISE
CONTROL
for No-diagnostic
Trouble Code
(DTC).>
E: CHECK CRUISE CONTROL SWITCH.

1
Step
CHECK CRUISE CONTROL SWITCH.
Check
Yes
When the cruise control is set, Go to step CHECK
does LED light up?
KICK-DOWN
SWITCH. <Ref. to
AT-112, CHECK
KICKDOWN
for No-diagnostic
Trouble Code
(DTC).>
AT-111
No
Check the cruise
control. <Ref. to
CC-29, Diagnostics Chart with
Trouble Code.>

F: CHECK KICKDOWN SWITCH.

DIAGNOSIS:
The kick-down switch is ON when the throttle is fully opened, but is OFF when the throttle is partially open
or fully closed.
TROUBLE SYMPTOM:
No kick-down occurs (when the throttle is fully opened).
WIRING DIAGRAM:
B3M2169
AT-112

Step
Check
Yes
CHECK KICK-DOWN SWITCH OPERATION. When the accelerator pedal is Go to step CHECK
depressed, does ON disPOWER MODE
played?
SWITCH. <Ref. to
AT-115, CHECK
POWER MODE
for No-diagnostic
Trouble Code
(DTC).>
CHECK KICK-DOWN SWITCH GROUND
Go to step 3.
LINE.
?
1)Disconnect the connector from kick-down
switch.
2)Measure the resistance of harness connector between kick-down switch and chassis
ground.
CHECK KICK-DOWN SWITCH.
Go to step 4.
Measure the resistance for kick-down switch ?
when depressing the accelerator pedal.
Terminals
No. 1 No. 2:
CHECK KICK-DOWN SWITCH.
Measure the resistance for kick-down switch M?
when pressing the accelerator pedal.
Terminals
No. 1 No. 2:
Go to step 6.
?
TCM AND KICK-DOWN SWITCH.
2)Disconnect the connectors from kick-down
switch.
3)Measure the resistance of harness connector between TCM and kick-down switch.
(B55) No. 11 (B129) No. 2:
CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Go to step 7.
TCM AND KICK-DOWN SWITCH.
M?
Go to step 8.
2)Connect the connector to kick-down switch.
4)Measure the signal voltage for TCM when
depressing the accelerator pedal.
Is the voltage more than 6.5 V? A temporary poor
Measure the signal voltage for TCM when
contact of the conpressing the accelerator pedal.
nector and harConnector & terminal
ness may be the
cause. Repair the
harness and connector in TCM.
AT-113
No
Go to step 2.
Repair the open

circuit in harness
between kickdown switch and
TCM.
Replace the kickdown switch. <Ref.

to SP-4, Accelerator Pedal.>
Replace the kickdown switch.
Repair the open

circuit in harness
between TCM and
kick-down switch.
Repair the short

circuit in harness
between TCM and
chassis ground.
Go to step 9.
Go to step 9.

Step
CHECK POOR CONTACT.
Check
Is there poor contact?
AT-114
Yes
Repair the poor
contact.
No
Replace the TCM.
<Ref. to AT-46,
(TCM).>

G: CHECK POWER MODE SWITCH.

DIAGNOSIS:
The LED does not come on when power switch is ON.
The power switch circuit is open or shorted.
TROUBLE SYMPTOM:
No power mode occurs.
WIRING DIAGRAM:
LHD MODEL
IGNITION
BATTERY
SWITCH
SBF-4
SBF-1
METER
B:
i11
B:
POWER
B56
B23
No.13
TCM
A7
B15
C:
B55
B16
COMBINATION
i10
C11
E
A:
23
i1
POWER MODE AND
B36
SNOW HOLD MODE SWITCH

POWER OFF
SNOW
HOLD
2
5
4
B133
B55
B133
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
1 2 3
4 5 6
i11
8 9 10 11 12 13 14
1 2 3 4 5 6 7
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B56
8
9
7
16 17 18
22 23 24
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
B36
i10
1 2 3 4 5 6
8
9
7
16 17 18
22 23 24
7 8 9 10
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
TR0923
AT-115

RHD MODEL
IGNITION
BATTERY
SWITCH
SBF-4
SBF-1
i10
B:
i11
B:
B56
TCM
B23
A7
No.13
POWER
B15
C:
B53
B16
METER
A:
C11
E
COMBINATION
22
i3
POWER MODE AND
B38

POWER OFF
SNOW
HOLD
2
5
4
B133
B133
B55
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
1 2 3
4 5 6
8
9
7
16 17 18
22 23 24
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
i3
8
9
7
16 17 18
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
i11
i10
1 2 3 4 5 6
B56
7 8 9 10
8 9 10 11 12 13 14
1 2 3 4 5 6 7
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
TR0924
AT-116

Step
CHECK POWER SWITCH OPERATION.
CHECK POWER SWITCH OPERATION.

3)Remove the POWER indicator light bulb

bulb OK?
CHECK POWER SWITCH GROUND LINE.

2)Disconnect the connector from power switch.
3)Measure the resistance of harness connector between power switch and chassis ground.
CHECK POWER SWITCH.
1)Turn the power switch to ON.
2)Measure the resistance between terminals of
power switch.
Terminals
No. 5 No. 4:
CHECK POWER SWITCH.
1)Turn the power switch to OFF.
power switch.
Terminals
No. 5 No. 4:
TCM AND POWER SWITCH.
between TCM and power switch.
(B55) No. 23 (B133) No. 3:
TCM AND POWER SWITCH.
1)Connect the connectors to TCM and power
switch.
turning power switch to OFF.

?
Check
When the power switch is
turned to OFF, does LED light
up?
When the power switch is
turned to ON, does LED light
up?
Yes
Go to step 5.
No
Go to step 2.
Go to step CHECK Go to step 3.

INHIBITOR
SWITCH. <Ref. to
AT-119, CHECK
INHIBITOR
for No-diagnostic
Trouble Code
(DTC).>
Go to step 4.
Replace the
POWER indicator
light bulb. <Ref. to
IDI-15, Combination Meter Assembly.>
Go to step 5.
Repair the open
circuit in harness
between power
switch and chassis
ground.

?
Go to step 6.
Repair the power

switch.

M?
Go to step 7.
Repair the power

switch.

?
Go to step 8.
Repair the open

circuit in harness
between TCM and
power switch connector.

M?
Go to step 9.
Repair the short

circuit in harness
between TCM and
power switch connector.
AT-117
Replace the TCM.

<Ref. to AT-46,
(TCM).>

10
11
Step
Check
Measure the signal voltage for TCM while turning power switch to ON.
CHECK POOR CONTACT.
AT-118
Yes
Go to step 11.
Repair the poor

contact.
No
Replace the TCM.
<Ref. to AT-46,
(TCM).>
A temporary poor
or connector in
power switch circuit.

H: CHECK INHIBITOR SWITCH.

DIAGNOSIS:
The input signal circuit of inhibitor switch is open or shorted.
TROUBLE SYMPTOM:
Shift characteristics are erroneous.
Engine brake is not effected when selector lever is in 3 range.
AT-119

WIRING DIAGRAM:
LHD MODEL
BATTERY
SBF-1
SBF-4
IGNITION
ILLUMINATION CONTROL CIRCUIT
SWITCH
COMBINATION
METER
C4
i10
C:
i12
C5
C10
C11
C12
C14
A7
C13
No.13
A:
16
15
14
18
19
23
i1
B36
INHIBITOR SWITCH
1
9
10
11
4
T3
B12
B55
T7
B12
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4
5 6 7 8
9 10 11 12
i12
1 2 3
4 5 6
1 2 3 10 11 12 13 14
TRANSMISSION
CONTROL MODULE
A:
i10
1 2 3 4 5 6
7 8 9 10
B36
B55
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
C:
T7
14
8
9
7
16 17 18
22 23 24
7 8 9 10 11
1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
TR0424
AT-120

RHD MODEL
BATTERY
SBF-1
SBF-4
IGNITION
COMBINATION
SWITCH
ILLUMINATION CONTROL CIRCUIT
A:
i10
C:
i12
C5
C11
C4
C10
C12
C13
i3
9
22
10
A7
C14
No.13
METER
B38
INHIBITOR SWITCH
1
3
2
10
11
4
T7
T3
B12
B55
T7
B12
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4
5 6 7 8
9 10 11 12
i12
TRANSMISSION
CONTROL MODULE
A:
i10
1 2 3 4 5 6
7 8 9 10
i3
B55
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
C:
1 2 3
4 5 6
1 2 3 10 11 12 13 14
9
8
14
8
9
7
16 17 18
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
TR0925
AT-121

Step
CHECK P RANGE SWITCH.
CHECK P RANGE SWITCH.
CHECK R RANGE SWITCH.
CHECK R RANGE SWITCH.
CHECK N RANGE SWITCH.
CHECK N RANGE SWITCH.
10
CHECK D RANGE SWITCH.
11
12
CHECK D RANGE SWITCH.
13
CHECK 3 RANGE SWITCH.
14
15
16
17
18
19
20
21
Check
When the P range is
selected, does LED light up?
Does the combination meter
P range indicator illuminate?
When the R range is
selected, does P range LED
light up?
When the R range is
R range indicator illuminate?
When the N range is
selected, does R range LED
light up?
When the N range is
N range indicator illuminate?
When the D range is
selected, does N range LED
light up?
When the D range is
D range indicator illuminate?
When the 3 range is
selected, does D range LED
light up?
When the 3 range is
3 range indicator illuminate?
When the 2 range is
selected, does 3 range LED
light up?
When the 2 range is
When the 1 range is
light up?
When the 1 range is
When the P range is
light UP?
AT-122
Yes
Go to step 2.
No
Go to step 22.
Go to step 3.
Go to step 26.
Go to step 28.
Go to step 4.
Go to step 5.
Go to step 29.
Go to step 6.
Go to step 32.
Go to step 34.
Go to step 7.
Go to step 8.
Go to step 35.
Go to step 9.
Go to step 38.
Go to step 40.
Go to step 10.
Go to step 11.
Go to step 41.
Go to step 12.
Go to step 44.
Go to step 46.
Go to step 13.
Go to step 14.
Go to step 47.
Go to step 15.
Go to step 50.
Go to step 52.
Go to step 16.
Go to step 17.
Go to step 53.
Go to step 18.
Go to step 56.
Go to step 58.
Go to step 19.
Go to step 20.
Go to step 59.
Go to step 21.
Go to step 62.
Go to step 64.
Go to step CHECK
HOLD SWITCH.
<Ref. to AT-129,
CHECK HOLD
for No-diagnostic
Trouble Code
(DTC).>

22
23
24
25
26
27
28
Step
INHIBITOR SWITCH AND CHASSIS
GROUND.
switch.
inhibitor switch and chassis ground.
(T7) No. 5 Chassis ground:
TCM AND INHIBITOR SWITCH.
inhibitor switch.
TCM and inhibitor switch connector.
(B55) No. 1 (T7) No. 9
2)Connect the connector to TCM and inhibitor
switch.
chassis ground.
CHECK P RANGE INDICATOR LIGHT
BULB.
3)Remove the P range indicator light bulb
combination meter.
TCM and combination meter.
(B55) No. 1 (i12) No. 14:
2)Disconnect the connectors from TCM, inhibitor switch and combination meter.
Check
?
Yes
Go to step 23.
No
Repair the open
circuit in harness
between inhibitor
switch connector
and chassis
ground, and poor

?
Go to step 24.
Repair the open

circuit in harness
between TCM and
inhibitor switch
connector, and
poor contact in
coupling connector.

P range?
Go to step 25.
Go to step 65.
Is the voltage more than 8 V in Go to step 65.

other ranges?
Is the P range indicator light

bulb OK?
Go to step 27.

?
Go to step 65.

M?
Go to step 29.
AT-123
Replace the TCM.

<Ref. to AT-46,
(TCM).>
Replace the P
range indicator
Repair the open
circuit in harness
between TCM
connector and
combination
meter, and poor
Repair the ground
short circuit in P
range circuit.

29
30
31
32
33
34
35
Step
inhibitor switch.
(B55) No. 3 (T7) No. 8:
switch.
chassis ground.
CHECK R RANGE INDICATOR LIGHT
BULB.
3)Remove the R range indicator light bulb
combination meter.
(B55) No. 3 (i12) No. 13:
inhibitor switch.
(B55) No. 14 (T7) No. 10:
Check
?
Yes
Go to step 30.
No
Repair the open
circuit in harness
between TCM and
inhibitor switch
connector, and
poor contact in
coupling connector.

R range?
Go to step 31.
Go to step 65.

other ranges?
Is R range indicator light bulb Go to step 33.

OK?

?
Go to step 65.

M?
Go to step 35.

?
Go to step 36.
AT-124
Replace the TCM.

<Ref. to AT-46,
(TCM).>
Replace the R
range indicator
Repair the open
circuit in harness
between TCM
connector and
combination
meter, and poor
contact in TCM
connector.
Repair the ground
short circuit in R
range circuit.
Repair the open

circuit in harness
between TCM and
inhibitor switch
connector, and
poor contact in
coupling connector.

36
37
38
39
40
41
42
43
Step
switch.
chassis ground.
CHECK N RANGE INDICATOR LIGHT
BULB.
3)Remove the N range indicator light bulb
combination meter.
(B55) No. 14 (i12) No. 12:
inhibitor switch.
(B55) No. 4 (T7) No. 3:
switch.
chassis ground.
Check
N range?
Yes
Go to step 37.

other ranges?
No
Go to step 65.
Replace the TCM.

<Ref. to AT-46,
(TCM).>
Replace the N
range indicator
Repair the open
circuit in harness
between TCM
connector and
combination
meter, and poor
contact in TCM
connector.
Repair the ground
short circuit in N
range circuit.
Is the N range indicator light

bulb OK?
Go to step 39.

?
Go to step 65.

M?
Go to step 41.

?
Go to step 42.
Repair the open

circuit in harness
between TCM and
inhibitor switch
connector, and
poor contact in
coupling connector.

D range?
Go to step 43.
Go to step 65.

other ranges?
AT-125
Replace the TCM.

<Ref. to AT-46,
(TCM).>

44
45
46
47
48
49
50
51
Step
CHECK D RANGE INDICATOR LIGHT
BULB.
3)Remove the D range indicator light bulb
combination meter.
(B55) No. 4 (i12) No. 11:
inhibitor switch.
(B55) No. 5 (T7) No. 11:
switch.
chassis ground.
CHECK 3 RANGE INDICATOR LIGHT
BULB.
3)Remove the 3 range indicator light bulb
combination meter.
(B55) No. 5 (i12) No. 10:
Check
Is the D range indicator light
bulb OK?
Yes
Go to step 45.

?
Go to step 65.

M?
Go to step 47.
Repair the ground

short circuit in D
range circuit.

?
Go to step 48.
Repair the open

circuit in harness
between TCM and
inhibitor switch
connector, and
poor contact in
coupling connector.

3 range?
Go to step 49.
Go to step 65.

other ranges?
Is the 3 range indicator light

bulb OK?
Go to step 51.

?
Go to step 65.
AT-126
No
Replace the D
range indicator
Repair the open
circuit in harness
between TCM
connector and
combination
meter, and TCM
connector.
Replace the TCM.

<Ref. to AT-46,
(TCM).>
Replace the 3
range indicator
Repair the open
circuit in harness
between TCM
connector and
combination
meter, and poor
contact in TCM
connector.

52
53
54
55
56
57
58
Step
inhibitor switch.
(B55) No. 6 (T7) No. 4:
switch.
chassis ground.
BULB.
combination meter.
(B55) No. 6 (i12) No. 4:
Check
M?
Yes
Go to step 53.
No
Repair the ground
short circuit in 3
range circuit.

?
Go to step 54.
Repair the open

circuit in harness
between TCM and
inhibitor switch
connector, and
poor contact in
coupling connector.

2 range?
Go to step 55.
Go to step 65.

other ranges?

bulb OK?
Go to step 57.

?
Go to step 65.

M?
Go to step 59.
AT-127
Replace the TCM.

<Ref. to AT-46,
(TCM).>
Replace the 2
range indicator
Repair the open
circuit in harness
between TCM and
combination
meter, and poor
contact in TCM
connector.
Repair the ground
short circuit in 2
range circuit.

59
60
61
62
63
64
65
Step
inhibitor switch.
(B55) No. 7 (T7) No. 6:
switch.
chassis ground.
BULB.
combination meter.
(B55) No. 7 (i12) No. 5:
CHECK POOR CONTACT.
Check
?
Yes
Go to step 60.
No
Repair the open
circuit in harness
between TCM and
inhibitor switch
connector, and
poor contact in
coupling connector.

1 range?
Go to step 61.
Go to step 65.

other ranges?

bulb OK?
Go to step 63.
Replace the TCM.

<Ref. to AT-46,
(TCM).>
Replace the 1
range indicator
Repair the open
circuit in harness
between TCM and
combination
meter, poor contact in TCM connector.

M?
Go to step 65.
Repair the ground

short circuit in 1
range circuit.
Is there poor contact in inhibitor switch circuit?
Repair the poor

contact.
Adjust the inhibitor switch and

select cable. <Ref.
to AT-28,
ADJUSTMENT,
Inhibitor Switch.>
and <Ref. to CS-9,
Select Cable.>
AT-128

I:
CHECK HOLD SWITCH.
DIAGNOSIS:
The LED does not come on when hold switch is ON.
The hold switch circuit is open or shorted.
TROUBLE SYMPTOM:
The 2nd gear is not held.
Failure of vehicle to start in 2nd gear except 1st range.
WIRING DIAGRAM:
LHD MODEL
IGNITION
BATTERY
SWITCH
SBF-4
SBF-1
E
COMBINATION
METER
A:
i10
B:
i11
HOLD
B:
B55
B23
B16
No.13
A7
B15
TCM
23
i1
POWER MODE AND
B36

POWER OFF
SNOW
HOLD
2
5
4
B133
B133
B55
1 2 3
4 5 6
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
B:
i11
8 9 10 11 12 13 14
1 2 3 4 5 6 7
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B36
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
9
7
16 17 18
22 23 24
A:
i10
1 2 3 4 5 6
7 8 9 10
TR0926
AT-129

RHD MODEL
IGNITION
BATTERY
SWITCH
SBF-4
SBF-1
E
COMBINATION
METER
A:
i10
B:
i11
HOLD
B55
22
16
23
No.13
A7
B15
TCM
i3
POWER MODE AND
B38

POWER OFF
SNOW
HOLD
2
5
4
B133
B133
B55
1 2 3
4 5 6
1 2 3 4
5 6
10 11 12 13 14 15
19 20 21
B36
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
9
7
16 17 18
22 23 24
i11
8 9 10 11 12 13 14
1 2 3 4 5 6 7
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
i10
1 2 3 4 5 6
i3
7 8 9 10
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
TR0927
Step
CHECK HOLD SWITCH OPERATION.
Check
Yes
When the hold switch is turned Go to step 5.
to OFF, does LED light up?
AT-130
No
Go to step 2.

Step
CHECK HOLD SWITCH OPERATION.
CHECK HOLD INDICATOR LIGHT.

3)Remove the HOLD indicator light bulb from
combination meter.
CHECK HOLD SWITCH GROUND LINE.
2)Disconnect the connector from hold switch.
3)Measure the resistance of harness connector between hold switch and chassis ground.
CHECK HOLD SWITCH.
1)Turn the hold switch to ON.
hold switch.
Terminals
No. 4 No. 2:
CHECK HOLD SWITCH.
1)Turn the hold switch to OFF.
hold switch.
Terminals
No. 4 No. 2:
TCM AND HOLD SWITCH.
1)Disconnect the connector TCM and combination meter.
2)Measure the resistance of harness connector between TCM and hold switch.
(B55) No. 16 (B133) No. 2:
(B55) No. 16 (i11) No. 15:
Check
Yes
No
When the hold switch is turned Go to step Symp- Go to step 3.
to ON, does LED light up?
tom Related Diagnostic. <Ref. to
AT-133, Symptom
Related Diagnostic.>
Is the HOLD indicator light bulb Go to step 4.
Replace the HOLD
OK?
indicator light bulb.
<Ref. to IDI-15,
Combination
Meter Assembly.>
Go to step 5.
Repair the open
?
circuit in harness
between hold
switch and chassis
ground.

?
Go to step 6.
Repair the hold

switch.

M?
Go to step 7.
Repair the hold

switch.

?
Go to step 8.
Repair the open

circuit in harness
between TCM and
hold switch connector and poor

?
Go to step 9.
Repair the open

circuit in harness
between TCM and
combination
meter, and poor
Repair the short
circuit in harness
between TCM and
hold switch connector.

TCM AND HOLD SWITCH.
M?
between TCM and chassis ground to make
sure that circuit does not short.
AT-131
Go to step 10.

10
11
12
Step
Check
1)Connect the connectors to TCM and hold
switch.
turning hold switch to OFF.
Measure the signal voltage for TCM while turning hold switch to ON.
CHECK POOR CONTACT.
AT-132
Yes
Go to step 11.
No
Replace the TCM.
<Ref. to AT-46,
(TCM).>
Go to step 12.
Replace the TCM.

<Ref. to AT-46,
(TCM).>
A temporary poor
or connector in
hold switch circuit.
Repair the poor

contact.
SYMPTOM RELATED DIAGNOSTIC

16.Symptom Related Diagnostic

A: INSPECTION
Symptom
Problem parts
Inhibitor switch
Starter does not rotate when select lever is in P or N range; Select cable
starter rotates when select lever is in R, D, 3 or 2 range. Select lever
Starter motor and harness
Strainer
Abnormal noise when select lever is in P or N range.
Oil pump
Drive plate
ATF level too high or too low
Strainer
Hissing noise occurs during standing start.
ATF level too high or too low
Noise occurs while driving in D1.
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
Control valve
Lock-up damper
Engine stalls while shifting from one range to another.
Engine performance
Input shaft
TCM
Vehicle moves when select lever is in N range.
Low clutch
TCM
Harness
Shock occurs when select lever is moved from N to D range.
Control valve
ATF deterioration
Control valve
Low clutch
Excessive time lag occurs when select lever is moved from N
to D range.
Seal ring
Front gasket transmission case
TCM
Harness
Shock occurs when select lever is moved from N to R range.
Control valve
ATF deterioration
Control valve
Low & reverse clutch
Excessive time lag occurs when select lever is moved from N Reverse clutch
to R range.
Seal ring
Parking brake mechanism
Vehicle does not start in any shift range (engine stalls).
Planetary gear
AT-133

Symptom
Problem parts
Strainer
Control valve
Drive pinion
Hypoid gear
Axle shaft
Differential gear
Vehicle does not start in any shift range (engine revving up).
Oil pump
Input shaft
Output shaft
Planetary gear
Drive plate
ATF level too low
Select cable
Select lever
Vehicle does not start in R range only (engine revving up).
Control valve
Reverse clutch
Low clutch
2-4 brake
Vehicle does not start in R range only (engine stalls).
Planetary gear
Parking brake mechanism
Low clutch
Vehicle does not start in D, 3 range only (engine revving up).
One-way clutch
Vehicle does not start in D, 3 or 2 range only (engine rev Low clutch
ving up).
Vehicle does not start in D, 3 or 2 range only (engine
Reverse clutch
stalls).
Vehicle starts in R range only (engine revving up).
Control valve
Control valve
Low clutch
Reverse clutch
Acceleration during standing starts is poor (high stall rpm).
ATF level too low
Oil pump
Acceleration during standing starts is poor (low stall rpm).
Torque converter one-way clutch
Engine performance
TCM
Control valve
Acceleration is poor when select lever is in D, 3 or 2 range
High clutch
(normal stall rpm).
2-4 brake
Planetary gear
Control valve
Acceleration is poor when select lever is in R (normal stall
High clutch
rpm).
2-4 brake
Planetary gear
TCM
No shift occurs from 1st to 2nd gear.
Shift solenoid 1
Control valve
2-4 brake
TCM
Control valve
No shift occurs from 2nd to 3rd gear.
High clutch
Shift solenoid 2
AT-134

Symptom
No shift occurs from 3rd to 4th gear.
Engine brake is not effected when select lever is in 3 range.

Engine brake is not effected when select lever is in 3 or 2
range.
Engine brake is not effected when select lever is in 1 range.
Shift characteristics are erroneous.
No lock-up occurs.
Parking brake is not effected.

Shift lever cannot be moved or is hard to move from P range.
ATF spurts out.
Differential oil spurts out.
Differential oil level changes excessively.
Odor is produced from ATF supply pipe.
Shock occurs from 1st to 2nd gear.
Slippage occurs from 1st to 2nd gear.
Problem parts
TCM
Shift solenoid 1
Control valve
2-4 brake
Inhibitor switch
TCM
Control valve
Control valve
Control valve
Low & reverse brake
Inhibitor switch
TCM
Control valve
Ground earth
TCM
Control valve
Lock-up facing
Engine speed signal
Select cable
Select lever
Parking mechanism
ATF level too high
Differential gear oil too high
Seal pipe
Double oil seal
High clutch
2-4 brake
Reverse clutch
Lock-up facing
ATF deterioration
TCM
Control valve
2-4 brake
ATF deterioration
Engine performance
TCM
Control valve
2-4 brake
High clutch
AT-135

Symptom
Problem parts
TCM
Shock occurs from 2nd to 3rd gear.
Control valve
High clutch
2-4 brake
ATF deterioration
Engine performance
TCM
Slippage occurs from 2nd to 3rd gear.
Control valve
High clutch
2-4 brake
TCM
Control valve
Shock occurs from 3rd to 4th gear.
2-4 brake
ATF deterioration
Engine performance
Low clutch
TCM
Slippage occurs from 3rd to 4th gear.
Control valve
2-4 brake
TCM
Shock occurs when select lever is moved from 3 to 2 range. Control valve
2-4 brake
ATF deterioration
TCM
Shock occurs when select lever is moved from D to 1 range. Control valve
ATF deterioration
AT-136

Symptom
Shock occurs when select lever is moved from 2 to 1 range.
Shock occurs when accelerator pedal is released at medium

speeds.
Vibration occurs during straight-forward operation.
Vibration occurs during turns (tight corner braking phenomenon).
Front wheel slippage occurs during standing starts.
Vehicle is not set in FWD mode.
Select lever is hard to move.
Select lever is too high to move (unreasonable resistance).

Select lever slips out of operation during acceleration or while
driving on rough terrain.
Problem parts
TCM
Control valve
ATF deterioration
TCM
Control valve
Lock-up damper
Engine performance
TCM
Lock-up facing
Lock-up damper
TCM
Transfer clutch
Transfer valve
ATF deterioration
Harness
TCM
FWD switch
Control valve
Transfer clutch
Transfer valve
Transfer pipe
TCM
FWD switch
Transfer clutch
Transfer valve
Select cable
Select lever
Detente spring
Manual plate
Detente spring
Manual plate
Select cable
Select lever
Detente spring
Manual plate
AT-137

AT-138
MANUAL TRANSMISSION AND

DIFFERENTIAL
MT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Page
Transmission Gear Oil ..............................................................................32
Manual Transmission Assembly ...............................................................33
Transmission Mounting System ................................................................40
Oil Seal......................................................................................................42
Switches and Harness ..............................................................................43
Vehicle Speed Sensor...............................................................................46
Transfer Case and Extension Case Assembly..........................................48
Transfer Drive Gear ..................................................................................52
Transfer Driven Gear ................................................................................54
Center Differential .....................................................................................56
Reverse Check Sleeve..............................................................................57
Transmission Case ...................................................................................61
Main Shaft Assembly for Single-Range ....................................................68
Main Shaft Assembly for Dual-Range .......................................................76
Input Shaft Assembly ................................................................................82
Drive Pinion Shaft Assembly.....................................................................86
Front Differential Assembly .......................................................................95
Speedometer Gear..................................................................................102
Reverse Idler Gear..................................................................................103
Shifter Fork and Rod ...............................................................................105
Counter Gear ..........................................................................................109
General Diagnostic..................................................................................111
GENERAL DESCRIPTION
MANUAL TRANSMISSION AND DIFFERENTIAL
A: SPECIFICATIONS
1. MANUAL TRANSMISSION AND DIFFERENTIAL
Model
1.6L
Type
Transmission gear
ratio
Auxiliary transmission gear ratio*

Front
reduction
gear
Rear
reduction
gear
Final
Transfer
Final
1st
2nd
3rd
4th
5th
Reverse
High
Low
Type of gear
Gear ratio
Type of gear
Gear ratio
Type of gear
Gear ratio
Front
Type and number of gear
differential
Center
Type and number of gear
differential
Transmission gear oil
2.0L Turbo
2.5L
Except
Except
Australia
Australia
Australia
Australia
5-forward speeds with synchromesh and 1-reverse
52-forward speeds with synchromesh and 2-reverse*
3.454
3.454
3.166
3.454
2.062
1.947
1.882
2.062
1.448
1.366
1.296
1.448
1.088
0.972
1.088
0.825
0.738
0.871
0.780
3.333
1.000
1.447
Hypoid
2.0L
Non-turbo
4.111
3.900
3.900
4.444
3.700
4.111
Helical
1.000
1.100
1.000
Hypoid
4.111
3.900
3.545
4.444
3.700
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
3.5 2 (3.7 US qt, 3.1 lmp qt)
4.0 2 (4.2 US qt, 3.5 lmp qt)*
Transmission oil capacity
*: Dual-range model only
2. TRANSMISSION GEAR OIL

Recommended oil
B1H0024
MT-2
GENERAL DESCRIPTION
3. TRANSMISSION CASE ASSEMBLY
4. DRIVE PINION ASSEMBLY
Drive pinion shim adjustment

Hypoid gear backlash
0.13 0.18 mm (0.0051 0.0071 in)
Preload adjustment of thrust bearing

Starting torque
0.3 0.8 Nm (0.03 0.08 kgf-m, 0.2 0.6 ftlb)
Part No.
32295AA031
32295AA041
32295AA051
32295AA061
Drive pinion shim

Thickness
Part No.
mm (in)
0.150
32295AA071
(0.0059)
0.175
32295AA081
(0.0069)
0.200
32295AA091
(0.0079)
0.225
32295AA101
(0.0089)
Adjusting washer No. 1

Part No.
Thickness mm (in)
803025051
3.925 (0.1545)
803025052
3.950 (0.1555)
803025053
3.975 (0.1565)
803025054
4.000 (0.1575)
803025055
4.025 (0.1585)
803025056
4.050 (0.1594)
803025057
4.075 (0.1604)
Thickness
mm (in)
0.250
(0.0098)
0.275
(0.0108)
0.300
(0.0118)
0.500
(0.0197)
Selection of main shaft rear plate

Main shaft rear plate
Dimension A mm (in)
Part No.
4.00 4.13
32294AA041
(0.1575 0.1626)
3.87 3.99
32294AA051
(0.1524 0.1571)

Part No.
Thickness mm (in)
803025059
3.850 (0.1516)
803025054
4.000 (0.1575)
803025058
4.150 (0.1634)
Mark
1
2
Snap ring to counter washer clearance

0.05 0.35 mm (0.0020 0.0138 in)
5. INPUT SHAFT ASSEMBLY

Snap ring (Outer-28) to ball bearing clearance
0 0.12 mm (0 0.0047 in)
Snap ring (Outer-28)
Part No.
Thickness mm (in)
805028050
2.48 (0.0976)
805028060
2.56 (0.1008)
805028070
2.64 (0.1039)

Part No.
Thickness mm (in)
031319000
1.50 (0.0591)
805019010
1.72 (0.0677)
Input shaft holder adjustment

Dimension D mm (in)
52.50 53.11
(2.0669 2.0909)
52.00 52.49
(2.0472 2.0665)
51.26 51.99
(2.0181 2.0468)
Number of shim
Snap ring (Inner-68) to bearing clearance

0 0.12 mm (0 0.0047 in)
Snap ring (Inner-68)

Part No.
Thickness mm (in)
805168020
1.84 (0.0724)
805168030
1.92 (0.0756)
805168040
2.00 (0.0787)
1
2
6. MAIN SHAFT
Snap ring (Outer-25) to synchronizer hub clearance
0.060 0.100 mm (0.0024 0.0039 in)
Part No.
805025051
805025052
805025053
805025054
MT-3

Thickness
Part No.
mm (in)
2.42 (0.0953) 805025055
2.47 (0.0972) 805025056
2.52 (0.0992) 805025057
2.57 (0.1012) 805025058
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
8. SHIFTER FORK AND ROD
Adjustment of reverse idler gear position

Reverse idler gear to transmission case (LH) wall
clearance
6.0 7.5 mm (0.236 0.295 in)
Select the suitable shifter forks so that both coupling sleeve and reverse driven gear are positioned
in the center of their synchromesh mechanisms.
Rod end clearance
A: 1st-2nd 3rd-4th
0.4 1.4 mm (0.016 0.055 in)
B: 3rd-4th 5th
0.5 1.3 mm (0.020 0.051 in)
Part No.
32820AA070
32820AA080
32820AA090
Reverse shifter lever

Mark
Remarks
7
Further from case wall
8
Standard
9
Closer to the case wall
Part No.
After installing a suitable reverse shifter lever, adjust the reverse idler gear to transmission case wall
clearance to within 0 to 0.5 mm (0 to 0.020 in) using
washers.
Part No.
803020151
803020152
803020153
Washer (20.5 26 t)
Thickness
Part No.
mm (in)
0.4 (0.016)
803020154
1.1 (0.043)
803020155
1.5 (0.059)
32804AA060
32804AA070
32804AA080
Thickness
mm (in)
1.9 (0.075)
2.3 (0.091)
Part No.
32810AA061
32810AA071
32810AA101
1st-2nd shifter fork

Mark
Remarks
Approach to 1st gear
1
by 0.2 mm (0.008 in)
No mark
Standard
Approach to 2nd gear
3
by 0.2 mm (0.008 in)
3rd-4th shifter fork
Mark
Remarks
Approach to 4th gear
1
by 0.2 mm (0.008 in)
No mark
Standard
Approach to 3rd gear
3
by 0.2 mm (0.008 in)
5th shifter fork (Non-turbo)

Part No.
Mark
Remarks
32812AA201
4
by 0.2 mm (0.008 in)
32812AA211
5
Standard
Become distant from
32812AA221
6
5th gear by 0.2 mm
(0.008 in)
Part No.
32812AA231
32812AA241
32812AA251
MT-4
5th shifter fork (Turbo)

Mark
Remarks
7
by 0.2 mm (0.008 in)
No mark
Standard
Become distant from
9
5th gear by 0.2 mm
(0.008 in)
GENERAL DESCRIPTION
9. TRANSFER CASE OR REAR CASE
10.EXTENSION ASSEMBLY
Neutral position adjustment
Thrust washer (50 61 t) to taper roller bearing

table outer race side clearance
0.2 0.3 mm T (0.0008 0.012 in T)
Adjustment shim
Part No.
Thickness mm (in)
32190AA000
0.15 (0.0059)
32190AA010
0.30 (0.0118)
Part No.
32188AA090
32188AA100
32188AA110
NOTE:
T: Tight
Thrust washer (50 61 t)
Part No.
Thickness mm (in)
803050060
0.50 (0.0197)
803050061
0.55 (0.0217)
803050062
0.60 (0.0236)
803050063
0.65 (0.0256)
803050064
0.70 (0.0276)
803050065
0.75 (0.0295)
803050066
0.80 (0.0315)
803050067
0.85 (0.0335)
803050068
0.90 (0.0354)
803050069
0.95 (0.0374)
803050070
1.00 (0.0394)
803050071
1.05 (0.0413)
803050072
1.10 (0.0433)
803050073
1.15 (0.0453)
803050074
1.20 (0.0472)
803050075
1.25 (0.0492)
803050076
1.30 (0.0512)
803050077
1.35 (0.0531)
803050078
1.40 (0.0551)
803050079
1.45 (0.0571)
Reverse accent shaft

Mark
Remarks
Neutral position is
3
closer to 1st.
0
Standard
Neutral position is
1
closer to reverse gear.
Reverse check plate adjustment
Part No.
32189AA000
32189AA010
33189AA020
32189AA030
32189AA040
Reverse check plate

Angle
Mark
Remarks
Arm stops closer to

0
28
5th gear.
Arm stops closer to
1
31
5th gear.
Arm stops in the cen2
34
ter.
Arm stops closer to
3
37
reverse gear.
Arm stops closer to
4
40
reverse gear.
Thrust washer to center differential side clearance

0.15 0.35 mm (0.0059 0.0138 in)
Part No.
803036050
803036054
803036051
803036055
803036052
803036056
803036053
803036057
803036058
MT-5
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)
GENERAL DESCRIPTION
11.FRONT DIFFERENTIAL
Bevel gear to pinion backlash
0.13 0.18 mm (0.0051 0.0071 in)
Part No.
803038021
803038022
Washer (38.1 50 t)
Thickness
Part No.
mm (in)
0.925
0.950
803038023
(0.0364
0.0374)
0.975
1.000
(0.0384
0.0394)
Thickness
mm (in)
1.025
1.050
(0.0404
0.0413)
Pinion shaft to axle drive shaft clearance

0 0.2 mm (0 0.008 in)
Part No.
805028011

Thickness
Part No.
mm (in)
1.05 (0.0413) 805028012
Thickness
mm (in)
1.20 (0.0472)
12.TRANSFER DRIVE GEAR

Snap ring (Outer-30) to ball bearing clearance
0.01 0.15 mm (0.0004 0.0059 in)
Part No.
Thickness mm (in)
805030041
1.53 (0.0602)
805030042
1.65 (0.0650)
805030043
1.77 (0.0697)
MT-6
GENERAL DESCRIPTION
MT-7
GENERAL DESCRIPTION
B: COMPONENT
1. TRANSMISSION CASE
(17)
(14)
(16)
(11)
(18)
(10)
(13)
(9)
(8)
(7)
(6)
(15)
(12)
(5)
(4)
(1)
(2)
(3)
TR0906
MT-8
GENERAL DESCRIPTION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Transmission case ASSY

Gasket
Drain plug
Snap ring (Outer)
Speedometer driven gear
Washer
Speedometer shaft
Snap ring (Outer)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Oil seal
Clamp
Pitching stopper bracket
Clip
Oil level gauge (Non-turbo model)
Oil seal (Dual-range)
Transmission case ASSY (Dualrange)
(16)
High-low cable bracket A (Dualrange)
(17)
High-low cable bracket B (Dualrange)
(18)
Oil level gauge (Turbo model)

T: 44 (4.5, 32.5)
Transmission case tightening torque
B3M2243A
Bolt No.
Bolt size
Tightening torque: Nm (kgf-m,

ft-lb)
<5> to <15>
8 mm
25 (2.5, 18.1)
<1> to <4>
<16>, <17>
10 mm
39 (4.0, 28.9)
MT-9
GENERAL DESCRIPTION
2. DRIVE PINION ASSEMBLY

(4) (5)
(2)
(3)
(1)
(11)
(18)
(8)
(17)
(16)
(7)
(15)
(14)
(13)
(12)
(10)
(9)
(29)
(6)
T3
(28)
(27)
T1
(26)
(25)
(22)
(24)
(36)
(23)
(35)
(22)
(21)
(20)
(19)
(30)
(33)
(32)
(30)
(31)
T2
(34)
TR0911
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Drive pinion shaft

Roller bearing
Washer
Thrust bearing
Needle bearing
Driven shaft
Key
Woodruff key
Drive pinion collar
Needle bearing
Snap ring (Outer)
Washer
Sub gear
1st driven gear
Baulk ring
(16)
(17)
(18)
(19)
1st-2nd synchronizer hub

Insert key
Reverse driven gear
Outer baulk ring (Except 1.6 L
model)
(20)
Synchro cone (Except 1.6 L

model)
(21)
Inner baulk ring (Except 1.6 L

model)
(22)
(23)
(24)
(25)
(26)
(27)
2nd driven gear

2nd driven gear bush
3rd-4th driven gear
Driven pinion shim
Roller bearing
5th driven gear
MT-10
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
Lock washer
Lock nut
Washer
Thrust bearing
Differential bevel gear sleeve
Washer
Lock washer
Lock nut
2nd baulk ring (1.6 L model)

T1: 29 (3.0, 21.7)
T2: 118 (12.0, 86.8)
T3: 265 (27, 195)
GENERAL DESCRIPTION
3. MAIN SHAFT ASSEMBLY
B3M2120B
(1)
(2)
(3)
(4)
(5)
(6)
Oil seal
Needle bearing
Transmission main shaft
Needle bearing
3rd drive gear
Inner baulk ring (Turbo and 2.5 L
model)
(13)
(14)
(15)
(16)
(17)
(18)
4th drive gear

4th needle bearing race
Needle bearing
4th gear thrust washer
Ball bearing
Baulk ring (Except turbo and 2.5 L
model)
(7)
3rd synchro cone (Turbo and 2.5 L

model)
(8)
Outer baulk ring (Turbo and 2.5 L

model)
(9)
(10)
(11)
(12)
3rd-4th coupling sleeve

3rd-4th synchronizer hub
3rd-4th shifting insert key
4th baulk ring
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
5th gear thrust washer

5th needle bearing race
Needle bearing
Main shaft rear plate
5th drive gear
5th baulk ring
5th-Rev shifting insert key
5th-Rev synchronizer hub
MT-11
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
5th-Rev coupling sleeve

Rev baulk ring
Rev synchro cone
Ball bearing
Synchro cone stopper
Snap ring
Lock washer
Lock nut
Reverse idler gear shaft
Straight pin
Reverse idler gear
Washer

T: 118 (12.0, 86.8)
GENERAL DESCRIPTION
4. AUXILIARY TRANSMISSION GEARS
B3M2173B
MT-12
GENERAL DESCRIPTION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
O-ring
High-low counter shaft
Straight pin
High-low counter washer
Counter gear
Needle bearing
Counter gear collar
Input shaft holder
Input shaft shim
Oil seal
O-ring
Oil squeeze
Straight pin
Ball bearing
Snap ring (Inner-68)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
Input shaft
Needle bearing
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
Needle bearing
Input low gear spacer
Ball
Main shaft
Straight pin
High-low shifter lever
Washer
MT-13
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
High-low shifter shaft

Low switch
Gasket
Straight pin
High-low shifter fork
High-low shifter piece
Ball
Spring
Gasket
Plug

T1: 15.7 (1.6, 11.6)
T2: 20 (2.0, 14.5)
T3: 25 (2.5, 18.1)
GENERAL DESCRIPTION
5. SHIFTER FORK AND SHIFTER ROD
H3M1966A
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Shifter arm
5th shifter fork
Straight pin
Reverse fork rod
Checking ball plug
Gasket
Checking ball spring
Ball
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
3rd-4th fork rod

Interlock plunger
1st-2nd fork rod
Ball
Spring
Snap ring (Outer)
MT-14
(17)
(18)
Reverse fork rod arm


T: 20 (2.0, 14.5)
GENERAL DESCRIPTION
6. TRANSFER CASE AND EXTENSION
TR0949
(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
Neutral switch
Gasket
Back-up light switch
Roller bearing
Transfer driven gear
Roller bearing
Adjusting washer
Ball bearing
Center differential
Adjusting washer
MT-15
(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, 7.2)
T3: 25 (2.5, 18.1)
T4: 26 (2.7, 20)
T5: 40 (4.1, 29.7)
GENERAL DESCRIPTION
7. FRONT DIFFERENTIAL
H3M1967B
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Drive pinion shaft

Hypoid driven gear
Pinion shaft
Straight pin
Washer
Differential bevel gear
Differential bevel pinion
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Snap ring (Outer)

Roller bearing
Differential case
Oil seal
Differential side retainer
O-ring
Axle drive shaft
MT-16
(15)
Retainer lock plate

T1: 25 (2.5, 18.1)
T2: 62 (6.3, 45.6)
GENERAL DESCRIPTION
8. TRANSMISSION MOUNTING
Except 1.6 L MODEL
(4)
(7)
T1
(3)
(5)
T4
(6)
(2)
T3
T5
T2
(1)
(8)
(9)
(3)
(11)
(2)
(10)
(8)
T2
T5
T5
T6
TR0012
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Pitching stopper
Spacer
Cushion C
Front plate
Dynamic damper
Rear cushion rubber
Rear crossmember
(8)
(9)
(10)
(11)
Cushion D
Center crossmember
Rear plate
Front crossmember
MT-17

T1: 7.5 (0.76, 5.5)
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
Remove contamination including dirt and corrosion before removal, installation, and disassembly.
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.

points.
Replace deformed or otherwise damaged snap
rings with new ones.
Before installing O-rings or oil seals, apply sufficient amount of gear oil to avoid damage and deformation.
Be careful not to incorrectly install or fail to install
O-rings, snap rings and other such parts.
Avoid damaging the mating surface of the case.
Before applying sealant, completely remove the
old seal.
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
398791700
DESCRIPTION
REMOVER
REMARKS
Used for removing and installing spring pin (6
mm).
ACCENT BALL
INSTALLER
Used for installing reverse shifter rail arm.
B3M1938
399411700
B3M1939
MT-18
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
399527700
DESCRIPTION
PULLER SET
REMARKS
Used for removing and installing roller bearing
(Differential).
(1) BOLT (899521412)
(2) PULLER (399527702)
(3) HOLDER (399527703)
(4) ADAPTER (398497701)
(5) BOLT (899520107)
(6) NUT (021008000)
399780104
WEIGHT
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.
B3M1940A
B3M1941
B3M1942
B3M1943
MT-19
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
498147000
DESCRIPTION
DEPTH GAUGE
REMARKS
Used for adjusting main shaft axial end play.
498247001
MAGNET BASE
Used for measuring backlash between side

gear and pinion, and hypoid gear.
Used with DIAL GAUGE (498247100).
498247100
DIAL GAUGE

Used with MAGNET BASE (498247001).
498427100
STOPPER
Used for securing the drive pinion shaft assembly and driven gear assembly when removing
the drive pinion shaft assembly lock nut.
B3M1944
B3M1945
B3M1946
B3M1947
MT-20
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
498787100
DESCRIPTION
MAIN SHAFT
STOPPER
REMARKS
Used for removing and installing transmission
main shaft lock nut.
498937000
TRANSMISSION
HOLDER
Used for removing and installing transmission

main shaft lock nut.
499277100
BUSH 1-2
INSTALLER
Used for installing 1st driven gear thrust plate

and 1st-2nd driven gear bush.
Used for installing roller bearing outer races to
differential case.
499277200
INSTALLER
Used for press-fitting the 2nd driven gear, roller

bearings, and 5th driven gear onto the driven
shaft.
B3M1948
B3M1949
B3M1950
B3M1951
MT-21
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
499757002
DESCRIPTION
INSTALLER
REMARKS
Used for installing snap ring (OUT 25), and
ball bearing (25 x 26 x 17).
Used for installing bearing cone of transfer
driven gear (extension core side).
499787000
WRENCH ASSY
Used for removing and installing differential side

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.
B3M1952
B3M1953
B3M1954
B3M1955
MT-22
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
499877000
DESCRIPTION
RACE 4-5
INSTALLER
REMARKS
Used for installing 4th needle bearing race and
ball bearing onto transmission main shaft.
Used with REMOVER (899714110).
499917500
DRIVE PINION
GAUGE ASSY
Used for adjusting drive pinion shim.
499927100
HANDLE
Used for fitting transmission main shaft.
499937100
TRANSMISSION
STAND SET
Stand used for transmission disassembly and

assembly.
B3M1956
B3M1957
B3M1958
B3M1959
MT-23
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
499987003
DESCRIPTION
SOCKET WRENCH
(35)
REMARKS
Used for removing and installing driven pinion
lock nut and main shaft lock nut.
499987300
SOCKET WRENCH
(50)
Used for removing and installing driven gear

assembly lock nut.
899714110
REMOVER
Used for fixing transmission main shaft, drive

pinion, rear drive shaft.
899864100
REMOVER
Used for removing parts on transmission main

shaft and drive pinion.
B3M1960
B3M1961
B3M1962
B3M1963
MT-24
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
899884100
DESCRIPTION
HOLDER
REMARKS
Used for tightening lock nut on sleeve.
899904100
REMOVER
Used for removing and installing straight pin.
899988608
SOCKET WRENCH
(27)
Used for removing and installing drive pinion

lock nut.
398497701
ADAPTER
Used for installing roller bearing onto differential case.

Used with INSTALLER (499277100).
B3M1964
B3M1965
B3M1966
B3M1967
MT-25
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
499587000
DESCRIPTION
INSTALLER
REMARKS
Used for installing driven gears to driven shaft.
899824100
PRESS
Used for installing speedometer shaft oil seal.
499987100
SOCKET WRENCH
(35)

lock nut.
899984103
SOCKET WRENCH
(35)

lock nut.
B3M1968
B3M1969
B3M1970
B3M1971
MT-26
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
498057300
DESCRIPTION
INSTALLER
REMARKS
Used for installing extension oil seal.
498255400
PLATE
Used for measuring backlash.
498077400
SYNCHRONIZER
CONE REMOVER
Used for removing synchronizer cone of main

shaft.
Used for removing 5th driven gear of drive pinion shaft.
ENGINE SUPPORT
BRACKET
B3M1972
B3M1973
B3M1974
41099AA010
B3M1975
MT-27
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
41099AA020
DESCRIPTION
ENGINE SUPPORT
REMARKS
398527700
PULLER ASSY
Used for removing extension case roller bearing.

Used for removing front differential side
retainer bearing cup.
398643600
GAUGE
Used for measuring total end play, extension

end play and drive pinion height.
38177700
INSTALLER
Used for installing bearing cone of transfer

driven gear (transfer case side).
Used for installing ball bearing of transfer drive
gear.
B3M1976
B3M1977
B3M1978
B3M1905
MT-28
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
398507703
DESCRIPTION
DUMMY COLLAR
REMARKS
Used for installing input shaft holder oil seal.
For dual-range model.
398663600
PLIERS
Used for removing and installing input shaft

snap ring.
499757001
SNAP RING GUIDE
Used for installing snap ring (OUT 25).

899858600
RETAINER
Used for removing ball bearing.

B3M2122
B3M2123
B3M2124
B3M2125
MT-29
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
899474100
DESCRIPTION
EXPANDER
REMARKS
Used for removing and installing snap ring.
899580100
INSTALLER
Used when pressing ball bearings into input

shaft.
399513600
INSTALLER
Used when pressing ball bearings into input

shaft.
499797000
INSTALLER
Used for installing differential side retainer oil

seal.
B3M2126
B3M2127
B3M2129
B3M2197
MT-30
GENERAL DESCRIPTION

TOOL NAME
Circuit Tester
REMARKS
MT-31
TRANSMISSION GEAR OIL

2. Transmission Gear Oil
5) Pour gear oil into the gauge hole.
A: INSPECTION
Recommended gear oil:

Use GL-5 or equivalent.

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 on it. If it is below the lower level, add oil
through the oil level gauge hole to bring the level up
to the upper level.
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 the transmission gear oil.
CAUTION:
When inserting the level gauge into transmission gear, align the protrusion on the side of
the top part of level gauge with the notch in the
gauge hole.
NOTE:
The level should be within the specified range
marked on the gauge.
GI0042A
B: REPLACEMENT
1) Pull out the oil level gauge.
3) Drain the transmission gear oil completely.
CAUTION:
transmission gear oil is hot. Be careful not to
burn yourself.
NOTE:
Tighten the transmission gear oil drain plug after
draining the transmission gear oil.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
S3M0470A
(A) Drain plug

(B) Gasket
MT-32
MANUAL TRANSMISSION ASSEMBLY

3. Manual Transmission Assembly
(4) Vehicle speed sensor
A: REMOVAL
1) Open the front hood fully, and support with stay.
3) Remove the air intake duct and cleaner case.
(Non-turbo model) <Ref. to IN-7, REMOVAL, Air Intake Duct.> and <Ref. to IN-6, REMOVAL, Air
Cleaner Case.>
4) Remove the air cleaner case stay. (Non-turbo
model)
S2M0907
7) Remove the snap pin and pin from drive select

cable.
8) Remove the drive select cable on transmission.
(Dual-range model)
S2M0900
5) Remove the intercooler (Turbo model) <Ref. to

6) Disconnect the following connectors:
(1) Neutral position switch connector
(2) Back-up light switch connector
(3) High-low switch connector (Dual-range
model)
Non-turbo MODEL
S3M0641A
(A) Snap pin

(B) Clevis pin
(C) Drive select cable
9) Remove the starter. <Ref. to SC-5, REMOVAL,

Starter.>
10) Remove the operating cylinder from transmission. (2.0 L and 2.5 L model)
Non-turbo MODEL
S2M0743
Turbo MODEL
TR0069
TR0428
MT-33

Turbo MODEL
(1) Remove the clutch operating cylinder from

transmission.
(2) Remove the plug using 10 mm hexagon
wrench.
TR0070
11) Disconnect the return spring and clutch cable.

(1.6 L model)
S2M1935
(3) Screw the 6 mm dia. bolt into release fork

shaft, and remove it.
G2M0545
TR0072
13) Set the ST.
S2M1936A
NOTE:
Also is available Part No. 41099AA010.
ST 41099AA020 ENGINE SUPPORT ASSY
(A) Shaft
(B) Bolt
(4) Raise the release fork and unfasten the release bearing tabs to free release fork.
NOTE:
Step (4) is required to prevent interference with engine when removing the engine from transmission.
G2M0313
14) Separate the clutch release fork from release

bearing. (Turbo model)
MT-34

15) Remove the bolt which holds right upper side of

22) Remove the gear shift rod and stay from transmission.
(1) Disconnect the stay from transmission.
(2) Disconnect the rod from transmission.
B2M2791

(Non-turbo model) with OBD <Ref. to EX-7, REMOVAL, Front Exhaust Pipe.> without OBD <Ref.
to EX(w/oOBD)-9, REMOVAL, Front Exhaust
Pipe.>
17) Remove the center exhaust pipe. (Turbo model). <Ref. to EX(TURBO)-8, REMOVAL, Center Exhaust Pipe.>
CAUTION:
When removing the exhaust pipes, be careful
each exhaust pipe does not drop out.
20) Remove the hanger bracket from right side of
transmission.
B3M1824A
(A) Stay
(B) Rod

link.
24) Remove the bolt securing ball joint of transverse link to housing.
G4M0491
Sedan turbo MODEL
B2M0032

TR0090
G4M0491
MT-35

25) Remove the spring pins and separate the front

drive shafts from each side of transmission.

from vehicle.
NOTE:
Discard the removing spring pin. Replace with a
new one.
G2M0831
29) Remove the transmission.

G2M0325

NOTE:
Move the transmission jack toward rear until main
shaft is withdrawn from clutch cover.
30) Separate the transmission assembly and rear
cushion rubber.
B2M2790

CAUTION:
Always support the transmission case with a
transmission jack.
G2M0326
MT-36

B: INSTALLATION
1) Install the rear cushion rubber to transmission
assembly.
Tightening torque:
35 Nm (3.57 kgf-m, 25.8 ft-lb)
2) Install the clutch release lever and bearing onto
transmission. (Turbo model) <Ref. to CL-26, INSTALLATION, Release Bearing and Lever.>
3) Install the transmission onto engine.
(1) Gradually raise the transmission with transmission jack.
(2) Engage them at splines.
7) Connect the engine and transmission.

(1) Install the starter.
<Ref. to SC-6, INSTALLATION, Starter.>
(2) Tighten the bolt which holds right upper side
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
NOTE:
Be careful not to strike the main shaft against clutch
cover.
B2M2791
Tightening torque:
T1: 70 Nm (7.1 kgf-m, 51 ft-lb)
T2: 140 Nm (14.3 kgf-m, 103 ft-lb)
8) Remove the ST.
G2M0313
G2M0832
5) Take off the transmission jack.

Tightening torque:
T1: 50 Nm (5.1 kgf-m, 37 ft-lb)
T2: 58 Nm (5.9 kgf-m, 43 ft-lb)
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
T1
T2
TR0086
B2M2790

11) Install the front drive shaft into transmission.
MT-37

12) Drive the spring pin into chamfered hole of

drive shaft.
NOTE:
Always use a new spring pin.
Sedan turbo MODEL

Tightening torque:
45 Nm (4.6 kgf-m, 33.2 ft-lb)
TR0090
G2M0325
13) Install the ball joints of lower arm into knuckle

arm of housing, and tighten the installing bolts.
15) Install the gear shift rod and stay.

(1) Install the gear shift rod onto transmission.
Tightening torque:
49 Nm (5.0 kgf-m, 36 ft-lb)
B3M1824A
(A) Stay
(B) Rod
B2M3402A
(A) Transverse link

(B) Ball joint
14) Install the stabilizer link from transverse link.

(2) Install the stay onto transmission.

18) Install the hanger bracket on right side of transmission.
Tightening torque:
30 Nm (3.1 kgf-m, 22.1 ft-lb)
B2M0032

TR0089
MT-38

20) Install the front exhaust pipe and center exhaust pipe. (Non-turbo model)
Without OBD
Exhaust Pipe.>
With OBD
Pipe.>
Exhaust Pipe.>
23) Install the operating cylinder. (2.0 L and 2.5 L
model)
25) Install the drive select cable on transmission.

(Dual-range model)
S3M0641A
(A) Snap pin

(B) Clevis pin
(C) Drive select cable
Tightening torque:
37 Nm (3.8 kgf-m, 27.5 ft-lb)
Non-turbo MODEL
26) Connect the following connectors:

TR0069
Turbo MODEL
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
(2) Vehicle speed sensor connector
(3) Neutral position switch connector
(4) Back-up light switch connector
(5) High-low switch connector (Dual-range
model)
27) Install the air cleaner case stay.
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
28) Install the air cleaner case and duct.
TR0070
24) Connect the return spring and clutch cable.

(1.6 L model)
G2M0545
MT-39

4. Transmission Mounting System
8) Remove the rear crossmember.
A: REMOVAL
1. PITCHING STOPPER
3) Remove the air intake duct (Non-turbo model).
4) Remove the air cleaner case (Non-turbo model).
5) Remove the intercooler (Turbo model). <Ref. to
G2M0831
9) Remove the rear cushion rubber.
B: INSTALLATION
1. PITCHING STOPPER
TR0072

racks.
(Non-turbo model)
Without OBD
Pipe.>
With OBD
4) Remove the center exhaust pipe. (Turbo model)
<Ref. to EX(TURBO)-8, REMOVAL, Center Exhaust Pipe.>
7) Set the transmission jack under the transmission
body.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 37 ft-lb)
T2: 58 Nm (5.9 kgf-m, 43 ft-lb)
2) Install the air intake duct and cleaner case.
(Non-turbo model)
and <Ref. to IN-7, INSTALLATION, Air Intake
Duct.>
CAUTION:
Always support the transmission case with a
transmission jack.
MT-40

C: INSPECTION
Repair or replace parts if the results of the inspection below are not satisfactory.
1) Install the rear cushion rubber.
1. PITCHING STOPPER
Tightening torque:
35 Nm (3.6 kgf-m, 26 ft-lb)
2) Install the rear crossmember.
Make sure that the pitching stopper is not bent or

damaged. Make sure that the rubber is not stiff,
cracked, or otherwise damaged.
Tightening torque:
T1: 70 Nm (7.1 kgf-m, 51 ft-lb)
T2: 140 Nm (14.3 kgf-m, 103 ft-lb)

Make sure that the crossmember is not bent or
damaged. Make sure that the cushion rubber is not
stiff, cracked, or otherwise damaged.
G2M0832
3) Remove the transmission jack.

5) Install the front and center exhaust pipes. (Nonturbo model)
Without OBD
Exhaust Pipe.>
With OBD
Pipe.>
Exhaust Pipe.>
MT-41
OIL SEAL
5. Oil Seal
7) Using the ST, install the oil seal.

ST 498057300
INSTALLER
A: INSPECTION
Check the oil seal portion for leakage. If leakage is
found, replace the oil seal with a new one.
B: REPLACEMENT
2) Drain the gear oil completely.
NOTE:
Tighten the drain plug after draining gear oil.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
B3M1982

9) Install the heat shield cover.
11) Pour gear oil and check the oil level. <Ref. to
MT-32, REPLACEMENT, Transmission Gear Oil.>
B3M0037

5) Remove the propeller shaft. <Ref. to DS-15, REMOVAL, Propeller Shaft.>
6) Using the ST, remove the oil seal.
ST 398527700
PULLER ASSY
B3M2135A
(A) Oil seal
MT-42
SWITCHES AND HARNESS

6. Switches and Harness
6) Remove the back-up light switch and neutral position switch with harness.
A: REMOVAL
1. BACK-UP LIGHT AND NEUTRAL POSITION SWITCH
(Non-turbo model) <Ref. to IN-6, REMOVAL, Air
Cleaner Case.> and <Ref. to IN-7, REMOVAL, Air
Intake Duct.>
4) Disconnect the connector of back-up light switch
and neutral position switch.
Non-turbo MODEL
B3M1372C
(A) Neutral switch (Brown connector)

(B) Back-up light switch (Gray connector)
2. HIGH-LOW SWITCH
<Ref. to IN-6, REMOVAL, Air Cleaner Case.> and
3) Disconnect the connector of high-low switch.
B2M0337B
(A) Neutral switch (Brown)

(B) Back-up light switch (Gray)
Turbo MODEL
S2M0743A
(A) Neutral switch (Brown)

(B) Back-up light switch (Gray)
(C) High-low switch (Black)
4) Remove the high-low switch cable from clamp.

5) Remove the high-low switch.
TR0428
(A)

(B)
TR0912
(A) Clamp
(B) High-low switch
MT-43

B: INSTALLATION
C: INSPECTION
1. BACK-UP LIGHT SWITCH AND NEUTRAL POSITION SWITCH
1. BACK-UP LIGHT SWITCH
1) Install the back-up light switch and neutral position switch with harness.
Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
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.
Non-turbo model:
Gear shift position
Neutral position
Other positions
Terminal No.
1 and 2
Specified resistance
Less than 1
More than 1M
Turbo model:
B3M1372C
Gear shift position

Neutral position
Other positions
(A) Neutral switch

(B) Back-up light switch
2) Connect the connector of back-up light switch

and neutral position switch.
3) Install the air intake duct and cleaner case.
(Non-turbo model) <Ref. to IN-6, INSTALLATION,
Air Cleaner Case.> and <Ref. to IN-7, INSTALLATION, Air Intake Duct.>
Terminal No.
1 and 3
Less than 1
More than 1M
Non-turbo MODEL
2 1
TR0100
2. HIGH-LOW SWITCH
Turbo MODEL
1) Install the high-low switch.

Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
2) Install the high-low switch cable to clamp.
3) Connect the connector of high-low switch.
4) Install the air intake duct and cleaner case. <Ref.
to IN-6, INSTALLATION, Air Cleaner Case.> and
2 1
4 3
TR0101
4) Replace defective parts.
MT-44

3. HIGH-LOW SWITCH
1) Turn ignition switch to OFF.
2) Disconnect connector high-low switch.
3) Measure the resistance between high-low
switch terminals.
Gear shift position
LO position
HIGH position
Terminal No.
1 and 2
Less than 1
More than 1M
B3M2134
4) Replace defective parts.
MT-45
VEHICLE SPEED SENSOR

7. Vehicle Speed Sensor

A: REMOVAL
3) Remove the front, center rear exhaust pipes and
muffler.
4) Disconnect the connector from vehicle speed
sensor.
5) Turn and remove the vehicle speed sensor.
B6M1449
B: INSTALLATION
NOTE:
Discard the vehicle speed sensor and after removal, replace with a new one.
Ensure the sensor mounting hole is clean and
free of foreign matter.
Align the tip end of key with key groove on end of
speedometer shaft during installation.
1) Hand tighten the vehicle speed sensor.
2) Tighten the vehicle speed sensor using suitable
tool.
Tightening torque:
5.9 Nm (0.6 kgf-m, 4.3 ft-lb)
3) Connect the connector to vehicle speed sensor.
4) Install the front, center exhaust pipes and muffler.
C: INSPECTION
Inspect the vehicle speed sensor.
Without OBD
<Ref. to EN(w/oOBD)-92, DTC 33 VEHICLE
SPEED SIGNAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
With OBD Non-Turbo model
<Ref. to EN-210, DTC P0500 VEHICLE SPEED
SENSOR MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Turbo model
<Ref. to EN(TURBO)-230, DTC P0500 VEHICLE SPEED SENSOR MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
MT-46

8. Preparation for Overhaul

A: PROCEDURE
1) Clean oil, grease, dirt and dust from transmission.
2) Remove the drain plug to drain oil. After draining, retighten it as before.
NOTE:
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
B3M0037
3) Attach the transmission to ST.

ST 499937100
TRANSMISSION STAND
G3M0517
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) Gaskets, lock washers and lock nut must be replaced with new ones.
7) Liquid gasket should be used where specified to
prevent leakage.
MT-47
TRANSFER CASE AND EXTENSION CASE ASSEMBLY

9. Transfer Case and Extension

Case Assembly
2) Remove the bearing cone from bearing of the

transfer driven gear.
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-33, REMOVAL, Manual
Transmission Assembly.>
2) Remove the back-up light switch and neutral position switch. <Ref. to MT-43, REMOVAL, Switches
and Harness.>
3) Remove the transfer case with extension case
assembly.
B3M2172A
(A) Bearing cone (Extension case)

(B) Extension case
3) While pressing the bearing cone horizontally,

turn the driven shaft ten rotations.
4) Measure the height W between transfer case
and taper roller bearing on the transfer driven gear.
B3M1373
4) Remove the shifter arm.

5) Remove the extension case assembly.
B3M1984A
5) Measure the depth X.

NOTE:
Measure with bearing cone and thrust washer removed.
B3M1374
B: INSTALLATION
1) Install the center differential and transfer driven
gear into transfer case.
B3M1406A
6) Calculate the space t using the following equation: t = X W + 0.2 to 0.3 mm (0.008 to 0.012 in)
B3M1983
MT-48

7) Select the nearest washer in the following table:

Standard clearance between thrust washer and
taper roller bearing:
0.2 0.3 mm T (0.008 0.012 in T)
11) Measure the depth T between extension case

and transfer drive gear.
ST 398643600
GAUGE
NOTE:
T: Tight
Thrust washer (50 61 t)
Part No.
Thickness mm (in)
803050060
0.50 (0.0197)
803050061
0.55 (0.0217)
803050062
0.60 (0.0236)
803050063
0.65 (0.0256)
803050064
0.70 (0.0276)
803050065
0.75 (0.0295)
803050066
0.80 (0.0315)
803050067
0.85 (0.0335)
803050068
0.90 (0.0354)
803050069
0.95 (0.0374)
803050070
1.00 (0.0394)
803050071
1.05 (0.0413)
803050072
1.10 (0.0433)
803050073
1.15 (0.0453)
803050074
1.20 (0.0472)
803050075
1.25 (0.0492)
803050076
1.30 (0.0512)
803050077
1.35 (0.0531)
803050078
1.40 (0.0551)
803050079
1.45 (0.0571)
B3M1395A
12) Calculate the space U using the following

equation: U = S T 30 mm (1.18 in) [Thickness of
ST]
13) Select the suitable washer in the following table:
Standard clearance:
0.15 0.35 mm (0.0059 0.0138 in)
8) Fit the thrust washers on transfer drive shaft.

9) Install the bearing cone into extension case.
10) Measure the depth S between transfer case
and center differential.
ST 398643600
GAUGE
Part No.
803036050
803036054
803036051
803036055
803036052
803036056
803036053
803036057
803036058
Thrust washer
Thickness mm (in)
0.9 (0.035)
1.0 (0.039)
1.1 (0.043)
1.2 (0.047)
1.3 (0.051)
1.4 (0.055)
1.5 (0.059)
1.6 (0.063)
1.7 (0.067)
14) Fit the thrust washer on center differential.

15) Apply proper amount of liquid gasket to the
transfer case mating surface.
Liquid gasket:
THREE BOND 1215
B3M1407A
TR0522
MT-49

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, 18.1 ft-lb)
B3M1374
17) Install the shifter arm to transfer case.
B3M1373
C: DISASSEMBLY
1. TRANSFER CASE
1) Remove the reverse check assembly. <Ref. to
MT-57, REMOVAL, Reverse Check Sleeve.>
2) Remove the oil guide.
B3M1396
18) Hang the shifter arm on 3rd-4th fork rod.
B3M1378
2. EXTENSION CASE
1) Remove the transfer drive gear assembly. <Ref.
to MT-52, REMOVAL, Transfer Drive Gear.>
2) Remove the shift bracket.
B3M1397B
(A) Shifter arm

(B) 3rd-4th fork rod
B3M1381
3) Remove the oil seal from extension case. <Ref.

to MT-42, Oil Seal.>
MT-50

D: ASSEMBLY
1. EXTENSION CASE
1) Using the ST, install the oil seal to extension
case. <Ref. to MT-42, Oil Seal.>
NOTE:
Use a new oil seal.
2) Install the shift bracket to extension case.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
B3M1381
3) Install the transfer drive gear to extension case.

<Ref. to MT-52, 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)
B3M1378
2) Install the reverse check sleeve assembly to

transfer case. <Ref. to MT-57, INSTALLATION,
Reverse Check Sleeve.>
MT-51
TRANSFER DRIVE GEAR

10.Transfer Drive Gear
C: DISASSEMBLY
A: REMOVAL
1) Remove the snap ring.

and Harness.>
assembly. <Ref. to MT-48, REMOVAL, Transfer
Case and Extension Case Assembly.>
5) Remove the transfer driven gear.
6) Remove the transfer drive gear.
B3M1988
2) Remove the ball bearing.
B3M1989
B3M1986
D: ASSEMBLY
B: INSTALLATION
1) Set the ST applying to inner race of bearing and

install to drive shaft.
ST 398177700
INSTALLER
1) Install the transfer drive gear.

Tightening torque:
26 Nm (2.7 kgf-m, 20 ft-lb)
CAUTION:
Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton)
ST
B3M1986
2) Install the transfer driven gear.

3) Install the extension case assembly.
4) Install the transfer case and extension case assembly. <Ref. to MT-48, INSTALLATION, Transfer
5) Install the back-up light switch and neutral position switch. <Ref. to MT-44, INSTALLATION,
Switches and Harness.>
6) Install the manual transmission assembly from
vehicle. <Ref. to MT-37, INSTALLATION, Manual
TR0523
2) Install the snap ring on transfer drive shaft.

3) Check the clearance between snap ring and ball
bearing. <Ref. to MT-53, INSPECTION, Transfer
Drive Gear.>
MT-52
TRANSFER DRIVE GEAR

E: INSPECTION
1) Bearings
Replace the bearings in the following cases:
Broken or rusty bearings
Worn or damaged
Bearings that fail to turn smoothly or make abnormal noise when turned after gear oil lubrication.
2) Drive gear
Replace the drive gear in the following cases:
If their tooth surfaces and shaft are excessively
broken or damaged.
3) Measure the clearance between snap ring and
inner race of ball bearing with a thickness gauge.
Clearance:
0.01 0.15 mm (0.0004 0.0059 in)
B3M1991
If the measurement is not within specification, select a suitable snap ring.

Part No.
Thickness mm (in)
805030041
1.53 (0.0602)
805030042
1.65 (0.0650)
805030043
1.77 (0.0697)
MT-53
TRANSFER DRIVEN GEAR

11.Transfer Driven Gear
B: INSTALLATION
A: REMOVAL
1) Install the bearing cup to extension case and

transfer case.

and Harness.>
5) Remove the transfer driven gear.
(C)
(A)
(B)
B3M1983
(D)
TR0125
6) Remove the bearing cup from extension case

and transfer case.
(A)
(B)
(C)
(D)
Bearing cup
Bearing cup
Transfer case
Extension case
2) Install the transfer driven gear.
B3M1983
B3M1993A
(A) Bearing cup (transfer case)

(B) Bearing cup (extension case)
3) Install the transfer case and extension case assembly.<Ref. to MT-48, INSTALLATION, Transfer
5) Install the manual transmission assembly to vehicle. <Ref. to MT-37, INSTALLATION, Manual
MT-54
TRANSFER DRIVEN GEAR

C: DISASSEMBLY
D: ASSEMBLY
1) Using the ST, remove the roller bearing (extension case side).
ST 498077000
REMOVER
1) Using the ST, install the roller bearing (extension

case side).
ST1 398177700 INSTALLER
ST2 899864100 REMOVER
CAUTION:
B3M2136A
(A) Roller bearing
2) Using the ST1 and ST2, remove the roller bearing (transfer case side).
B3M2138A
(A) Roller bearing
2) Using the ST, install the roller bearing (transfer

case side).
ST 499757002
INSTALLER
CAUTION:
B3M2137A
(A) Roller bearing
B3M2139A
(A) Roller bearing
E: INSPECTION
1) Bearings
Worn or damaged
2) Driven gear
Replace the drive gear in the following cases:
If their tooth surfaces and shaft are excessively
broken or damaged.
MT-55
CENTER DIFFERENTIAL
12.Center Differential
D: ASSEMBLY
A: REMOVAL
Install the ball bearing to center differential assembly.

assembly.<Ref. to MT-48, REMOVAL, Transfer
3) Remove the extension case assembly. <Ref. to
MT-48, REMOVAL, Transfer Case and Extension
Case Assembly.>
4) Remove the transfer driven gear. <Ref. to MT54, REMOVAL, Transfer Driven Gear.>
5) Remove the center differential.
CAUTION:
1.1 US ton, 1.0 Imp ton).
B: INSTALLATION
1) Install the center differential into transfer case.
2) Install the transfer driven gear. <Ref. to MT-54,
INSTALLATION, Transfer Driven Gear.>
3) Install the extension case assembly. <Ref. to
MT-48, INSTALLATION, Transfer Case and Extension Case Assembly.>
4) Install the transfer case with extension case assembly. <Ref. to MT-48, REMOVAL, Transfer
5) Install the back-up light switch and neutral position switch. <Ref. to MT-43, REMOVAL, Switches
and Harness.>
C: DISASSEMBLY
B3M1399B
(A) Ball bearing
E: INSPECTION
1) Bearings
Worn or damaged
Bearings having other defects
2) Center differential
Replace the center differential assembly in the following case:
Worn or damaged
NOTE:
Do not disassemble the center differential because
it is a non-disassemble part.
Remove the ball bearing using ST.
NOTE:
Do not reuse the ball bearing.
ST 498077300
CENTER DIFFERENTIAL
BEARING REMOVER
B3M1398C
MT-56
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, 7.2 ft-lb)
B3M1376
B3M1376
3) Install the shifter arm to transfer case assembly.

4) Install the transfer case with extension case assembly. <Ref. to MT-48, INSTALLATION, Transfer
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 deformed
or weakened.
B3M1377
B: INSTALLATION
1) Install the reverse check sleeve.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
B3M1383C
(A) Snap ring
B3M1377
MT-57

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).
D: ASSEMBLY
1) Install the return spring (1st-2nd), return spring
cap, reverse accent shaft, check cam, return spring
and check spring onto reverse check sleeve.
NOTE:
Be sure the bent section of reverse check spring is
positioned in the groove in check cam.
B3M1384A
(A)
(B)
(C)
(D)
(E)
(F)
(G)
Reverse check plate

Return spring (5th-Rev)
Reverse check cam
Return spring cap
Return spring (1st-2nd)
B3M1384A
(A)
(B)
(C)
(D)
(E)
(F)
(G)
3) Remove the O-ring.

NOTE:
Reverse check sleeve assembly uses an O-ring
which should not be scratched.
Be careful not to break the adjustment shim
placed between reverse check sleeve assembly
and case.

Reverse check cam
Return spring (5th-Rev)
Return spring cap
Return spring (1st-2nd)
Reverse check sleeve
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 the cam held in that position, install the
plate onto reverse check sleeve and hold with snap
ring.
5) Position the O-ring in groove in sleeve.
MT-58

E: INSPECTION
F: ADJUSTMENT
Make sure the cutout section of reverse accent

shaft is aligned with the opening in reverse check
sleeve.
Spin the cam by hand for smooth rotation.
Move the cam and shaft all the way toward plate
and release.
If the cam does not return properly, replace the reverse check spring; if shaft does not, check for
scratches on the inner surface of sleeve. If sleeve
is in good order, replace the spring.
1. NEUTRAL POSITION ADJUSTMENT

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 adjustment
shim (0 to 1 ea.) between sleeve assembly and
case to adjust the clearance.
CAUTION:
Be careful not to break the O-ring when placing
shim(s).
NOTE:
When the shim is removed, the neutral position
will move closer to reverse; when shim is added,
the neutral position will move closer to 1st gear.
If the shims alone cannot adjust clearance, replace the reverse accent shaft and re-adjust.
B3M0048D
(A)
(B)
(C)
(D)
Snap ring
Reverse check plate
Check spring
Check cam
Select a suitable reverse accent shaft and reverse check plate.<Ref. to MT-59, ADJUSTMENT,
Reverse Check Sleeve.>
Part No.
32190AA000
32190AA010
Part No.
32188AA090
32188AA100
32188AA110
MT-59
Adjustment shim
Thickness mm (in)
0.15 (0.0059)
0.30 (0.0118)

Mark
Remarks
Neutral position is closer to 1st
3
gear.
0
Standard
Neutral position is closer to
1
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 reverse position. If the arm
does not return properly, replace the reverse check
plate.
Part No.
32189AA000
32189AA010
32189AA020
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.
B3M0054D
MT-60
TRANSMISSION CASE
14.Transmission Case
7) Separate the transmission case into right and

left cases by loosening the coupling bolts and nuts.
A: REMOVAL
1. SINGLE-RANGE
2) Remove the clutch release lever. <Ref. to CL26, REMOVAL, Release Bearing and Lever.>
4) Remove the bearing mounting bolts.
B3M1359
8) Remove the drive pinion shaft assembly from left

side transmission case.
NOTE:
Use a hammer handle, etc. to remove if too tight.
S3M0099
5) Remove the main shaft rear plate.

B3M0101H
(A) Main shaft assembly

(B) Drive pinion shaft assembly
9) Remove the main shaft assembly.
S3M0100C
(A) Main shaft rear plate
6) Put vinyl tape around the splines of right and left

axle drive shafts to prevent damage to oil seal.
B3M1405B
(A) Vinyl tape
MT-61
TRANSMISSION CASE
10) Remove the differential assembly.

NOTE:
Be careful not to confuse the right and left roller
bearing outer races.
Be careful not to damage the retainer oil seal.
6) Using the ST, drive out the straight pin, and remove high-low shifter lever.
ST 398791700
STRAIGHT PIN REMOVER 2
NOTE:
When driving out the straight pin, remove it in the
direction that it does not butt against transmission
case.
G3M0557
2. DUAL-RANGE
H3M1420B

2) Remove the clutch release lever. <Ref. to CL26, REMOVAL, Release Bearing and Lever.>
4) Remove the input shaft holder.
(A) Straight pin

(B) High-low shifter lever
7) Remove the main shaft rear plate.
S3M0100C
(A) Main shaft rear plate
8) Put vinyl tape around the splines of right and left

axle drive shafts to prevent damage to oil seals.
B3M2175A
(A) Input shaft holder

(B) Input shaft
5) Remove the high-low switch. <Ref. to MT-43,

REMOVAL, Switches and Harness.>
B3M1405B
(A) Vinyl tape
MT-62
TRANSMISSION CASE
9) Separate the transmission case into right and

left cases by loosening the seventeen coupling
bolts and nuts.
12) Remove the main shaft assembly and input

shaft assembly.
CAUTION:
Be careful not to drop the input shaft and main
shaft as they are separable.
B3M1359
10) Remove the drive pinion shaft assembly from

left side transmission case.
H3M1424B
NOTE:
(A) Main shaft ASSY

(B) Input shaft ASSY
(A)

NOTE:
TR0146
(A) Drive pinion shaft assembly
11) 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.
B3M0075C
(A) High-low shifter fork

(B) Input shaft ASSY
G3M0557
B: INSTALLATION
1. SINGLE-RANGE
1) Wipe off grease, oil and dust on the mating surfaces of transmission cases with white gasoline.
2) Install the front differential assembly.
3) Install the main shaft assembly.
Install the needle bearing knock pin hole into transmission case knock pin.
4) Install the drive pinion shaft assembly.
Install the roller bearing knock pin hole into transmission case knock pin.
5) Apply liquid gasket, and then put the case right
side and left side together.
Liquid gasket:
MT-63
TRANSMISSION CASE
6) Tighten the seventeen bolts with bracket, clip,

etc. as shown in the figure.
8) Backlash adjustment of hypoid gear and preload

adjustment of roller bearing:
NOTE:
Insert the bolts from bottom and tighten the nuts
at top.
Put the cases together so that drive pinion shim
and input shaft holder shim are not caught up in between.
Confirm that the speedometer gear is meshed.
NOTE:
Support the drive pinion assembly with ST.
ST 498427100
STOPPER
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)
B3M1362A
B3M0399B
7) Tighten the ball bearing attachment bolts.

Tightening torque:
29 Nm (3.0 kgf-m, 21.7 ft-lb)
9) Place the transmission with case left side facing

downward and put ST1 on bearing cup.
10) Screw 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
B3M1361A
S3M0099
MT-64
TRANSMISSION CASE
11) 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:
At this point, the backlash between hypoid gear
and drive pinion shaft is zero.
ST 499787000
WRENCH ASSY
17) After checking the tooth contact of hypoid

gears, remove the lock plate. Then loosen the retainer until the O-ring groove appears. Fit the Oring into groove and tighten the retainer into the position where retainer has been tightened in.
Tighten the lock plate.
NOTE:
Carry out this job on both upper and lower retainers.
Tightening torque:
T: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
B3M1360A
12) Fit the lock plate. Loosen the retainer on the

lower side by 1-1/2 notches of lock plate and turn in
the retainer on upper side by the same amount in
order to obtain the backlash.
NOTE:
The notch on the lock plate moves by 1/2 notch if
the plate is turned upside down.
13) Turn in the retainer on the upper side additionally by 1 notch in order to apply preload on taper
roller bearing.
14) Tighten temporarily both the upper and lower
lock plates and mark both holder and lock plate for
later readjustment.
15) Turn the transmission main shaft several times
while tapping around the retainer lightly with plastic
hammer.
16) Inspect and adjust the backlash and tooth contact of hypoid gear. <Ref. to MT-99, INSPECTION,
Front Differential Assembly.>
S3M0014C
18) Selecting of main shaft rear plate. <Ref. to MT75, ADJUSTMENT, Main Shaft Assembly for Single-Range.>
19) Install the clutch release lever and bearing.
<Ref. to CL-26, INSTALLATION, Release Bearing
and Lever.>
21) Install the manual transmission assembly into
the vehicle.<Ref. to MT-37, INSTALLATION, Manual Transmission Assembly.>
2. DUAL-RANGE
1) Wipe off grease, oil and dust on the mating surfaces of transmission cases with white gasoline.
2) Install the front differential assembly.
3) Install the main shaft assembly and input shaft
assembly.
Connect the main shaft assembly and input the
shaft assembly, and install needle bearing knock
pin hole into transmission case knock pin.
4) Install the drive pinion shaft assembly.
Install the roller bearing knock pin hole into transmission case knock pin.
5) Apply liquid gasket, and then put the case right
side and left side together.
Liquid gasket:
MT-65
TRANSMISSION CASE
6) Tighten the seventeen bolts with bracket, clip,

etc. as shown in the figure.
NOTE:
Insert the bolts from bottom and tighten the nuts
at top.
Put the cases together so that the drive pinion
shim and input shaft holder shim are not caught up
in between.
Confirm that the speedometer gear is meshed.
8) Tighten the input shaft holder attaching bolts.

Tightening torque:
20 Nm (2.0 kgf-m, 14.5 ft-lb)
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)
B3M2175A

(B) Input shaft
9) Backlash adjustment of hypoid gear and preload

adjustment of roller bearing
NOTE:
Support the drive pinion assembly with ST.
ST 498427100
STOPPER
S3M0161A
7) Tighten the ball bearing attachment bolts.

Tightening torque:
29 Nm (3.0 kgf-m, 21.7 ft-lb)
B3M1362A
10) Place the transmission with case left side facing downward and put ST1 on bearing cup.
S3M0099
MT-66
TRANSMISSION CASE
11) 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.
ST2 499787000 WRENCH ASSY
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 MT-99, INSPECTION,
Front Differential Assembly.>
18) After checking the tooth contact of hypoid
gears, remove the lock plate. Then loosen the retainer until the O-ring groove appears. Fit the Oring into groove and tighten the retainer into the position where retainer has been tightened in.
Tighten the lock plate.
NOTE:
Carry out this job on both upper and lower retainers.
Tightening torque:
T: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
B3M1361A
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:
At this point, the backlash between hypoid gear
and drive pinion shaft is zero.
ST 499787000
WRENCH ASSY
B3M1360A
13) Fit the lock plate. Loosen the retainer on the

lower side by 1-1/2 notches of lock plate and turn in
the retainer on upper side by the same amount in
order to obtain the backlash.
S3M0014C
19) Selection of main shaft rear plate <Ref. to MT75, ADJUSTMENT, Main Shaft Assembly for Single-Range.>
21) Install the clutch release lever and bearing.
<Ref. to CL-26, INSTALLATION, Release Bearing
and Lever.>
22) Install the manual transmission assembly into
the vehicle.<Ref. to MT-37, INSTALLATION, Manual Transmission Assembly.>
C: INSPECTION
Check the transmission case for cracks, damage,
and oil leaks.
NOTE:
The notch on the lock plate moves by 1/2 notch if
the plate is turned upside down.
14) Turn in the retainer on the upper side additionally by 1 notch in order to apply preload on taper
roller bearing.
15) Tighten temporarily both the upper and lower
lock plates and mark both holder and lock plate for
later readjustment.
MT-67
MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE

15.Main Shaft Assembly for Single-Range

A: REMOVAL
3) Remove the transmission case. <Ref. to MT-48,
REMOVAL, Transfer Case and Extension Case
Assembly.>
4) Remove the drive pinion shaft assembly. <Ref.
to MT-86, REMOVAL, Drive Pinion Shaft Assembly.>
C: DISASSEMBLY
1) Put 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.
NOTE:
Remove the caulking before removing lock nut.
ST1 499987000 TRANSMISSION HOLDER
ST2 498937003 SOCKET WRENCH (35)
B: INSTALLATION
1) Install the needle bearing and oil seal onto the
front of transmission main shaft assembly.
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 one.
2) Install the needle bearing outer race knock pin
hole into transmission case knock pin.
B3M0439A
3) Remove the 5th-Rev sleeve and hub assembly,

baulk ring, 5th drive gear and needle bearing.
NOTE:
Align the end face of seal with surface (A) when installing oil seal.
B3M0437B
(A) 5th-Rev sleeve and hub ASSY

(B) Baulk ring
(C) 5th drive gear
4) Remove the snap ring and synchro cone stopper

from 5th-Rev sleeve and hub assembly.
B3M0528A
3) Install the drive pinion assembly. <Ref. to MT86, INSTALLATION, Drive Pinion Shaft Assembly.>
4) Install the transmission case. <Ref. to MT-63,
INSTALLATION, Transmission Case.>
MT-68
B3M0435B
(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).
6) Using the ST1 and ST2, remove rest of the

parts.
NOTE:
Replace the sleeve and hub with new ones. Do
not attempt to disassemble because they must engage at a specified point. If they should be disassembled, mark engagement point on splines
beforehand.
ST2 498077400 SYNCHRO CONE REMOVER
NOTE:
Replace the sleeve and hub with new ones. Do not
attempt to disassemble because they must engage
at a specified point. If they should be disassembled, mark engagement point on splines beforehand.
B3M1365A
(A) Ball bearing

(B) Synchro cone
(C) Baulk ring
B3M0835A
MT-69

D: ASSEMBLY
3) Install the 4th needle bearing race onto transmission main shaft using ST1, ST2 and a press.
1. EXCEPT 2.5 L AND TURBO MODEL

1) Assemble when each sleeve and hub assembly
are disassembled.
NOTE:
Position the open ends of spring 120 apart.
CAUTION:
ST2 499877000 RACE 4-5 INSTALLER
B3M0543D
(A) 4th needle bearing race
4) Install the baulk ring, needle bearing, 4th drive

gear and 4th gear thrust washer to transmission
main shaft.
NOTE:
Align the baulk ring and gear & hub assembly with
key groove.
B3M1366A
2) Install the 3rd drive gear, baulk ring, sleeve and

hub assembly for 3rd needle bearing on transmission main shaft.
NOTE:
Align the groove in baulk ring with shifting insert.
S3M0045A
(A) Groove
(B) 4th gear side
MT-70

5) Drive the ball bearing onto the rear section of

transmission main shaft using ST1, ST2 and a
press.
8) Install the baulk ring and synchro cone onto 5thRev sleeve and hub assembly using ST and a
press.
CAUTION:
CAUTION:
NOTE:
Use a new ball bearing.
After press fitting, make sure the synchro cone
rotates freely.
ST 499757002
INSTALLER
B3M0553F
6) Using the ST1 and ST2, install the 5th gear

thrust washer and 5th needle bearing race onto the
rear section of transmission main shaft.
B3M1370A
CAUTION:
NOTE:
Face the thrust washer in correct direction.
(A) Baulk ring

(B) Synchro cone
(C) Ball bearing
9) Install the synchro cone stopper and snap ring to

5th-Rev sleeve and hub assembly.
B3M0435B
B3M0091D

(B) Snap ring
(A) Face this surface to 5th gear side.
7) Install the bearing onto synchro cone.
MT-71

10) Install rest of the parts to the rear section of

transmission main shaft.
NOTE:
2. 2.5 L AND TURBO MODEL

1) Assemble each sleeve and hub assembly.
NOTE:
B3M1371A
(A)
(B)
(C)
(D)
(E)
(F)
Needle bearing
5th drive gear
Baulk ring
5th-Rev sleeve and hub ASSY
Lock washer
Lock nuts
11) Tighten the lock nuts to the specified torque using ST1 and ST2.
NOTE:
Secure the lock nuts in two places after tightening.
ST1 499987003 SOCKET WRENCH
Tightening torque:
118 Nm (12.0 kgf-m, 86.8 ft-lb)
B3M1366A
2) Install the 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, sleeve and hub assembly for 3rd needle bearing on transmission main
shaft.
NOTE:
B3M0837A
(A)
(B)
(C)
(D)
(E)
(F)
MT-72
3rd needle bearing

3rd drive gear
Inner baulk ring
Synchro cone
Outer baulk ring
Sleeve and hub ASSY

CAUTION:

press.
CAUTION:
B3M0543D
B3M0553F

main shaft.
NOTE:
Align the baulk ring and gear & hub assembly with
key groove.

CAUTION:
NOTE:
S3M0045A
(A) Groove
(B) 4th gear side
B3M0091D
MT-73

press.
CAUTION:
10) Install the rest parts to the rear section of transmission main shaft.
NOTE:
NOTE:
rotates freely.
ST 499757002
INSTALLER
B3M1371A
(A)
(B)
(C)
(D)
(E)
(F)
B3M1370A
Needle bearing
5th drive gear
Baulk ring
Lock washer
Lock nuts
(A) Baulk ring

(B) Synchro cone
(C) Ball bearing

NOTE:
Tightening torque:
118 Nm (12.0 kgf-m, 86.8 ft-lb)
B3M0435B

(B) Snap ring
MT-74

E: INSPECTION
F: ADJUSTMENT
Disassembled parts should be washed clean first

and then inspected carefully.
1) Bearings
Bearings whose balls, outer races and inner races are broken or rusty.
Worn bearings
2) Bushing (each gear)
Replace the bushing in the following cases:
When the sliding surface is damaged or abnormally worn.
When the inner wall is abnormally worn.
3) Gears
Replace the gears with new ones if their tooth
surfaces are broken, damaged, or excessively
worn.
Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
Correct or replace if the inner surface or end face
is damaged.
4) Baulk ring
Replace the ring in the following cases:
When the inner surface and end face are damaged.
When the ring inner surface is abnormally or partially worn down.
When the contact surface of the synchronizer
ring insert is scored or abnormally worn down.
5) Shifting insert key
Replace the insert if deformed, excessively worn,
or defective in any way.
Selection of main shaft rear plate:

Using the ST, measure the amount (A) of ball bearing protrusion from transmission main case surface
and select the proper plate in the following table:
NOTE:
Before measuring, tap the end of main shaft with a
plastic hammer lightly in order to make the clearance zero between the main case surface and the
moving flange of bearing.
ST 498147000
DEPTH GAUGE
S3M0189
6) Oil seal
Replace the oil seal if the lip is deformed, hardened, damaged, worn, or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn, or defective in any way.
8) Gearshift mechanism
Repair or replace the gearshift mechanism if excessively worn, bent, or defective in any way.
MT-75
Dimension (A)
mm (in)
4.00 4.13
(0.1575
0.1626)
3.87 3.99
(0.1524
0.1571)
Part No.
Mark
32294AA041
32294AA051
B3M0531A
MAIN SHAFT ASSEMBLY FOR DUAL-RANGE

16.Main Shaft Assembly for

Dual-Range
C: DISASSEMBLY
A: REMOVAL
REMOVAL, Transmission Case.>
5) Remove the main shaft assembly and input shaft
assembly.
1) Put 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.
NOTE:
Remove the caulking before taking off lock nut.
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.
B3M0439A
3) Remove the 5th-Rev sleeve and hub assembly,

baulk ring, 5th drive gear and needle bearing.
B3M0437B
(A) 5th-Rev sleeve and hub ASSY

(B) Baulk ring
(C) 5th drive gear
4) Remove the snap ring and synchro cone stopper

from 5th-Rev sleeve and hub assembly.
B3M0435B

(B) Snap ring
MT-76

5) Using the ST1, ST2 and a press, remove the ball

bearing, synchro cone and baulk ring (Rev).
6) Using the ST1 and ST2, remove rest of the

parts.
NOTE:
Replace the sleeve and hub with new ones. Do
not attempt to disassemble because they must engage at a specified point. If they should be disassembled, mark engagement point on splines
beforehand.
ST2 498077400 SYNCHRO CONE REMOVER
NOTE:
Replace the sleeve and hub with new ones. Do not
attempt to disassemble because they must engage
at a specified point. If they should be disassembled, marking engagement point on splines beforehand.
B3M1365A
(A) Ball bearing

(B) Synchro cone
(C) Baulk ring
B3M0835A
7) Remove the snap ring from main shaft.

ST 899474100
EXPANDER
H3M1432B
MT-77

8) Remove rest of the parts.
2) Install the 3rd drive gear, baulk ring, sleeve and

hub assembly for 3rd-4th needle bearing on transmission main shaft.
NOTE:
S3M0169A
(A)
(B)
(C)
(D)
(E)
(F)
(G)
Sleeve and hub ASSY

High-low baulk ring
Friction damper
Low input gear
Needle bearing
Ball
B3M0543D
D: ASSEMBLY
1) Assemble when each sleeve and hub assembly

are disassembled.
NOTE:

main shaft.
NOTE:
S3M0444A
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
(J)
S3M0045A
High-low coupling sleeve

Shifting insert
High-low synchronizer spring
High-low synchronizer hub
Sleeve
Insert key
3rd-4th synchronizer hub
Sleeve
Insert key
5th-Rev synchronizer hub
(A) Groove
(B) 4th gear side
MT-78


press.

press.
NOTE:
rotates freely.
ST 499757002
INSTALLER
B3M0553F

B3M1370A
NOTE:
(A) Baulk ring

(B) Synchro cone
(C) Ball bearing

B3M0091D

B3M0435B

(B) Snap ring
MT-79

10) Install rest of the parts to the rear section of

transmission main shaft.
13) Install the parts to the front section of transmission main shaft.
NOTE:
NOTE:
Be careful not to damage the graded section of
transmission main shaft when installing the needle
bearing.
NOTE:
Face the grooved side toward input gear.
Align the high-low baulk ring's groove with shifting insert.
B3M1371A
(A)
(B)
(C)
(D)
(E)
(F)
Needle bearing
5th drive gear
Baulk ring
Lock washer
Lock nuts
S3M0169B
(A)
(B)
(C)
(D)
(E)
(F)
(G)
NOTE:
Tightening torque:
118 Nm (12.0 kgf-m, 86.8 ft-lb)
12) Install the needle bearing on main shaft.
Ball
Needle bearing
Low input gear
Friction damper
High-low baulk ring
Sleeve and hub ASSY
14) 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
Snap ring
Part No.
805025051
805025052
805025053
805025054
805025055
805025056
805025057
805025058
MT-80
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
Worn bearings
3) Gears
worn.
is damaged.
4) Baulk ring
6) Oil seal
7) O-ring
F: ADJUSTMENT
Choose the main shaft rear plate. <Ref. to MT-75,
ADJUSTMENT, Main Shaft Assembly for SingleRange.>
MT-81
INPUT SHAFT ASSEMBLY

17.Input Shaft Assembly
C: DISASSEMBLY
A: REMOVAL
1) Remove the O-ring from input shaft holder. Also,

remove the input shaft holder shim.

5) Remove the main shaft assembly and input shaft
assembly.
NOTE:
Use a new O-ring.
Number of shims used varies from none to two.
B: INSTALLATION
S3M0167A
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 vehicle. <Ref. to MT-37, INSTALLATION, Manual

(B) O-ring
(C) Input shaft holder shim
2) Put vinyl tape around the input shaft splines to

protect oil seal from damage.
3) Remove the inner snap ring.
ST 398663600
PLIERS
G3M0828
4) Hold the input shaft holder stationary and remove the input shaft by tapping its end with a plastic hammer.
H3M1430B

(B) Input shaft
MT-82

5) Remove the outer snap ring. Then remove the

oil squeeze plate and straight pin.
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 5) as a
guide in selecting a suitable snap ring.
S3M0157C
(A) Snap ring

(B) Oil squeeze plate
6) Remove the snap ring.

G3M0831
2) Install the snap ring on input shaft.
S3M0158C
(A) Snap ring
7) Using a press and ST, remove the ball bearing.

NOTE:
Remove the inner snap ring before pressing.
ST 498077000
REMOVER
S3M0158C
(A) Snap ring
3) Inspect the clearance between ball bearing and

snap ring. <Ref. to MT-85, INSPECTION, Input
Shaft Assembly.>
4) Install the straight pin and oil squeeze plate to input shaft.
G3M0830
8) Remove the oil seal from input shaft holder.

S3M0159C
(A) Straight pin

(B) Oil squeeze plate
5) Install the snap ring.
MT-83

6) Drive the oil seal into input shaft holder.
8) Install the snap ring to input shaft holder.
NOTE:
Apply a coat of grease to sealing lips before installing oil seal.
ST 398507703
DUMMY COLLAR
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
G3M0833
G3M0828
7) Wind vinyl tape around the shaft splines and insert input shaft into holder by lightly tapping it by
hand.
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.
B3M2140A
(A) Vinyl tape

(B) Input shaft
S3M0168C
(A) O-ring
(B) Input shaft holder
MT-84

E: INSPECTION
1) Bearings
Worn bearings
3) Gears
worn.
is damaged.
4) Baulk ring
6) Oil seal
7) O-ring
9) Measure the clearance between snap ring and

ball bearing using thickness gauge.
Clearance:
0 0.12 mm (0 0.0047 in)
S3M0160C
(A) Snap ring
If the measurement is not within specification, select a suitable snap ring.
MT-85
Snap ring
Part No.
805028050
805028060
805028070
Thickness mm (in)
2.48 (0.0976)
2.56 (0.1008)
2.64 (0.1039)
DRIVE PINION SHAFT ASSEMBLY

18.Drive Pinion Shaft Assembly
4) Inspection and adjustment of ST:
A: REMOVAL
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

4) Remove the drive pinion shaft assembly.
NOTE:
B3M0064B
(A) Plate
(B) Scale
B3M0101H
(A) Main shaft assembly

(B) Drive pinion shaft assembly
B: INSTALLATION
2) Alignment marks/numbers on hypoid gear set:
The upper number on driven pinion is the match
number for combining it with hypoid driven gear.
The lower number is for shim adjustment. If no lower number is shown, the value is zero. The number
on hypoid driven gear indicates a number for combination with drive pinion.
5) Position the ST by inserting the knock pin of ST

into the knock hole in 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
B3M0065C
(A) Adjust clearance to zero without shim.
G3M0554
3) Place the drive pinion shaft assembly on right

hand transmission main case without shim and
tighten the bearing mounting bolts.
7) The thickness of shim shall be determined by

adding the value indicated on drive pinion to the
value indicated on 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
MT-86

8) Select one to three shims from the next table for

the value determined as described above and take
a shim thickness which is closest to the indicated
value.
Part No.
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)
9) Install the differential assembly. <Ref. to MT-95,

INSTALLATION, Front Differential Assembly.>
10) Set the transmission main shaft assembly and
drive pinion assembly in position. (So there is no
clearance between the two when moved all the way
to the front). Inspect the suitable 1st 2nd, 3rd
4th and 5th shifter fork so that coupling sleeve and
reverse driven gear are positioned in the center of
their synchronizing mechanisms. <Ref. to MT-92,
INSPECTION, Drive Pinion Shaft Assembly.>
13) Install the manual transmission assembly to vehicle.<Ref. to MT-33, Manual Transmission Assembly.>
C: DISASSEMBLY
NOTE:
Attach a cloth to the end of driven shaft (on the frictional side of thrust needle bearing) during disassembly or reassembly to prevent damage.
1) Straighten the lock nut at staked portion. Remove the lock nut using ST1, ST2 and ST3.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
G3M0595
2) Withdraw the drive pinion from driven shaft.

Remove the differential bevel gear sleeve, adjusting washer No. 1, adjusting washer No. 2, thrust
bearing, needle bearing, drive pinion collar, needle
bearing and thrust bearing.
B3M0536G
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
MT-87

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
7) Remove the roller bearing, 3rd-4th driven gear

using ST1 and ST2.
G3M0610
G3M0607
4) Straighten the lock nut at staked portion. Remove the lock nut using ST1 and ST2.
8) Remove the key.

9) Remove the 2nd driven gear, inner baulk ring,
synchro cone and outer baulk ring. (Except 1.6 L
model)
S3M0445A
G3M0608
(A)
(B)
(C)
(D)
5) Remove the 5th driven gear using ST.

ST 499857000
5TH DRIVEN GEAR REMOVER
2nd driven gear

Inner baulk ring
Synchro cone
Outer baulk ring
10) Remove the 2nd driven gear assembly. (1.6 L

model)
G3M0609
6) Remove the woodruff key.
MT-88

11) Remove the 1st driven gear, 2nd gear bushing,

gear and hub using ST1 and ST2.
4) Install the 2nd driven gear bushing onto driven

shaft using ST1, ST2 and press.
NOTE:
Replace the gear and hub if necessary. Do not attempt to disassemble if at all possible because they
must engage at a specified point. If they should be
disassembled, mark engagement point beforehand.
CAUTION:
NOTE:
Attach a cloth to the end of driven shaft to prevent damage.
When press fitting, align the oil holes of shaft and
bush.
G3M0611
12) Remove the sub gear for 1st driven gear.

B3M0078F
D: ASSEMBLY
1) Install the sleeve and assembly by matching
alignment marks.
NOTE:
Use a new gear and hub assembly, if gear or hub
have been replaced.
5) Install the 2nd driven gear, inner baulk ring, synchro cone, outer baulk ring and insert onto driven
shaft. (Except 1.6 L model)
S3M0445A
(A)
(B)
(C)
(D)
B3M0077E
(A)
(B)
(C)
(D)
1st gear side

2nd gear side
Flush surface
Stepped surface
2nd driven gear

Inner baulk ring
Synchro cone
Outer baulk ring
6) Install the 2nd driven gear, 1st-2nd bulk ring and

insert onto driven shaft. (1.6 L model)
2) Install the washer, snap ring and sub gear to 1st

driven gear.
3) Install the 1st driven gear, 1st baulk ring, gear
and hub assembly onto driven shaft.
NOTE:
Take care to install the gear and hub assembly in
proper direction.
Align the baulk ring and gear & hub assembly
with key groove.
MT-89

7) After installing the key on driven shaft, install the

3rd-4th driven gear using ST and press.
CAUTION:
10) Install the lock washer. Install the lock nut and
tighten to the specified torque using ST.
ST 499987300
SOCKET WRENCH (50)
Tightening torque:
265 Nm (27 kgf-m, 195 ft-lb)
NOTE:
Align the groove in baulk ring with insert.
ST 499277200
INSTALLER
G3M0618
G3M0615
8) Install a set of roller bearings onto the driven

shaft using ST and press.
NOTE:
Stake the lock nut at two points.
Using the 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).
CAUTION:
ST 499277200
INSTALLER
B3M0079
11) Install the roller bearing onto drive pinion.

G3M0616
9) Position the woodruff key in groove on the rear

of driven shaft. Install the 5th driven gear onto drive
shaft using ST and press.
NOTE:
When installing the roller bearing, note its directions (front and rear) because the knock pin hole in
outer race is offset.
CAUTION:
ST 499277200
INSTALLER
B3M1661A
(A) Roller bearing

(B) Knock pin hole
G3M0617
MT-90

12) Install the washer using ST1, ST2 and press.

NOTE:
Discard the old lock nuts, replace with new ones.
Secure the lock nut in four places.
ST1 499277100 BUSH 1-2 INSTALLER
14) Install the drive pinion collar, needle bearing,

adjusting washer No. 2, thrust bearing, adjusting
washer No. 1 and differential bevel gear sleeve in
that order.
NOTE:
Be careful because the spacer must be installed in
proper direction.
B3M0080E
B3M0083D
(A) Washer
13) Install the thrust bearing and needle bearing.

Install the driven shaft assembly.
B3M0082
MT-91
(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)

E: INSPECTION
1) Bearings
Worn bearings
The ball bearing on the rear side of the drive pinion shaft should be checked for smooth rotation before the drive pinion assembly is disassembled. In
this case, because a preload is working on the
bearing, its rotation feels like it is slightly dragging
unlike the other bearings.
4) Baulk ring
If the gap between the end faces of the ring and
the gear splined part is excessively small when the
ring is pressed against the cone.
Clearance (A):
0.5 1.0 mm (0.020 0.040 in)
S3M0188A

B3M0038E
(A) Drive pinion shaft

(B) Ball bearing

3) Gears
worn.
is damaged.
S3M0189
6) Oil seal
7) O-ring
MT-92

F: ADJUSTMENT
1. THRUST BEARING PRELOAD
1) After completing the preceding steps 1) through
3), select the adjusting washer No. 1 so that dimension (H) is 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).
3) After removing the ST2, measure the starting

torque using torque driver.
Starting torque:
0.3 0.8 Nm
(0.03 0.08 kgf-m, 0.2 0.6 ft-lb)
B3M0085A
4) If the starting torque is not within specified limit,

select a new adjusting washer No. 1 and recheck
starting torque.
B3M0538A
2) Using the ST1, ST2 and ST3, tighten the lock nut
to specified torque.
ST2 498427100 STOPPER
Tightening torque:
118 Nm (12 kgf-m, 86.8 ft-lb)
B3M0536I
(A) Adjusting washer No.1

(B) Adjusting washer No.2
Part No.
Thickness mm (in)
803025051
3.925 (0.1545)
803025052
3.950 (0.1555)
803025053
3.975 (0.1565)
803025054
4.000 (0.1575)
803025055
4.025 (0.1585)
803025056
4.050 (0.1594)
803025057
4.075 (0.1604)
G3M0626
MT-93

5) If the specified starting torque range cannot be

obtained when a No. 1 adjusting washer is used,
then select a suitable No. 2 adjusting washer from
those listed in the following table. Repeat steps 1)
through 4) to adjust starting torque.
B3M0536I
(A) Adjusting washer No. 1

(B) Adjusting washer No. 2
Starting torque
Low
High
Dimension H
Small
Large
Washer No. 2
Select thicker one.
Select thinner one.

Part No.
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.
MT-94
FRONT DIFFERENTIAL ASSEMBLY

19.Front Differential Assembly
B: INSTALLATION
A: REMOVAL
1) Install the differential side retainers using ST.

ST 499787000
WRENCH ASSY
2) Install the differential assembly.

Single-range model
<Ref. to MT-68, REMOVAL, Main Shaft Assembly
for Single-Range.>
Dual-range model
for Dual-Range.>
NOTE:
NOTE:
Be careful not to fold the sealing lip of oil seal.
Wrap the right and left spline sections of axle
shaft with vinyl tape to prevent scratches.
G3M0557
3) Install the main shaft assembly. <Ref. to MT-76,

INSTALLATION, Main Shaft Assembly for DualRange.>
G3M0557
7) Remove the differential side retainers using ST.

ST 499787000
WRENCH ASSY
B3M1360A
MT-95

C: DISASSEMBLY
4) Pull out the pinion shaft, and remove the differential bevel pinion and gear and washer.
1. DIFFERENTIAL CASE ASSEMBLY

1) Remove the right and left snap rings from differential, and then remove the two axle drive shafts.
NOTE:
During reassembly, reinstall each axle drive shaft
in the same place from which it was removed.
2) Loosen the twelve bolts and remove the hypoid
driven gear.
B3M0552C
(A)
(B)
(C)
(D)
Pinion shaft
Bevel pinion
Bevel gear
Washer
5) Remove the roller bearing using ST.

ST 399527700
PULLER SET
G3M0668
B3M0551C
2. SIDE RETAINER
1) Remove the O-ring.
(A) Snap ring

(B) Axle drive shaft
(C) Hypoid driven gear
3) Drive out the straight pin from differential assembly toward hypoid driven gear.
ST 899904100
REMOVER
B3M2192
G3M0667
MT-96

5) Remove the bearing outer race from side retainer.

ST 398527700
PULLER ASSY
NOTE:
Do not reuse the oil seal. Prepare a new oil seal.
NOTE:
Fix the shaft of ST secure enough that it will not
loosen and fall from side retainer.
When replacing the bearing outer race, replace it
with inner race as a set.
B3M2193
3) Remove either side of split pin and pin, and remove the claw.
ST 398527700
PULLER ASSY
B3M2195A
(A) Shaft
(B) Side retainer
D: ASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
1) Install the bevel gear and bevel pinion together
with washers, and insert pinion shaft.
B3M2198A
NOTE:
Face the chamfered side of washer toward gear.
(A) Claw
(B) Split pin
(C) Pin
4) Attach two claws to the outer race securely, and

set ST to side retainer.
ST 398527700
PULLER ASSY
NOTE:
Attach notch portions of the two shafts securely
to side retainer.
Restore the removed claws to original position,
and install the pin and split pin.
B3M0099D
(A) Bevel pinion

(B) Bevel gear
(C) Pinion shaft
B3M2194A
(A) Shaft
(B) Claw
MT-97

2) Measure the backlash between bevel gear and

pinion. If it is not within specifications, install a suitable washer to adjust it. <Ref. to MT-100, ADJUSTMENT, Front Differential Assembly.>
4) Install the roller bearing to differential case.
NOTE:
Be sure the pinion gear tooth contacts adjacent
gear teeth during measurement.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
NOTE:
Be careful because the roller bearing outer races
are used as a set.
ST1 499277100 BUSH 1-2 INSTALLER
ST2 398497701 ADAPTER
CAUTION:
Standard backlash:
0.13 0.18 mm (0.0051 0.0071 in)
G3M0671
5) Install the hypoid driven gear to differential case

using twelve bolts.
G3M0670
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.
Tightening torque:
T: 62 Nm (6.3 kgf-m, 45.6 ft-lb)
NOTE:
Lock the straight pin after installing.
ST 899904100
REMOVER
B3M0554C
(A) Hypoid driven gear

(B) Differential case
B3M0609C
(A) Pinion shaft

(B) Differential case
(C) Straight pin
MT-98

2. SIDE RETAINER
E: INSPECTION
1) Install the bearing outer race to side retainer.
Repair or replace the differential gear in the following cases:

The hypoid drive gear and drive pinion shaft
tooth surface are damaged, excessively worn, or
seized.
The roller bearing on the drive pinion shaft has a
worn or damaged roller path.
There is damage, wear, or seizure of the differential bevel pinion, differential bevel gear, washer,
pinion shaft, and straight pin.
The differential case has worn or damaged sliding surfaces.
NOTE:
Press-in while being careful not to scratch the side
retainer and bearing outer race.
2) Install a new oil seal.
ST 49979700
INSTALLER
B3M2196A
3) Install a new O-ring.

NOTE:
Do not stretch or damage the O-ring.
B3M2192
B3M0558C
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
(J)
MT-99
Drive pinion shaft

Hypoid driven gear
Pinion shaft
Straight pin
Washer
Differential bevel gear
Differential bevel pinion
Snap ring
Roller bearing
Differential case

1. BEVEL PINION GEAR BACKLASH
3. TOOTH CONTACT OF HYPOID GEAR
Measure the backlash between bevel gear and pinion. If it is not within specifications, install a suitable
washer to adjust it.
Check the tooth contact of hypoid gear as follows:

Apply a uniform thin coat of red lead on both tooth
surfaces of 3 or 4 teeth of the hypoid gear. Move
the hypoid gear back and forth by turning the transmission main shaft until a definite contact pattern is
developed on hypoid gear, and judge whether face
contact is correct. If it is inaccurate, make adjustment. <Ref. to MT-100, ADJUSTMENT, Front Differential Assembly.>
Tooth contact is correct.
NOTE:
Be sure the pinion gear tooth contacts adjacent
gear teeth during measurement.
Standard backlash:
0.13 0.18 mm (0.0051 0.0071 in)
B3M0070D
G3M0670
(A)
(B)
(C)
(D)
2. HYPOID GEAR BACKLASH

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 at a
right angle and check the backlash.
ST3 498255400 PLATE
Backlash:
0.13 0.18 mm (0.0051 0.0071 in)
Toe
Coast side
Heel
Drive side
F: ADJUSTMENT
1. BEVEL PINION GEAR BACKLASH
1) Disassemble the front differential. <Ref. to MT95, REMOVAL, Front Differential Assembly.>
2) Select a different washer from the table and install.
Washer
Part No.
803038021
803038022
803038023
Thickness mm (in)
0.925 0.950
(0.0364 0.0374)
0.975 1.000
(0.0384 0.0394)
1.025 1.050
(0.0404 0.0413)
3) Adjust until the specified value is obtained.

B3M1363A
NOTE:
If the backlash is outside specified range, adjust it
by turning the holder in right side case.
Standard backlash:
0.13 0.18 mm (0.0051 0.0071 in)
MT-100

2. HYPOID GEAR BACKLASH

Adjust backlash by turning the holder in right side
case.
ST 499787000
WRENCH ASSY
Backlash is insufficient.
To increase backlash, loosen the holder on lower
side (case left side) and turn in the holder on upper
side (case right side) by the same amount.
B3M0072
B3M1360A
NOTE:
Each time holder rotates one tooth, backlash
changes by 0.05 mm (0.020 in).
The drive pinion shim selected before is too

thick.
Reduce its thickness.
B3M0073
H3M1203C
The drive pinion shim selected before is too thin.

Increase its thickness.
3. TOOTH CONTACT OF HYPOID GEAR

Adjust until the teeth contact is correct.
Backlash is excessive.
To reduce backlash, loosen the holder on upper
side (case right side) and turn in the holder on lower
side (case left side) by the same amount.
B3M0074
B3M0071
MT-101
SPEEDOMETER GEAR
20.Speedometer Gear
B: INSTALLATION
A: REMOVAL
1) Install the washer and speedometer shaft, and

press fit the oil seal with ST.

and Harness.>
5) Remove the vehicle speed sensor. <Ref. to MT46, REMOVAL, Vehicle Speed Sensor.>
6) Remove the outer snap ring and pull out speedometer driven gear. Next, remove the oil seal,
speedometer shaft and washer.
NOTE:
Use a new oil seal, if it has been removed.
ST 899824100 or 499827000PRESS
2) Install the vehicle speed sensor. <Ref. to MT-46,
INSTALLATION, Vehicle Speed Sensor.>
3) Install the speedometer driven gear and snap
ring.
NOTE:
Use a new snap ring, if it has been removed.
B3M0525C
(A) Outer snap ring

(B) Speedometer driven gear
B3M0525C
(A) Outer snap ring

(B) Speedometer driven gear

C: INSPECTION
Check the speedometer gear, oil seal and speedometer shaft for damage. Replace if damaged.
MT-102
REVERSE IDLER GEAR

21.Reverse Idler Gear
B: INSTALLATION
A: REMOVAL
1) Install the reverse shifter lever, reverse idler

gear and reverse idler gear shaft, and secure with
straight pin.

and Harness.>
REMOVAL, Drive Pinion Shaft Assembly.>
Single-range model
for Single-Range.>
Dual-range model
for Dual-Range.>
7) Remove the differential assembly. <Ref. to MT95, REMOVAL, Front Differential Assembly.>
8) Remove the shifter forks and rods. <Ref. to MT105, REMOVAL, Shifter Fork and Rod.>
9) Pull out the straight pin, and remove the idler
gear shaft, reverse idler gear and washer.
B3M0524C
(A)
(B)
(C)
(D)
Straight pin
Idler gear shaft
Idler gear
Washer
10) Remove the reverse shifter lever.
NOTE:
Be sure to install the reverse idler shaft from rear
side.
B3M0526C
(A)
(B)
(C)
(D)

Reverse idler gear
Reverse idler gear shaft
Straight pin
2) Inspect and adjust the clearance between reverse idler gear and transmission case wall. <Ref.
to MT-103, INSTALLATION, Reverse Idler Gear.>
and <Ref. to MT-104, ADJUSTMENT, Reverse
Idler Gear.>
3) Install the shifter forks and rods. <Ref. to MT105, INSTALLATION, Shifter Fork and Rod.>
4) Install the differential assembly. <Ref. to MT-95,
INSTALLATION, Front Differential Assembly.>
Single-range model
<Ref. to MT-68, INSTALLATION, Main Shaft Assembly for Single-Range.>
Dual-range model
<Ref. to MT-76, INSTALLATION, Main Shaft Assembly for Dual-Range.>
6) Install the drive pinion shaft assembly. <Ref. to
MT-86, INSTALLATION, Drive Pinion Shaft Assembly.>
MT-103
REVERSE IDLER GEAR

C: INSPECTION
D: ADJUSTMENT
1) Move the reverse shifter rod toward the reverse

side. Inspect the clearance between reverse idler
gear and transmission case wall.
If out of specification, select the appropriate reverse shifter lever and adjust.
1) Select the appropriate reverse shifter lever from

the table below, and adjust until the gap between
the reverse idler gear and transmission case wall is
within specification.
Clearance A:
6.0 7.5 mm (0.236 0.295 in)
Clearance A:
6.0 7.5 mm (0.236 0.295 in)
G3M0796
G3M0796
2) After installing a suitable reverse shifter lever,

shift into neutral. Inspect the clearance between reverse idler gear and transmission case wall.
If out of specification, select the appropriate washer
and adjust.
Part No.
32820AA070
32820AA080
32820AA090

Mark
Remarks
7
Further from case wall
8
Standard
9
Closer to case wall
2) Select the appropriate washer from the table below, and adjust until the gap between the reverse
idler gear and transmission case wall is within
specification.
Clearance:
0 0.5 mm (0 0.020 in)
Clearance:
0 0.5 mm (0 0.020 in)
B3M0063
3) Check the reverse idler gear and shaft for damage. Replace if damaged.
B3M0063
Washer
Part No.
803020151
803020152
803020153
803020154
803020155
MT-104
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

22.Shifter Fork and Rod
10) Drive out the straight pin, and pull out 3-4 fork
rod and shifter fork.
A: REMOVAL
and Harness.>
Single-range model
for Single-Range.>
Dual-range model
for Dual-Range.>
7) Remove the differential assembly. <Ref. to MT95, REMOVAL, Front Differential Assembly.>
8) Drive out the straight pin with ST, and 5th shifter
fork.
ST 398791700
STRAIGHT PIN REMOVER
NOTE:
When removing the 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.
B3M0523C
(A) Straight pin

(B) 3-4 fork rod
(C) Shifter fork
11) Drive out the straight pin, and pull out 1-2 fork
rod and shifter fork.
12) Remove the outer snap ring, and pull out the
reverse shifter rod arm from reverse fork rod. Then
take out the ball, spring and interlock plunger from
rod.
And then remove the rod.
NOTE:
When pulling out the reverse shifter rod arm, be
careful not to let the 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 hole in reverse fork rod arm, and
hold it with outer snap ring using ST.
B3M0333I
(A) Straight pin

(B) 5th shifter fork
9) Remove the plugs, springs and checking balls.
NOTE:
Apply grease to plunger to prevent it from falling.
ST 399411700
ACCENT BALL INSTALLER
2) Position the ball, spring and new gasket in reverse shifter rod hole, on left side transmission
case, and tighten the checking ball plug.
3) Install the 1-2 fork rod into 1-2 shifter fork via the
hole on the rear of transmission case.
4) Align the holes in rod and fork, and new drive
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
MT-105

5) Install the interlock plunger onto 3-4 fork rod.

NOTE:
Apply a coat of grease to plunger to prevent it from
falling.
6) Install the 3-4 fork rod into 3-4 shifter fork via the
hole on the rear of transmission case.
7) Align the holes in rod and fork, and new drive
straight pin into these holes.
NOTE:
Set the reverse fork rod to neutral.
Make sure the interlock plunger (installing before) is on the reverse fork rod side.
ST 398791700
8) Install the 5th shifter fork onto the rear of reverse
fork rod. Align holes in the two parts and new drive
straight pin into place.
ST 398791700

Single-range model
<Ref. to MT-68, INSTALLATION, Main Shaft Assembly for Single-Range.>
Dual-range model
<Ref. to MT-76, INSTALLATION, Main Shaft Assembly for Dual-Range.>
12) Install the drive pinion shaft assembly. <Ref. to
MT-86, INSTALLATION, Drive Pinion Shaft Assembly.>
B3M0333J
(A) 5th shifter fork

(B) Reverse fork rod
(C) Straight pin
9) Position the balls, checking ball springs and new

gaskets into 3-4 and 1-2 rod holes, and install
plugs.
B3M0333J
(A) 5th shifter fork

(B) Reverse fork rod
(C) Straight pin
10) Install the differential assembly. <Ref. to MT95, INSTALLATION, Front Differential Assembly.>
MT-106

C: INSPECTION
1) Check the shift shaft and shift rod for damage.
Replace if damaged.
2) Gearshift mechanism:
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.
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.
Clearance (a) and (b):
9.3 mm (0.366 in)
Clearance (a) and (b):

9.5 mm (0.374 in)
B3M1411A
(A) 3rd drive gear

(B) Coupling sleeve
(C) 4th drive gear
S3M0430A
Part No.
(A) 1st driven gear
(B) Reverse driven gear
(C) 2nd driven gear
Part No.
32804AA060
32804AA070
32804AA080
32810AA061
32810AA071

Mark
Remarks
Approach to 1st gear
1
by 0.2 mm (0.008 in).
Standard
Become distant from
3
2nd gear by 0.2 mm
(0.008 in).
MT-107
32810AA101

Mark
Remarks
1
by 0.2 mm (0.008 in).
Standard
Become distant from
3
3rd gear by 0.2 mm
(0.008 in).

5) Inspect the clearance between 5th drive gear

and coupling sleeve. If any clearance is not within
specifications, replace the shifter fork as required.
6) Inspect the rod end clearances (A) and (B). If

any clearance is not within specifications, replace
the rod or fork as required.
Clearance (a):
9.3 mm (0.366 in)
Clearance (A):
1st 2nd to 3rd 4th:
0.4 1.4 mm (0.016 0.055 in)
Clearance (B):
3rd 4th to 5th:
0.5 1.3 mm (0.020 0.051 in)
S3M0191A
(A) 5th drive gear

(B) Coupling sleeve
B3M0530A
5th shifter fork (Non-turbo)

Part No.
Mark
Remarks
32812AA201
4
by 0.2 mm (0.008 in).
32812AA211
5
Standard
Become distant from
32812AA221
6
5th gear by 0.2 mm
(0.008 in).
Part No.
32812AA231
32812AA241
32812AA251
5th shifter fork (Turbo)

Mark
Remarks
7
by 0.2 mm (0.008 in).
Standard
Become distant from
9
5th gear by 0.2 mm
(0.008 in).
MT-108
COUNTER GEAR
23.Counter Gear
6) Remove the counter shaft from transmission

case, taking care not to drop the counter gear and
two washers.
A: REMOVAL
4) Move the counter gear shaft until it touches
transmission case, and remove the snap ring with a
suitable tool.
NOTE:
Be careful not to damage the O-ring.
Be careful not to drop the straight pin on front
side.
Be careful not to drop the two needle bearings
and collar contained in counter gear.
H3M1427B
(A) Counter shaft

(B) Counter gear
(C) Washers
S3M0102A
5) Slide the washer at rear of high-low counter

shaft, and remove the straight pin from counter
shaft.
H3M1426B
B: INSTALLATION
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 MT-37, 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
as shown in the figure.
MT-109
COUNTER GEAR
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 measured value, select
a snap ring and install to put clearance within measured value. <Ref. to MT-110, ADJUSTMENT,
Counter Gear.>
D: ADJUSTMENT
Selection of snap ring:
If the measurement is not within specification, select suitable snap ring.
Snap ring
Part No.
031319000
805019010
Thickness mm (in)
1.50 (0.0591)
1.72 (0.0677)
MT-110
GENERAL DIAGNOSTIC
24.General Diagnostic
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
malfunction of the gear shift system and
the other is malfunction of the transmission. However, if the operation is heavy
and engagement of the gears is difficult,
defective clutch disengagement may also
be responsible. Check whether the clutch
is correctly functioning, before checking
the gear shift system and transmission.
2. Gear slips out.
Gear slips out when coasting on rough
road.
Gear slips out during acceleration.
3. Unusual noise comes from transmission.

NOTE:
If an unusual noise is heard when the vehicle is parked with its engine idling and if
the 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
(responsible for slip-out of 3rd gear)
(g) Worn 1st driven gear, needle bearing
and race
(h) Worn 2nd driven gear, needle bearing
and race
(i) Worn 3rd drive gear and bushing
(j) Worn 4th drive gear and bushing
(k) Worn reverse idler gear and bushing
(a) Insufficient or improper lubrication
(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.
MT-111
Remedy
Replace.
Replace.
Replace.
Correct or replace.
Adjust.
Tighten or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Lubricate or replace with specified oil.
Replace.
GENERAL DIAGNOSTIC
2. DIFFERENTIAL
Symptom
1. Broken differential (case, gear, bearing, etc.)
NOTE:
Abnormal noise will develop and finally it
will become impossible to continue to run
due to broken pieces obstructing the gear
revolution.
2. Differential and hypoid gear noises

Troubles of the differential and hypoid
gear always appear as noise problems.
Therefore noise is the first indication of
the trouble. However noises from the
engine, muffler, tire, exhaust gas, bearing, body, etc. are easily mistaken for the
differential noise. Pay special attention to
the hypoid gear noise because it is easily
confused with other gear noises. There
are the following four kinds of noises.
Gear noise when driving: If noise
increases as vehicle speed increases it
may be due to insufficient gear oil, incorrect gear engagement, damaged gears,
etc.
Gear noise when coasting: Damaged
gears due to maladjusted bearings and
incorrect shim adjustment
Bearing noise when driving or when
coasting: Cracked, broken or damaged
bearings
Noise which mainly occurs when turning: Unusual noise from differential side
gear, differential pinion, differential pinion
shaft, etc.
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 vehicle under severe operating
conditions.
(f) Loose hypoid driven gear clamping
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
MT-112
Remedy
Disassemble the differential and replace
broken components and at the same time
check other components for any trouble,
and replace if necessary.
Readjust the bearing preload and backlash and face contact of gears.
Adjust.
Adjust.
Add recommended oil to specified level.
Do not use the vehicle under severe
operating conditions.
Tighten.
Lubricate.
Check tooth contact.
Replace as a set.
Readjust the bearing preload.
Readjust the 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.
13.
Page
Clutch Disc and Cover ..............................................................................20
Flywheel ....................................................................................................24
Release Bearing and Lever.......................................................................26
Operating Cylinder ....................................................................................29
Master Cylinder .........................................................................................31
Clutch Pipe and Hose ...............................................................................35
Clutch Fluid ...............................................................................................37
Clutch Fluid Air Bleeding...........................................................................38
Clutch Pedal..............................................................................................41
Clutch Cable..............................................................................................49
Clutch Switch ............................................................................................50
General Diagnostic Table..........................................................................51
GENERAL DESCRIPTION
CLUTCH SYSTEM
A: SPECIFICATIONS
Model
1.6 L
Type
Clutch cover
Diaphragm set load
Facing material
Clutch disc
O.D. x I.D. x thickness
Spline O.D.
Clutch release lever ratio
Release bearing
Full stroke
Clutch pedal
Free play
Clutch disc
kgf (lb)
mm (in)
mm (in)
mm (in)
mm (in)
Stroke
mm (in)
Play at release lever

center
mm (in)
Depth of rivet head

mm (in)
Limit for deflection
Standard
Limit of
sinking
mm (in)
2.0 L NON-TURBO
2.0 L TURBO
2.5 L
Push type
Pull type
Push type
450 (992)
830 (1,830)
550 (1,213)
Woven (Non asbestos)
230 x 150 x 3.5 228.6 x 155 x 6.6
225 x 150 x 3.5 (8.86 x 5.91 x 0.138)
(9.06 x 5.91 x
(9.00 x 6.10 x
0.138)
0.260)
25.2 (0.992), (No. of teeth: 24)
3.0
1.6
1.7
1.6
Grease-packed self-aligning
130 135 (5.12 5.31)
3 13
10 12
10 20 (0.39 0.79)
(0.12 0.51)
(0.39 0.79)
13.3 14.7
24 26
24 26 (0.94 1.02)
(0.524 0.579)
(0.94 1.02)
34
3 4 (0.12 0.16)
(0.12 0.16)
1.3 1.9 (0.051 0.075)
0.3 (0.012)
0.8 (0.031) at
R = 107 (4.21)
I.D.: Inner diameter

O.D.: Outer diameter
CL-2
0.8 (0.031) at R = 110 (4.33)
1.0 (0.039) at
R = 110 (4.33)
GENERAL DESCRIPTION
CLUTCH SYSTEM
B: COMPONENT
1. CLUTCH ASSEMBLY FOR 1.6 L NON-TURBO MODEL
(2)
(1)
(6)
(5)
(12)
(4)
(7)
(9)
(3)
(8)
(10)
(11)
(7)
TR0430
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Clutch release lever sealing

Clutch cable bracket
Retainer spring
Pivot
Clutch release lever
Return spring
Clip
Clutch release bearing
(9)
(10)
(11)
(12)
Clutch cover
Clutch disk
Flywheel
Clutch return spring bracket

T: 15.7 (1.6, 11.6)
CL-3
GENERAL DESCRIPTION
CLUTCH SYSTEM
2. CLUTCH ASSEMBLY FOR 2.0 L NON-TURBO MODEL
S2M2066A
(1)
(2)
(3)
(4)
(5)

Retainer spring
Pivot
Clip
(6)
(7)
(8)
(9)

Clutch cover
Clutch disc
Flywheel
CL-4

T1: 15.7 (1.6, 11.6)
T2: 72 (7.3, 52.8)
GENERAL DESCRIPTION
CLUTCH SYSTEM
3. CLUTCH ASSEMBLY FOR 2.5 L MODEL
B2M4686A
(1)
(2)
(3)
(4)
(5)
Clutch release lever seal

Retainer spring
Pivot
Release lever
Clip
(6)
(7)
(8)
(9)
Release bearing
Clutch cover
Clutch disc
Double mass flywheel
CL-5

T1: 15.7 (1.6, 11.6)
T2: 72 (7.3, 52.8)
GENERAL DESCRIPTION
CLUTCH SYSTEM
4. CLUTCH ASSEMBLY FOR TURBO MODEL
S2M2158A
(1)
(2)
(3)
(4)
(5)

Clutch release lever shaft
Plug
(6)
(7)
(8)
Clutch cover
Clutch disc
Flywheel
CL-6

T1: 15.7 (1.6, 11.6)
T2: 44 (4.5, 32.5)
T3: 72 (7.3, 52.8)
GENERAL DESCRIPTION
CLUTCH SYSTEM
5. CLUTCH PIPE AND HOSE FOR NON-TURBO MODEL

LHD MODEL
(10)
(7)
(8)
(9)
T3
T2
T3
T3
(6)
(3)
(4)
(5)
T4
(2)
(1)
T1
TR0535
(1)
(2)
(3)
(4)
(5)
Operating cylinder
Washer
Clutch hose
Bracket
Clip
(6)
(7)
(8)
(9)
(10)
Pipe
Master cylinder ASSY
Clevis pin
Snap pin
Lever
CL-7

T1: 8 (0.8, 5.8)
T2: 15 (1.5, 10.8)
T3: 18 (1.8, 13.0)
T4: 37 (3.8, 27.5)
GENERAL DESCRIPTION
CLUTCH SYSTEM
RHD MODEL
(10)
(8)
(7)
(4)
(9)
T2
T3
(11)
(6)
T4
(3)
T2
(12)
T4
T5
(2)
(5)
(1)
T1
(11)
TR0896
(1)
(2)
(3)
(4)
(5)
(6)
Operating cylinder
Washer
Clutch hose
Bracket
Clip
Clutch pipe
(7)
(8)
(9)
(10)
(11)
(12)

Clevis pin
Snap pin
Pedal
Clamp
Bracket
CL-8

T1: 8 (0.8, 5.8)
T2: 15 (1.5, 10.8)
T3: 18 (1.8, 13.0)
T4: 25 (2.5, 18.1)
T5: 37 (3.8, 27.5)
GENERAL DESCRIPTION
CLUTCH SYSTEM
6. CLUTCH PIPE AND HOSE FOR TURBO MODEL

LHD MODEL
(8)
(9)
(7)
(10)
T2
T3
T3
(6)
(3)
(4)
(2)
(5)
T3
(1)
T1
T4
TR0536
(1)
(2)
(3)
(4)
(5)
Operating cylinder
Washer
Clutch hose
Bracket
Clip
(6)
(7)
(8)
(9)
(10)
Pipe
Clevis pin
Snap pin
Lever
CL-9

T1: 8 (0.8, 5.8)
T2: 15 (1.5, 10.8)
T3: 18 (1.8, 13.0)
T4: 37 (3.8, 27.5)
GENERAL DESCRIPTION
CLUTCH SYSTEM
RHD MODEL
(9)
(7)
T4
(6)
(8)
T3
B
(10)
A
T3
(4)
T1
(11)
(11)
B
T3
A
T3
T3
(3)
(12)
(5)
(10)
(12)
(10)
T5
(2)
T5
(11)
(1)
T5
T2
T6
TR0897
(1)
(2)
(3)
(4)
(5)
(6)
Operating cylinder
Washer
Clutch hose
Bracket
Clip
(7)
(8)
(9)
(10)
(11)
(12)
Clevis pin
Snap pin
Pedal
Clamp
Clutch pipe
Bracket
CL-10

T1: 7.5 (0.76, 5.53)
T2: 8 (0.8, 5.8)
T3: 15 (1.5, 10.8)
T4: 18 (1.8, 13.0)
T5: 25 (2.5, 18.1)
T6: 37 (3.8, 27.5)
GENERAL DESCRIPTION
CLUTCH SYSTEM
7. MASTER CYLINDER
NON-TURBO MODEL
(1)
(12)
T1
(11)
(2)
(10)
(3)
(9)
(4)
(8)
(5)
(7)
(6)
T2
TR0898
(1)
(2)
(3)
(4)
(5)
(6)
Reservoir cap
Reservoir tank
Oil seal
Straight pin
Master cylinder
Clutch damper
(7)
(8)
(9)
(10)
(11)
(12)
Gasket
Return spring
Piston
Push rod
Piston stop ring
Cylinder boot
CL-11

T1: 10 (1.0, 7)
T2: 46.6 (4.75, 34.4)
GENERAL DESCRIPTION
CLUTCH SYSTEM
LHD TURBO MODEL
(12)
(1)
T1
(11)
(2)
(10)
(3)
(4)
(9)
(8)
(5)
(7)
(6)
T2
TR0899
(1)
(2)
(3)
(4)
(5)
(6)
Reservoir cap
Reservoir tank
Oil seal
Straight pin
Master cylinder
Clutch damper
(7)
(8)
(9)
(10)
(11)
(12)
Gasket
Return spring
Piston
Push rod
Piston stop ring
Cylinder boot
CL-12

T1: 10 (1.0, 7)
T2: 46.6 (4.75, 34.4)
GENERAL DESCRIPTION
CLUTCH SYSTEM
RHD TURBO MODEL
(6)
(1)
T3
(5)
(4)
(4)
(2)
(3)
(13)
T2
(12)
(3)
T3
(11)
(7)
T1
(10)
(9)
(8)
TR0900
(1)
(2)
(3)
(4)
(5)
(6)
Reservoir cap
Reservoir tank
Washer
Clip
Hose
Reservoir tank bracket
(7)
(8)
(9)
(10)
(11)
(12)
Oil seal
Master cylinder
Return spring
Piston
Push rod
Piston stop ring
CL-13
(13)
Cylinder boot

T1: 8 (0.8, 5.8)
T2: 10 (1.0, 7)
T3: 18 (1.8, 13.3)
GENERAL DESCRIPTION
CLUTCH SYSTEM
8. CLUTCH PEDAL FOR 2.0 L AND 2.5 L MODEL

LHD MODEL
(7)
(3)
(26)
(11)
(4)
(25)
T2
T2
(2)
(24)
T2
(23)
(11)
T1
(27)
T1
(22)
(20)
(1)
(2)
(21)
T1
(19) (18)
(14)
(1)
(13) (14)
(4)
(8)
(2)
(12)
(2)
(17)
(16)
(15)
(7)
(12) (11)
(5)
(1)
(6)
(9)
(10)
TR0901
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Stopper
Bushing
Spring pin
Snap pin
Brake pedal pad
Brake pedal
Clevis pin
Brake pedal spring
Clutch pedal pad
Clutch pedal
Bushing C
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Clutch clevis pin

Assist rod A
Clip
Assist spring
Assist bushing
Assist rod B
Spring A
Rod
Bushing B
O-ring
Clip
CL-14
(23)
(24)
(25)
(26)
(27)
Stop light switch

Pedal bracket
Clutch master cylinder bracket
Lever
Adjust bolt

T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
GENERAL DESCRIPTION
CLUTCH SYSTEM
RHD MODEL
(10)
(9)
(8)
(5)
(6)
(7)
(4)
(19)
T2
(16)
T3
(15)
(1)
(14)
T1
(13)
(11)
(12)
(17)
(18)
(4)
(1)
(18)
(2)
(3)
(4)
TR0902
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Stopper
Clutch pedal pad
Clutch pedal
Bushing
Clutch clevis pin
Assist rod A
Clip
Assist spring
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Assist bushing
Assist rod B
Spring A
Rod S
Bushing B
O-ring
Clip
Clutch switch (With cruise control)
CL-15
(17)
(18)
(19)
Spacer
Bushing
Clutch pedal bracket

T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
T3: 30 (3.1, 22.4)
GENERAL DESCRIPTION
CLUTCH SYSTEM
9. CLUTCH PEDAL FOR 1.6 L MODEL

LHD MODEL
T1
T3
(11)
(12)
T4
(3)
T3
(15)
T2
(16)
(13)
(2)
(14)
T2
(1)
(2)
(4)
(8)
(2)
(5)
(13)
(7)
(6)
(1)
(2)
(14)
(8)
(9)
(10)
TR0903
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Stopper
Bushing
Snap pin
Brake pedal pad
Brake pedal
Clevis pin
Spring
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Clutch pedal pad

Clutch pedal
Clutch cable
Clutch cable clamp
Clip
Spring assist
Stop light switch
Adjust bolt
CL-16

T1: 5.9 (0.60, 4.3)
T2: 8 (0.8, 5.8)
T3: 18 (1.8, 13.0)
T4: 29 (3.0, 21.7)
GENERAL DESCRIPTION
CLUTCH SYSTEM
RHD MODEL
(7)
T1
(6)
T3
(3)
(9)
T4
T3
(10)
(1)
(8)
T2
(11)
(2)
(2)
(2)
(2)
(1)
(1)
(4)
(5)
TR0904
(1)
(2)
(3)
(4)
(5)
(6)
Stopper
Bushing
Clutch pedal pad
Clutch pedal
Clutch cable
(7)
(8)
(9)
(10)
(11)
Clutch cable clamp

Spacer
Bracket
Adjust bolt
Spring
CL-17

T1: 5.9 (0.6, 4.3)
T2: 8 (0.8, 5.8)
T3: 18 (1.8, 13.0)
T4: 29 (3.0, 21.7)
GENERAL DESCRIPTION
CLUTCH SYSTEM
C: CAUTION
Use SUBARU genuine fluid, grease etc. or the
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 TOOLS
ILLUSTRATION
TOOL NUMBER
498497100
DESCRIPTION
CRANKSHAFT
STOPPER
REMARKS
Used for stopping rotation of flywheel when loosening tightening bolt, etc.
CLUTCH DISC
GUIDE
Used when installing clutch disc to flywheel.
B2M3853
499747100
B2M4112
CL-18
GENERAL DESCRIPTION
CLUTCH SYSTEM
ILLUSTRATION
TOOL NUMBER
499057000
DESCRIPTION
TORX PLUS
REMARKS
Used for removing flywheel (Dual mass flywheel type).
For 2.5 L model.
B2M4213

TOOL NAME
Circuit Tester
Dial Gauge
REMARKS
Used for measuring clutch disk run-out.
CL-19
CLUTCH DISC AND COVER

CLUTCH SYSTEM
2. Clutch Disc and Cover
2. EXCEPT 2.5 L MODEL
A: REMOVAL
1) Remove the transmission assembly from vehicle

body. <Ref. to MT-33, REMOVAL, Manual Transmission Assembly.>
2) Install the ST on flywheel.
ST 499747100
CRANKSHAFT STOPPER
1. 2.5 L MODEL
2) Insert the ST on flywheel.
ST 499747100
CLUTCH DISC GUIDE
S2M1847A
(A) Clutch cover
3) Remove the clutch cover and clutch disc.
B2M3345B
(A) Double mass flywheel
3) Remove the clutch cover and clutch disc.

NOTE:
Take care not to allow oil on the clutch disc facing.
Do not disassemble either the clutch cover or
clutch disc.
Put matching marks to the flywheel and clutch
cover before removing the clutch cover.
NOTE:
Take care not to allow oil on the clutch disc facing.
Do not disassemble either the clutch cover or
clutch disc.
B: INSTALLATION
1. 2.5 L MODEL
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
B2M3346
B2M4687A
(A) Flywheel
(B) Flywheel side
CL-20

CLUTCH SYSTEM
2) Install the clutch cover on flywheel and tighten

the bolts to specified torque.
2) Install the clutch cover on flywheel and tighten

the bolts to specified torque.
NOTE:
Align matching marks.
Note the front and rear of the clutch disc when installing.
Tighten the clutch cover installing bolts gradually. Each bolt should be tightened to the specified
torque in a crisscross fashion.
NOTE:
When installing the clutch cover on flywheel, position the clutch cover so that there is a gap of 120
or more between 0 marks on the flywheel and
clutch cover. (0 marks indicate the directions of
residual unbalance.)
Note the front and rear of the clutch disc when installing.
Temporarily tighten the bolts by hand. Each bolt
should be tightened to the specified torque in a
crisscross fashion.
Tightening torque:
15.7 Nm (1.6 kgf-m, 11.6 ft-lb)
Tightening torque:
15.7 Nm (1.6 kgf-m, 11.6 ft-lb)
B2M3346A
3) Remove the ST.

ST 499747100
CLUTCH DISC GUIDE

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
B2M1011B
(A) 0 marks
B2M4608A
3) Remove the ST.

ST 499747100
CLUTCH DISC GUIDE
4) Install the transmission assembly. <Ref. to MT37, INSTALLATION, Manual Transmission Assembly.>
(A) Flywheel side
CL-21

CLUTCH SYSTEM
C: INSPECTION
1. CLUTCH DISC
1) Facing wear
Measure the depth of rivet head from the surface of
facing. Replace if facings are worn locally or worn
down to less than the specified value.
3) Oil soakage 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.
2.5 L MODEL
Depth of rivet head:

Limit of sinking
0.3 mm (0.012 in)
NOTE:
Do not wash the clutch disc with any cleaning fluid.
2.5 L MODEL
B2M3349C
Except 2.5 L MODEL
B3M3348
Except 2.5 L MODEL

B2M3355C
4) Deflection on facing
If deflection exceeds the specified value at the outer circumference of facing, repair or replace.
ST 499747100
CLUTCH DISC GUIDE
B3M3354
2) Hardened facing
Correct by using emery paper or replace.
Limit for deflection:

1.6 L model
0.8 mm (0.031 in) at R = 107 mm (4.21 in)
2.0 L model
0.8 mm (0.031 in) at R = 110 mm (4.33 in)
2.5 L model
1.0 mm (0.039 in) at R = 110 mm (4.33 in)
2.5 L MODEL
B2M3350B
CL-22

CLUTCH SYSTEM
2. CLUTCH COVER
Except 2.5 L MODEL
NOTE:
Visually check for the following items without disassembling, and replace or repair if defective.
1) Loose thrust rivet.
2) Damaged or worn bearing contact area at center
of diaphragm spring.
2.5 L MODEL
B2M3356B
5) Worn spline, loose rivets and torsion spring failure

Replace defective parts.
2.5 L MODEL
B2M3351A
Except 2.5 L MODEL
B2M3349A
Except 2.5 L MODEL
B2M3358A
(A) Thrust rivet

(B) Diaphragm spring
B2M3355D
(A) Spline
(B) Rivet
(C) Torsion spring
CL-23
FLYWHEEL
CLUTCH SYSTEM
3. Flywheel
B: INSTALLATION
A: REMOVAL
1. 2.5 L MODEL
1. 2.5 L MODEL
1) Install the flywheel and ST.

ST 498497100
CRANKSHAFT STOPPER
1) Remove the transmission assembly. <Ref. to

MT-33, REMOVAL, Manual Transmission Assembly.>
2) Remove the clutch cover and clutch disc. <Ref.
to CL-20, REMOVAL, Clutch Disc and Cover.>
3) Remove the flywheel using ST1 and ST2.
ST1 498497100 CRANKSHAFT STOPPER
ST2 499057000 TORX PLUS
B2M3359A
2) Tighten the flywheel attaching bolts to the 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 fashion.
B2M3347B
Tightening torque:
72 Nm (7.3 kgf-m, 52.8 ft-lb)
(A) Flywheel

1) Remove the transmission assembly. <Ref. to
MT-33, REMOVAL, Manual Transmission Assembly.>
2) Remove the clutch cover and clutch disc. <Ref.
to CL-20, REMOVAL, Clutch Disc and Cover.>
3) Using the ST, remove the flywheel.
ST 498497100
CRANKSHAFT STOPPER
B2M3360A
3) Install the clutch disc and cover. <Ref. to CL-20,

2.5 L MODEL, INSTALLATION, Clutch Disc and
Cover.>
B2M0332B
(A) Flywheel
CL-24
FLYWHEEL
CLUTCH SYSTEM
C: INSPECTION
1) Install the flywheel and ST.

ST 498497100
CRANKSHAFT STOPPER
CAUTION:
Since this bearing is grease sealed and is of a
non-lubrication type, do not wash with gasoline
or any solvent.
1) Damage of facing and ring gear
If defective, replace the flywheel.
2.5 L MODEL
B2M3361A
2) Tighten the flywheel attaching bolts to the specified torque.

NOTE:
Tighten the flywheel installing bolts gradually. Each
bolt should be tightened to the specified torque in a
crisscross fashion.
Tightening torque:
72 Nm (7.3 kgf-m, 52.8 ft-lb)
B2M3353B
(A) Flywheel
(B) Ring gear
Except 2.5 L MODEL
B2M0331B
S2M1851A
3) Install the clutch disc and cover. <Ref. to CL-21,

EXCEPT 2.5 L MODEL, INSTALLATION, Clutch
Disc and Cover.>
(A) Flywheel
(B) Ring gear
2) Smoothness of rotation
Rotate the ball bearing applying pressure in thrust
direction.
3) If noise or excessive play is noted, replace the
flywheel.
CL-25
RELEASE BEARING AND LEVER

CLUTCH SYSTEM
4. Release Bearing and Lever
4) Remove the clutch release bearing from the

clutch cover using flat-type screwdriver.
A: REMOVAL
1. NON-TURBO MODEL
body.
<Ref. to MT-33, REMOVAL, Manual Transmission
Assembly.>
2) Remove the two clips from clutch release lever
and remove the release bearing.
CAUTION:
Be careful not to deform clips.
3) Remove the release lever seal.
S2M1843A
(A) Clutch release bearing
B: INSTALLATION
1. NON-TURBO MODEL
B2M4222A
(A) Clutch release lever

(B) Release lever seal
4) Remove the release lever retainer spring from

release lever pivot with a screwdriver by accessing
it through clutch housing release lever hole. Then
remove the release lever.
NOTE:
Before or during assembling, lubricate the following
points with a light coat of grease.
Contact surface of lever and pivot
Contact surface of lever and bearing
Transmission main shaft spline (Use grease containing molybdenum disulphide.)
Contact surface of lever and operating cylinder
1) While pushing the release lever to pivot and
twisting it to both sides, fit the retainer spring onto
the constricted portion of pivot.
NOTE:
Apply grease (SUNLIGHT 2: P/N 003602010) to
the contact point of release lever and operating cylinder.
Confirm that the retainer spring is securely fitted
by observing it through the main case hole.
B2M4223A

(B) Screwdriver
B2M4224A
2. TURBO MODEL
(A) Release lever

2) Remove the clutch release lever from transmission.
3) Put the clutch release bearing in engine side.
2) Install the release bearing and fasten it with two

clips.
CL-26

CLUTCH SYSTEM
3) Install the release lever seal.
3) Apply grease to the specified points:

Spline FX2200
Shaft SUNLIGHT 2
B2M4222A
(A) Release lever

(B) Release lever seal
4) Install the transmission assembly.

<Ref. to MT-37, INSTALLATION, Manual Transmission Assembly.>
2. TURBO MODEL
1) Install the release bearing on transmission.
2) Insert the release fork into release bearing tab.
S2M1938A
(A) Spline (FX2200)

(B) Shaft (SUNLIGHT 2)
4) Insert the release fork shaft into release fork.
S2M1937A
NOTE:
Make sure the cutout portion of release fork shaft
contacts spring pin.
(A) Release fork

(B) Release bearing
S2M1845A
(A) Release fork

(B) Release shaft
(C) Spring pin
CL-27

CLUTCH SYSTEM
5) Tighten the plug.
2) Check the bearing for smooth rotation by applying pressure in the thrust direction.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
S2M1844A
S2M1846
(A) Bearing case
3) Check wear and damage of the bearing case

surface contacting with lever.
C: INSPECTION
2. RELEASE LEVER
1. RELEASE BEARING
1) Check the lever pivot portion and the point of

contact with release bearing case for wear.
NOTE:
Since this bearing is grease sealed and is of a nonlubrication type, do not wash with gasoline or any
solvent when servicing the clutch.
1) Check the bearing for smooth movement by applying force in the radial direction.
Radial direction stroke:
1.4 mm (0.055 in)
S2M1102E

(B) Pivot
(C) Clutch release bearing
B2M0173B
(A) Bearing case
CL-28
OPERATING CYLINDER
CLUTCH SYSTEM
5. Operating Cylinder
4) Remove the operating cylinder from transmission.

Non-turbo MODEL
A: REMOVAL
1) Remove the air cleaner case and air intake duct
(Non-turbo model). <Ref. to IN-6, REMOVAL, Air
Intake Duct.>
3) Remove the clutch hose from operating cylinder.
CAUTION:
Cover the hose joint to prevent clutch fluid from
flowing out.
Non-turbo MODEL
B2M1263
Turbo MODEL
B2M1179J
S2M1853A
(A) Clutch hose

(B) Operating cylinder
(A) Operating cylinder
Turbo MODEL
S2M1842B
(A) Clutch hose

(B) Operating cylinder
CL-29
OPERATING CYLINDER
CLUTCH SYSTEM
B: INSTALLATION
NOTE:
Before installing the operating cylinder, apply
grease (SUNLIGHT 2: P/N 003602010) to contact
point of the release lever and operating cylinder.
Tightening torque:
T1: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
T2: 37 Nm (3.8 kgf-m, 27.5 ft-lb)
Non-turbo MODEL
2) After bleeding air from the operating cylinder,

ensure that clutch operates properly.
<Ref. to CL-38, Clutch Fluid Air Bleeding.>
C: INSPECTION
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.
B2M1179C
Turbo MODEL
G2M0978
NOTE:
Be sure to install the clutch hose with the mark
side facing upward.
Be careful not to twist the clutch hose during installation.
H2M2666B
(A) Marking
(B) Clutch hose
(C) Operating cylinder
CL-30
MASTER CYLINDER
CLUTCH SYSTEM
6. Master Cylinder
B: INSTALLATION
A: REMOVAL
1) Install the master cylinder to body, and install the

clutch pipe to master cylinder.
1) Thoroughly drain the brake fluid from reservoir

tank.
2) Remove the snap pin, clevis pin and separate
the push rod of master cylinder from clutch pedal.
CAUTION:
Check that the pipe is routed properly.
Tightening torque:
T1: 15 Nm (1.5 kgf-m, 10.8 ft-lb)
T2: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
T2
B4M1189E
(A)
(B)
(C)
(D)
T1
Clevis pin
Snap pin
Push rod
Lock nut
TR0469
2) Connect the push rod of master cylinder to

clutch pedal, and install the clevis pin and snap pin.
3) Remove the air cleaner case and air intake duct

(Non-turbo model). <Ref. to IN-6, REMOVAL, Air
Intake Duct.>
5) Remove the clutch pipe from master cylinder.
6) Remove the master cylinder with reservoir tank.
NOTE:
Apply grease to the clevis pin.
CAUTION:
Be extremely careful not to spill brake fluid.
Brake fluid spilt on the vehicle body will harm
the paint surface; wipe it off quickly if spilt.
B4M1189C
(A) Clevis pin

(B) Snap pin
(C) Push rod
TR0468
3) After bleeding air from the system, ensure that

clutch operates properly.
<Ref. to CL-38, Clutch Fluid Air Bleeding.>
4) Install the air cleaner case and air intake duct
(Non-turbo model). <Ref. to IN-6, INSTALLATION,
Air Cleaner Case.> and <Ref. to IN-7, INSTALLATION, Air Intake Duct.>
5) Install the intercooler (Turbo model). <Ref. to
IN(TURBO)-11, INSTALLATION, Intercooler.>
CL-31
MASTER CYLINDER
CLUTCH SYSTEM
C: DISASSEMBLY
2. RHD TURBO MODEL
1. EXCEPT RHD TURBO MODEL
1) Remove the hose.
1) Remove the straight pin and reservoir tank.
(A)
(B)
TR0530
2) Remove the reservoir tank and bracket.
TR0471
(B)
(A) Reservoir tank

(B) Straight pin
(A)
(A)
TR0531
(A) Reservoir tank

(B) Bracket
(B)
3) Remove the straight pin and adapter.
TR0472
(B)
(A) Oil seal

(B) Master cylinder
(A)
3) Move the cylinder boot backward.

(A)
TR0524
(A) Straight pin

(B) Adapter
(B)
TR0473
(A) Cylinder boot

(B) Master cylinder
4) Remove the stop ring.

CAUTION:
Be careful when removing the snap ring to prevent the rod, washer, piston and return spring
from flying out.
5) Remove the clutch damper.
CL-32
MASTER CYLINDER
CLUTCH SYSTEM
D: ASSEMBLY

1) Install the clutch damper.
Tightening torque:
46.6 Nm (4.75 kgf-m, 34.4 ft-lb)
2) Apply a coat of grease to the contacting surfaces
of the push rod and piston before installation.
Grease:
SILICONE GREASE G40M (Part No.
004404003)
TR0525
5) Move the cylinder boot backward.

(A)
(B)
TR0474
TR0473
3) To assemble the master cylinder, reverse the

sequence of disassembly procedure.
(A) Cylinder boot

(B) Master cylinder
Tightening torque:
10 Nm (1.0 kgf-m, 7 ft-lb)
6) Remove the stop ring.

CAUTION:
Be careful when removing the snap ring to prevent the rod, washer, piston and return spring
from flying out.
7) Remove the air bleeder.
CL-33
MASTER CYLINDER
CLUTCH SYSTEM
2. RHD TURBO MODEL

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)
TR0526
2) Assemble in the reverse order of disassemble.
E: INSPECTION
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 and hose replace the faulty
part.
(C)
(B)
(A)
(G)
(D)
(F)
(E)
TR0905
(A)
(B)
(C)
(D)
(E)
(F)
(G)
Master cylinder body

Return spring
Piston
Stop ring
Rod ASSY
Clutch damper
Cylinder boot
CL-34
CLUTCH PIPE AND HOSE

CLUTCH SYSTEM
7. Clutch Pipe and Hose
2. RHD TURBO MODEL
A: REMOVAL

2) Drain the clutch fluid. <Ref. to CL-37, Clutch Fluid.>
3) Remove the clutch pipe from the master cylinder, connector and clutch hose.

1) Remove the air cleaner case and air intake duct.
2) Drain the clutch fluid. <Ref. to CL-37, Clutch Fluid.>
3) Remove the clutch pipe from the clutch hose and
master cylinder.
4) Pull out the clamp, then remove the clutch hose
from bracket.
(B)
(A)
(C )
(A)
(B)
(D)
(B)
B2M4113A
(A) Clamp
(B) Clutch hose
(A)
5) Remove the hose from operating cylinder.

6) Remove the bracket.
TR0527
(A)
(B)
(C)
(D)
Clutch pipe
Clip
Connector
Clutch hose
4) Pull out the clamp, then remove the clutch hose

from bracket.
B2M4113A
(A) Clamp
(B) Clutch hose
5) Remove the connector.

6) Remove the bracket.
CL-35
CLUTCH PIPE AND HOSE

CLUTCH SYSTEM
B: INSTALLATION
2. RHD TURBO MODEL
NOTE:
Bleed the clutch fluid. <Ref. to CL-38, Clutch Fluid
Air Bleeding.>
NOTE:
Bleed the clutch fluid. <Ref. to CL-38, 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, 18.1 ft-lb)
Tightening torque:
T1: 7.5 Nm (0.76 kgf-m, 5.53 ft-lb)
T2: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
T3: 15 Nm (1.5 kgf-m, 10.8 ft-lb)
T4: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
T5: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
T1
(A)
T3
T3
T1
T1
(A)
(D)
T3
T3
T1
(C)
(A)
(B)
T3
T5
T3
(C)
(B)
T4
T2
(A)
T5
T2
TR0477
(A)
(B)
(C)
(D)
TR0528
Clutch pipe (LHD model)

Clip
Clutch hose
Clutch pipe (RHD model)
(A) Clutch pipe

(B) Connector
(C) Clutch hose
C: INSPECTION
Check the pipes and hoses for cracks, breakage, or
damage. Check the joints for fluid leakage. If any
cracks, breakage, damage, or leakage is found, repair or replace the applicable pipe or hose.
CL-36
CLUTCH FLUID
CLUTCH SYSTEM
8. Clutch Fluid
A: INSPECTION
2) Inspect the fluid level using scale on the outside
of the reservoir tank. If the level is below MIN, add
fluid to bring it up to MAX, and also inspect for
leakage.
6) Refill the brake fluid before reservoir tank becomes empty, and drain contaminated fluid again.
7) Repeat the above procedure until the contaminated fluid is completely drained.
(C)
(A)
(B)
TR0478
(A) Max. level

(B) Min. level
(C) Reservoir tank
B: REPLACEMENT
CAUTION:
The FMVSS No. 116, fresh DOT3 or 4 brake
fluid must be used.
Cover the bleeder with waste cloth, when
loosening it, to prevent brake fluid from being
splashed over surrounding parts.
Avoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
Be careful not to allow dirt or dust to get into
the reservoir tank.
NOTE:
During bleeding operation, keep the clutch reservoir tank filled with brake fluid to eliminate entry of
air.
Clutch pedal operating must be very slow.
For convenience and safety, it is advisable to
have two men working.
m2 (2.4 US fl oz, 2.5 Imp fl oz) for total clutch system.
1) Remove the air cleaner case and air duct.
stand under it, or lift-up the vehicle.
3) Draw out the brake fluid from reservoir tank with
syringe.
brake fluid.
5) Drain fluid in the same method as air bleeding.
CL-37
CLUTCH FLUID AIR BLEEDING

CLUTCH SYSTEM
9. Clutch Fluid Air Bleeding
5) Tighten the air bleeder.
A: PROCEDURE
Tightening torque:
T: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
1. NON-TURBO MODEL
NOTE:
Bleed air from the oil line with help of a co-worker.
1) Remove the air cleaner case and air intake duct.
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.
B2M1179A
6) After depressing the clutch pedal, make sure

that there are no leaks evident in the entire system.
2. TURBO MODEL
B2M1179K
(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.
NOTE:
Bleed air from the oil line with help of a co-worker.
master cylinder and put the air bleeder of other end
into a brake fluid container. (RHD turbo model)
together with the fluid. Release the air bleeder for 1
or 2 seconds. Next, with the bleeder closed, slowly
release the clutch pedal. (RHD turbo model)
(A)
TR0909
B2M1178C
(A) Vinyl tube

(B) Vinyl tube
4) Repeat these steps until there are no more air

bubbles in the vinyl tube.
NOTE:
Cover the bleeder with waste cloth when loosening
it, to prevent brake fluid from being splashed over
surrounding parts.

bubbles in the vinyl tube. (RHD turbo model)
CAUTION:
Cover the bleeder with waste cloth when loosening to prevent brake fluid from being
CL-38

CLUTCH SYSTEM
5) Tighten the air bleeder. (RHD turbo model)
together with the fluid.
Release the air bleeder for 1 or 2 seconds. Next,
with the bleeder closed, slowly release the clutch
pedal.
Tightening torque:
T: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
NOTE:
Set the air breather screw part higher than tip of operating cylinder when performing this procedure.
T
(A)
TR0910
6) Remove the operationg cylinder.

NOTE:
Do not remove the clutch hose.
(B)
TR0893

(B) Vinyl tube

bubbles in the vinyl tube.
TR0070
7) Fix the piston with clamp to avoid the piston from

jumping out.
CAUTION:
Cover the bleeder with waste cloth when loosening it, to prevent brake fluid from being
TR0892

operating cylinder and put the other end into a
brake fluid container.
CL-39

CLUTCH SYSTEM
11) Tighten the air bleeder.

Tightening torque:
T: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
12) Install the operating cylinder.
Tightening torque:
T: 37 Nm (3.8 kgf-m, 27.5 ft-lb)
TR0070
13) After depressing the clutch pedal, make sure

that there are no leaks evident in the entire system.
CL-40
CLUTCH PEDAL
CLUTCH SYSTEM
10.Clutch Pedal
7) Remove the cable clamp, and disconnect the

PHV cable from PHV. (with hill holder)
A: REMOVAL
CAUTION:
Carefully protect the boot and inner cable from
damage when disconnecting the PHV cable.
1. LHD MODEL
Except 1.6 L MODEL
1) Remove the steering column. <Ref. to PS-29,
REMOVAL, Tilt Steering Column.>
2) Disconnect the connectors from stop light and
clutch switches.
3) Remove the snap pins which secure lever to
push rod and operating rod.
4) Remove the clevis pins which secure lever to
push rod and operating rod.
S4M0242B
(A) PHV cable

(B) Clamp
8) Remove the nut which secures clutch master

cylinder.
B4M1743A
(A)
(B)
(C)
(D)
Operating rod
Push rod
Snap pin
Clevis pin
5) Remove the air cleaner case and intake duct.

6) Remove the PHV adjusting nut and lock nut.
(with hill holder)
B4M1744
9) Remove the bolts and nuts which secure brake

and clutch pedals, and remove the pedal assembly.
1.6 L MODEL
S4M0241B

3) Disconnect the clutch cable from release lever.
4) Remove the instrument panel lower cover.
5) Disconnect the operating rod of brake pedal.
6) Remove the electrical connectors (for stop light
switch, etc.)
(A) Adjusting nut

(B) Lock nut
(C) PHV
CL-41
CLUTCH PEDAL
CLUTCH SYSTEM

and clutch pedals, and remove pedal bracket and
clutch cable as a unit.
6) Remove the PHV adjusting nut and lock nut.

(with hill holder)
S4M0241B
(A) Adjusting nut

(B) Lock nut
(C) PHV
7) Remove the cable clamp and disconnect the

PHV cable from PHV. (with hill holder)
(A)
CAUTION:
damage when disconnecting the PHV cable.
(B)
TR0494
(A) Clutch pedal

(B) Brake pedal
8) Depress the clutch pedal, then disconnect the

clutch cable from clutch pedal.
2. RHD MODEL
2) Disconnect the connector from clutch. (With
cruise control)
4) Remove the snap pin and clevis pin that join
push rod and clutch pedal. (Except 1.6 L model)
5) Remove the master cylinder mounting nuts. (Except 1.6 L model)
S4M0242B
(A) PHV cable

(B) Clamp

(1.6 L model)
9) Remove the clutch pedal and bracket as a unit.
B4M1752B
B4M1749B
(A) Clutch pedal bracket

(B) Clutch pedal
(A) Master cylinder
CL-42
CLUTCH PEDAL
CLUTCH SYSTEM
10) Depress the clutch pedal, then disconnect the

clutch cable from clutch pedal. (1.6 L model)
3) Remove the clutch pedal and bushings.
B: INSTALLATION
CAUTION:
a new one.
boot.
2) Adjust the clutch pedal after installation. <Ref. to
CL-46, ADJUSTMENT, Clutch Pedal.>
B2M4117A
(A) Clutch pedal

(B) Bushing
C: DISASSEMBLY
4) Remove the stopper, clip, O-ring, rod S, and

then remove the spring and bushing S.
1. LHD MODEL
Except 1.6 L MODEL
1) Remove the clips, assist spring, rod and bushing.
B2M4118A
(A)
(B)
(C)
(D)
(E)
(F)
B2M4115A
(A)
(B)
(C)
(D)
(E)
Clip
Assist spring
Assist rod
Bushing
Clevis pin
Clip
O-ring
Bushing S
Spring S
Rod S
Stopper
5) Remove the stoppers from clutch pedal.

6) Remove the clutch pedal pad. (Non-turbo model)
2) Remove the spring pin and lever.
B2M4116A
(A) Pin
(B) Lever
CL-43
CLUTCH PEDAL
CLUTCH SYSTEM
2) Remove the clip, then pull out the clevis pin.
1.6 L MODEL
1) Remove the clip, and then remove the spring assist and spring.
(A)
(A)
B2M4226A
(B)
(A) Clevis pin
TR0943
3) Remove the assist rod, spring and bushing.

4) Remove the clutch pedal from clutch pedal
bracket.
(A) Spring assist

(B) Spring
2) Remove the clutch pedal and brake pedal.
B2M4227A
TR0944
3) Remove the bushing, stopper and clutch pedal

pad.
(A)
(A) Clutch pedal bracket

(B) Clutch pedal
5) Remove the following parts (B to H) from clutch

pedal bracket (A) as shown in the figure.
(B)
(A)
(C)
TR0945
B2M4228A
(A) Bushing
(B) Stopper
(C) Clutch pedal pad
4) Remove the adjuster bolt.
2. RHD MODEL
Except 1.6 L MODEL
1) Remove the clutch switch. (With cruise control)
CL-44
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)

Bushing C
Clip
O-ring
Bushing S
Spring S
Rod S
Bushing
CLUTCH PEDAL
CLUTCH SYSTEM
6) Remove the spacer, bushing and pedal pad from

clutch pedal.
3) Remove the spacer, bushing, stopper and clutch

pedal pad.
(B)
(A)
(B)
(C)
(E)
(D)
TR0948
B2M4229A
(A)
(B)
(C)
(D)
(E)
(F)
Spacer
Bushing
Bushing
Pedal pad
Clutch pedal
Bushing C
(A)
(B)
(C)
(D)
Spacer
Bushing
Stopper
Clutch pedal pad
4) Remove the adjust bolt and stopper.
D: ASSEMBLY
1.6 L MODEL
1. LHD MODEL
1) Remove the spring and bushing.
(B)
1) Attach the stopper, etc. to pedal bracket temporarily.

2) Clean inside of bores of clutch pedal and brake
pedal, apply grease, and set bushings into bores.
3) Align bores of pedal bracket, clutch pedal and
brake pedal, attach the brake pedal return spring,
assist rods, spring, and bushing. (Except 1.6L model)
(A)
(A)
TR0946
(A) Bushing
(B) Spring
2) Remove the clutch pedal.
NOTE:
Clean up inside of bushings and apply grease before installing the spacer.
4) Align the bores of pedal bracket, clutch pedal
and brake pedal, then attach the brake pedal,
bushings, spring and clutch cable. (1.6L model)
5) Install the hill holder cable to clutch pedal. (Vehicle with hill holder)
2. RHD MODEL
1) Clean and apply grease to the hole of sliding
portion between clutch pedal and bushing.
2) Install the pad, stopper, spacer and bushings to
clutch pedal.
TR0947
NOTE:
Clean up inside of bushings and apply grease before installing the spacer.
3) Install the rod S, spring S, bushing S, O-ring,
clip, bushing, clutch switch and bushing C to clutch
pedal bracket. (Except 1.6L model)
4) Install the pedal assembly, stopper, adjust rod,
clutch cable, bushings and spring to clutch pedal
bracket.
CL-45
CLUTCH PEDAL
CLUTCH SYSTEM
5) Install the clutch pedal to pedal bracket.
F: ADJUSTMENT
Tightening torque:
T: 29 Nm (3.0 kgf-m, 21.7 ft-lb)
1. CLUTCH PEDAL
Except 1.6 L MODEL
1) Turn the lock nuts until clutch pedal full stroke
length is within specifications.
CAUTION:
Do not attempt to turn the clutch switch to adjust clutch pedal full stroke length.
NOTE:
If lock nuts cannot adjust the clutch pedal full stroke
length to specifications, turn the master cylinder
push rod to adjust it.
B4M1753B
6) Install the assist rod, bushing and assist spring

to clutch pedal and pedal bracket.
7) Install the PHV cable to clutch pedal. (Vehicle
with hill holder).
Specified clutch pedal full stroke: A

130 135 mm (5.12 5.31 in)
Tightening torque (Clutch switch lock nut):
T: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
E: INSPECTION
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 pedal deflection is in specified range.
CAUTION:
bushings with new ones.
Deflection of clutch pedal:
Service limit
B4M1190C
2) Turn the master cylinder push rod so that clevis

pin moves to the left and then to the right. Clevis pin
must move without resistance while it is rattling.
Tightening torque (Push rod lock nut):
T: 10 Nm (1.0 kgf-m, 7 ft-lb)
B2M4119A
(A) Clutch pedal

(B) Brake pedal
B4M1189G
(A) Clevis pin

(B) Snap pin
(C) Push rod
CL-46
CLUTCH PEDAL
CLUTCH SYSTEM
3) Depress and release the clutch pedal two to

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-38, Clutch
Fluid Air Bleeding.>
4) 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)
5) 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.
6) 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 the 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-31, Master Cylinder.>
7) Push the release lever until operating cylinder

push rod retracts. Check that the clutch fluid level in
reservoir tank increases.
B4M1191B
(1) Push rod

(2) Release lever
(3) Operating cylinder
8) If the clutch fluid level increases, hydraulic clutch

play is correct.
9) If the clutch fluid level does not increase or push
rod does not retract, clutch pedal must be readjusted.
10) 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)
B4M1191B
(1) Push rod

(2) Release lever
(3) Operating cylinder
(A)
(B)
TR0478
(A) Max. level

(B) Min. level
(C) Reservoir tank
1.6 L MODEL
3) Remove the release lever return spring from lever.
4) Loosen the lock nut.
CL-47
CLUTCH PEDAL
CLUTCH SYSTEM
5) Adjust the spherical nut of the lever end so that

the play and full stroke is within the specified value,
(center of spherical nut).
CAUTION:
Take care not to twist the cable during adjustment.
Play: 3 4 mm (0.12 0.16 in)
Full stroke: 24 26 mm (0.94 1.02 in)
(A)
(B)
TR0504
(A) Play
(B) Full stroke
6) Upon completion of adjustment, securely lock

the spherical nut with lock nut.
Tightening torque:
5.9 Nm (0.60 kgf-m, 4.3 ft-lb)
(A)
(C)
(B)
TR0505
(A) Lock nut

(B) Spherical nut
(C) Clutch release lever
7) Install the return spring on lever.

NOTE:
Hook the long hook side of the return spring with
the lever.
8) Depress the clutch pedal to assure there is no
abnormality in the clutch system.
9) Install the air cleaner case and intake duct. <Ref.
CL-48
CLUTCH CABLE
CLUTCH SYSTEM
11.Clutch Cable
A: REMOVAL
4) Depress the clutch pedal to the floor.
5) Remove the clutch cable clamp from pedal
bracket.
(A)
(B)
TR0529
(A) Clamp
(B) Clutch cable
6) Remove the clutch cable from body.
B: INSTALLATION
1) Clean the clutch pedal fitting hole, and apply
grease. Connect the clutch cable to body.
2) Fit the clutch pedal to pedal bolt, and connect
the clutch cable to bracket with clamp.
3) Connect the clutch cable end to pedal end.
4) Connect the clutch cable to release lever.
5) Install the grommet to toe board.
6) Adjust the cable after installation. <Ref. to CL46, ADJUSTMENT, Clutch Pedal.>
7) Install the air cleaner case and intake duct. <Ref.
C: INSPECTION
cracks.
CL-49
CLUTCH SWITCH
CLUTCH SYSTEM
12.Clutch Switch
2) Check the clutch switch continuity. If continuity is

not as specified, replace the switch.
(1) Disconnect the clutch switch connector.
(2) Measure the resistance between 1 and 2 of
switch terminal.
A: REMOVAL
2) Disconnect the connector from clutch switch.
3) Remove the clutch switch.
B: INSTALLATION
1) Move the clevis pin of the push rod right and left
and hold where it moves smoothly, then measure
stroke of clutch pedal.
Specified clutch pedal full stroke:A
130 135 mm (5.12 5.31 in)
Terminals/Specified resistance
When clutch pedal depressed:
1 2/Less than 1
Terminals/Specified resistance
When clutch pedal not depressed:
1 2/More than 1 M
Clutch switch (With cruise control)
Tightening torque:
T: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
2 1
B2M4122
B4M1190C
2) If the clutch pedal stroke is out of specification,

adjust the stroke. <Ref. to CL-46, ADJUSTMENT,
Clutch Pedal.>
3) Connect clutch switch connector.
C: INSPECTION
1) If the clutch switch does not operate properly (or
if it does not stop at the specified position), replace
with a new one.
Specified position: L
2+1.5/0mm (0.079+0.059/0 in)
G4M0327
CL-50

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 speed up when shifting.
High speed driving is impossible; especially rapid acceleration impossible and
vehicle speed does not increase in proportion to an increase in engine speed.
Power falls, particularly when ascending a slope, and there is a smell of burning of the clutch facing.
Method of testing: Put the vehicle in
stationary condition with parking brake
fully applied. Disengage the clutch and
shift the transmission gear into the first.
Gradually allow the clutch to engage
while gradually increasing the engine
speed. The clutch function is satisfactory
if the engine stalls. However, the clutch is
slipping if the vehicle does not start off
and the engine does not stall.
2. Clutch drags.
As a symptom of this trouble, a harsh
scratching noise develops and control
becomes quite difficult when shifting
gears. The symptom becomes more
apparent when shifting into the first gear.
However, because much trouble of this
sort is due to defective synchronization
mechanism, carry out the test as
described after.
Method of testing: <Ref. to CL-52,
DIAGNOSTIC DIAGRAM OF CLUTCH
DRAG, INSPECTION, General Diagnostic Table.>
It may be judged as insufficient disengagement of clutch if any noise occurs
during this test.
3. Clutch chatters.
Clutch chattering is an unpleasant vibration to the whole body when the vehicle is
just started with clutch partially engaged.
Possible cause
(a) Clutch facing smeared by oil
(b) Worn clutch facing
(c) Deteriorated diaphragm spring
(d) Distorted pressure plate or flywheel
(e) Defective release bearing holder
Corrective
Replace.
Replace.
Replace.
Correct or replace.
Correct or replace.
(a) Worn or rusty clutch disc hub spline

(b) Excessive deflection of clutch disc
facing
(c) Seized crankshaft pilot needle bearing
(d) Cracked clutch disc facing
(e) Sticked clutch disc (smeared by oil or
water)
Replace the clutch disc.

Correct or replace.
(a) Adhesion of oil on the facing

(b) Weak or broken torsion spring
(c) Defective facing contact or excessive
disc
(d) Warped pressure plate or flywheel
(e) Loose disc rivets
(f) Loose engine mounting
(g) Improper adjustment of pitching stopper
CL-51
Replace.
Replace.
Replace.

Replace the clutch disc defection.
Correct or replace.
Retighten or replace the mounting.
Adjustment.

CLUTCH SYSTEM
Symptom
4. Noisy clutch
Examine whether the noise is generated
when the clutch is disengaged, engaged,
or partially engaged.
5. Clutch grabs.
When starting the vehicle with the clutch
partially engaged, the clutch engages
suddenly and the vehicle jumps instead
of making a smooth start.
Possible cause
(a) Broken, worn or unlubricated release
bearing
(b) Insufficient lubrication of pilot bearing
(c) Loose clutch disc hub
(d) Loose torsion spring retainer
(e) Deteriorated or broken torsion spring
(a) Grease or oil on facing
(b) Deteriorated cushioning spring
(c) Worn or rusted spline of clutch disc or
main shaft
(d) Deteriorated or broken torsion spring
(e) Loose engine mounting
(f) Deteriorated diaphragm spring
Corrective
Replace the release bearing.
Apply grease.
Take off rust, apply grease or replace the
clutch disc or main shaft.
Retighten or replace the mounting.
Replace.
2. CLUTCH PEDAL
Trouble
Corrective action
Insufficient pedal play

Clutch pedal free play insufficient
Excessively worn and damaged pedal shaft and/or bushing
Adjust pedal play.

Adjust pedal free play.
Replace the bushing and/or shaft with a new one.
3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG
Step
CHECK GEAR NOISE.
1)Start the engine.
2)Disengage the clutch and shift quickly from
neutral to reverse in idling condition.
CHECK GEAR NOISE.
Disengage the clutch at idle and shift from neutral to reverse within 0.5 1.0 seconds.
CHECK GEAR NOISE.

1)Disengage the clutch at idle and shift from
neutral to reverse within 0.5 1.0 seconds.
2)With the clutch disengaged, shift from N to
R, R to N several times.
Check
Is there any abnormal noise
from the transmission gear?
Yes
Go to step 2.

Go to step 3.

CL-52
No
Clutch is normal.
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 the clutch Inspect the clutch
disc, clutch cover, disc, spline of
clutch release, and clutch disc hub.
clutch 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
BRAKE
BR
PARKING BRAKE
PB
POWER ASSISTED SYSTEM

(POWER STEERING)
PS

approval.
G1840GE5
FRONT SUSPENSION
FS
1.
2.
3.
4.
5.
6.
7.
8.
9.
Page
Wheel Alignment .........................................................................................8
Front Transverse Link ...............................................................................16
Front Ball Joint ..........................................................................................18
Front Strut .................................................................................................19
Front Stabilizer ..........................................................................................23
Front Crossmember ..................................................................................24
Sub Frame ................................................................................................25
GENERAL DESCRIPTION
FRONT SUSPENSION
A: SPECIFICATIONS
Model
Front
Camber (tolerance: 045)

Caster (common difference: 045)
Toe-in
Kingpin angle (tolerance: 045)
Wheel arch height
[tolerance: 12 mm (0.47 in)]
Diameter of stabilizer
Rear

Toe-in
Thrust angle
Wheel arch height
Sedan
Wagon
OUTBACK
Non-turbo
Turbo
Non-turbo
015
020
010
005
325
335
325
325
03 mm (00.12 in) Each toe angle: 00730
1435
1420
1345
1330
1320
396 mm
406 mm
387 mm
397 mm
402 mm
(15.59 in)
(15.98 in)
(15.24 in)
(15.28 in)
(15.83 in)
20 mm
20 mm
20 mm
20 mm
20 mm
(0.79 in)
(0.79 in)
(0.79 in)
(0.79 in)
(0.79 in)
130
125
120
115
110
12 mm (0.0390.079 in) Each toe angle: 00730
020
376 mm
381 mm
376 mm
381 mm
386 mm
(14.80 in)
(15.0 in)
(14.80 in)
(15.0 in)
(15.20 in)
20 mm
17 mm
(0.79 in)
(0.67 in)
Turbo
025
335
NOTE:
Front and rear toe-ins and front camber can be
adjusted. If toe-in or camber tolerance exceeds
specifications, adjust toe-in and camber to the middle value of specification.
The other items indicated in the specification table cannot be adjusted. If the other items exceeds
specifications, check suspension parts and connections for deformities; replace with new ones as
required.
B4M2250B
(1) Front
A B = Positive: Toe-in, Negative: Toe-out
= Each toe angle
FS-2
GENERAL DESCRIPTION
FRONT SUSPENSION
FS-3
GENERAL DESCRIPTION
FRONT SUSPENSION
B: COMPONENT
T8
FS-4
SU0037
GENERAL DESCRIPTION
FRONT SUSPENSION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Front crossmember
Bolt ASSY
Housing
Washer
Stopper rubber (Rear)
Rear bushing
Stopper rubber (Front)
Ball joint
Transverse link
Cotter pin
Front bushing
Stabilizer link
Clamp
Bushing
Stabilizer
Jack-up plate
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
Dust seal
Strut mount
Spacer
Upper spring seat
Rubber seat
Dust cover
Helper
Coil spring
Damper strut
Adjusting bolt
Castle nut
Self-locking nut
Sub frame
Cover
Boss
Clip
FS-5

T1: 20 (2.0, 14.5)
T2: 25 (2.5, 18.1)
T3: 30 (3.1, 22)
T4: 34 (3.5, 25)
T5: 40 (4.1, 30)
T6: 45 (4.6, 33)
T7: 50 (5.1, 37)
T8: 55 (5.6, 41)
T9: 71 (7.2, 52)
T10: 100 (10.2, 74)
T11: 155 (15.8, 114)
T12: 175 (17.8, 129)
T13: 190 (19.4, 140)
T14: 250 (25.5, 184)
GENERAL DESCRIPTION
FRONT SUSPENSION
C: CAUTION
points.
FS-6
GENERAL DESCRIPTION
FRONT SUSPENSION
D: PREPARATION TOOL
1. SPECIAL TOOLS
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
927680000
INSTALLER &
REMOVER SET
Used for replacing transverse link bushing.
927760000
STRUT MOUNT
SOCKET
Used for disassembling and assembling strut

and shock mount.
B4M2378A
B4M2385
B4M2384

TOOL NAME
Alignment gauge
Turning radius gauge
Toe-in gauge
Dial gauge
REMARKS
Used for wheel alignment measurement.
Used for toe-in measurement.
Used for damper strut measurement.
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 air pressure
unbalanced right and left tire wear, size difference
tire run-out
ball joint excessive play, wear
tie rod end excessive play, wear
wheel bearing excessive play
right and left wheel base imbalance
steering link part deformed, excessive play
suspension part deformed, excessive play
Check, adjust and/or measure the wheel alignment in accordance with procedures indicated in the figure:
B4M1088B
FS-8
WHEEL ALIGNMENT
FRONT SUSPENSION
1. WHEEL ARCH HEIGHT

1) Set the vehicle on a level surface.
2) Set the vehicle to curb weight conditions. (Empty luggage compartment, install spare tire, jack, service
tools, and top up fuel tank.)
3) Set the steering wheel in a straight line, then remove the vehicle straight ahead more than 5 m (16 ft) to
settle the suspension.
4) Suspend the thread from wheel arch (point A in figure below) to determine a point directly above center
of wheel.
5) Measure the distance between measuring point A and center of wheel.
Wheel arch height
Front fender
Wheel arch height
Inner
rear
arch
Outer
rear quarter
Cross-section
of arch
Measuring
point
Wheel arch height
Rear wheel arch height
Front wheel arch height
End of spindle
SU0009
Specified wheel arch height
Model
Sedan
Wagon
OUTBACK
Turbo
Non-turbo
Front
39612 mm (15.590.47 in)
40612 mm (15.980.47 in)
Rear
37612 mm (14.800.47 in)
38112 mm (15.00.47 in)
Front
38712 mm (15.240.47 in)
39712 mm (15.630.47 in)
Rear
37612 mm (14.800.47 in)
38112 mm (15.00.47 in)
Front
40212 mm (15.830.47 in)
Rear
38612 mm (15.200.47 in)
FS-9
WHEEL ALIGNMENT
FRONT SUSPENSION
2. CAMBER
2) Turn the camber adjusting bolt so that camber is

set at the specification.
Inspection
1) Place the front wheel on turning radius gauge.
Make sure 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 install the wheel alignment gauge.
ST 927380002
ADAPTER
NOTE:
Moving the adjusting bolt by one scale graduation
changes camber by approx. 010.
B4M0567B
(1) Alignment gauge

(2) Turning radius gauge
3) Follow the wheel alignment gauge operation

manual to measure camber angle.
NOTE:
Refer to the SPECIFICATIONS for camber values.
Front: <Ref. to FS-2, SPECIFICATIONS, General
Description.>
Rear: <Ref. to RS-2, SPECIFICATIONS, General
Description.>
Front Camber Adjustment
1) Loosen the two self-locking nuts located at lower
front portion of strut.
CAUTION:
When adjusting bolt needs to be loosened or
tightened, hold its head with a wrench and turn
self-locking nut.
Discard the loosened self-locking nut and replace with a new one.
FS-10
S4M0300B
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Strut
Adjusting bolt
Housing
Outer
Inner
Camber is increased.
Camber is decreased.
WHEEL ALIGNMENT
FRONT SUSPENSION
Left side
Right side
Rotate counterclockwise.
Camber is increased.
Rotate clockwise.
B4M0190
Camber is decreased.
B4M0350
Rotate clockwise.
B4M0350
B4M0190
3) Tighten the two self-locking nuts.
4. STEERING ANGLE
Tightening torque:
175 Nm (17.8 kgf-m, 129 ft-lb)
Inspection
3. CASTER
Inspection
1) Place the front wheel on turning radius gauge.
Make sure 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 install the wheel alignment gauge.
ST 927380002
ADAPTER
1) Place the vehicle on a turning radius gauge.

2) While depressing the brake pedal, turn the steering wheel fully to the right and left. With the steering
wheel held at each fully turned position, measure
both the inner and outer wheel steering angle.
Steering angle:
Model
Inner wheel
Outer wheel
Turbo and OUTBACK

34301.5
34301.5
Others
37201.5
32251.5
Adjustment
Turn the tie-rod to adjust steering angle of both inner and outer wheels.
CAUTION:
Check the toe-in.
Correct the boot if it is twisted.
B4M0567B
(1) Alignment gauge

(2) Turning radius gauge
3) Follow the wheel alignment gauge operation

manual to measure caster angle.
NOTE:
Refer to the SPECIFICATIONS for caster values.
<Ref. to FS-2, SPECIFICATIONS, General Description.>
FS-11
S4M0348A
(1) Lock nut
WHEEL ALIGNMENT
FRONT SUSPENSION
5. FRONT WHEEL TOE-IN
3) Tighten the tie-rod lock nut.
Inspection
Tightening torque:
83 Nm (8.5 kgf-m, 61.5 ft-lb)
1) Using a toe gauge, measure the front wheel toein.

Toe-in:
03 mm (00.12 in)
2) Mark the rear sides of right and left tires at height
corresponding to center of spindles and measure
the distance A between marks.
3) Move the vehicle forward so that marks line up
with front sides at height corresponding to center of
spindles.
4) Measure the distance B between right and left
marks. Toe-in can then be obtained by the following equation:
A B = Toe-in
CAUTION:
Correct the tie-rod boot, if it is twisted.
NOTE:
Check the right and left wheel steering angle is
6. REAR WHEEL TOE-IN

Inspection
1) Using a toe-in gauge, measure the rear wheel
toe-in.
Toe-in:
12 mm (0.0390.079 in)
2) Mark the rear sides of right and left tires at height
corresponding to center of wheels and measure the
distance A between marks.
3) Move the vehicle forward so that marks line up
with front sides at height corresponding to center of
spindles.
4) Measure the distance B between right and left
marks. Toe-in can then be obtained by the following equation:
A B = Toe-in
H4M1279B
Adjustment
1) Loosen the right and left side steering tie-rods
lock nuts.
2) Turn the right and left tie rods equal amounts until the toe-in is at the specification.
Both the right and left tie-rods are right-hand
threaded. To increase toe-in, turn both tie-rods
clockwise equal amounts (as viewed from inside of
the vehicle).
S4M0348A
(1) Lock nut
FS-12
H4M1279B
WHEEL ALIGNMENT
FRONT SUSPENSION
Adjustment
1) Loosen the self-locking nut on inner side of link
rear.
CAUTION:
When loosening or tightening the adjusting
bolt, hold the bolt head and turn self-locking
nut.
S4M0349A
(1) Adjusting bolt

(2) Link rear
2) Turn the adjusting bolt head until toe-in is at the specification.

NOTE:
When right and left wheels are adjusted for toe-in at the same time, the movement of one scale graduation
changes toe-in by approx. 1.5 mm (0.6 in).
Left side
Toe-in is increased.
Right side
Rotate clockwise.
B4M0192
B4M0352
Toe-in is decreased.
B4M0352
Rotate clockwise.
B4M0192
3) Tighten the self-locking nut.

Tightening torque:
100 Nm (10.2 kgf-m, 74 ft-lb)
FS-13
WHEEL ALIGNMENT
FRONT SUSPENSION
7. THRUST ANGLE
Inspection
1) Position the vehicle on a level surface.
2) Move the vehicle 3 to 4 m (10 to 13 ft) directly
forward.
3) Determine the locus of both front and rear axles.
4) Measure the distance L between center line of
loci of the axles.
3) When the right and left adjusting bolts are turned

incrementally by one graduation in the same direction, the thrust angle will change approx. 16 [L is
almost equal to 12 mm (0.472 in)].
Thrust angle:
020
Thrust angle:
Less than 20 when L is equal to or less
than 15 mm (59 in).
S4M0350B
(1) Center line of loci (front axle)

(2) Center line of loci (rear axle)
NOTE:
Thrust angle refers to a mean value of right and left
rear wheel toe angles in relation to the vehicle body
center line. Vehicle is driven straight in the thrust
angle direction while swinging in the oblique direction depending on the degree of the mean thrust
angle.
S4M0350B
(1) Center line of loci (front axle)

(2) Center line of loci (rear axle)
Adjustment
1) Make the thrust angle adjustments by turning
toe-in adjusting bolts of rear suspension equally in
the same direction.
2) When one rear wheel is adjusted in a toe-in direction, adjust the other rear wheel equally in toeout direction, in order to make thrust angle adjustment.
B4M0193B
(1) Front
(2) Thrust angle
(3) Body center line
FS-14
WHEEL ALIGNMENT
FRONT SUSPENSION
Thrust angle: r = ( )/2

: Right rear wheel toe-in angle
: Left rear wheel toe-in angle
NOTE:
Here, use only positive toe-in values from each
wheel to substitute for and in the equation.
B4M0194B
(1) Front
(2) Body center line
FS-15
FRONT TRANSVERSE LINK

FRONT SUSPENSION
3. Front Transverse Link
B: INSTALLATION
A: REMOVAL
1) Temporarily tighten the two bolts used to secure

rear bushing of transverse link to body.
1) Set the vehicle on the lift.

2) Lift-up the vehicle and remove the wheel.
3) Remove the sub frame.
link.
5) Remove the bolt securing ball joint of transverse
link to housing.
NOTE:
These bolts should be tightened to such an extent
that they can still move back and forth in the oblong
shaped hole in the bracket (which holds the bushing).
2) Install the bolts used to connect transverse link
to crossmember and temporarily tighten with nut.
CAUTION:
3) Insert the ball joint into housing.
4) Connect the stabilizer link to transverse link, and
temporarily tighten the bolts.
CAUTION:
S4M0090
6) Remove the nut (do not remove bolt) securing

transverse link to crossmember.
7) Remove the two bolts securing bushing bracket
of transverse link to the vehicle body at rear bushing location.
S4M0090
5) Tighten the following points in the order shown

below when wheels are in full contact with the
ground and vehicle is curb weight.
(1) Transverse link and stabilizer
S4M0091
8) Extract the ball joint from housing.

9) Remove the bolt securing transverse link to
crossmember, and then extract the transverse link
from crossmember.
Tightening torque:
Sedan Turbo model:
45 Nm (4.6 kgf-m, 33 ft-lb)
Except sedan Turbo model:
30 Nm (3.1 kgf-m, 22 ft-lb)
(2) Transverse link and crossmember
Tightening torque:
100 Nm (10.2 kgf-m, 74 ft-lb)
SU0010
FS-16
FRONT TRANSVERSE LINK

FRONT SUSPENSION
D: ASSEMBLY
(3) Transverse link rear bushing and body

Tightening torque:
250 Nm (25.5 kgf-m, 184 ft-lb)
1. FRONT BUSHING
NOTE:
Move the rear bushing back and forth until transverse link-to-rear bushing clearance is established
(as indicated in the figure) before tightening.
Check the wheel alignment and adjust if necessary.

CAUTION:
Install the front bushing in correct direction, as
S4M0351A
(1) Face bushing toward center of ball joint

(2) Ball joint
S4M0352A
(1) Rear bushing
2. REAR BUSHING
C: DISASSEMBLY
1. FRONT BUSHING
Using the ST, press the front bushing out of place.
ST 927680000
INSTALLER & REMOVER
SET
1) Install the rear bushing to transverse link and

align aligning marks scribed on the two.
2) Tighten the self-locking nut.
CAUTION:
While holding the rear bushing so as not to
change position of aligning marks, tighten the
self-locking nut.
Tightening torque:
190 Nm (19.4 kgf-m, 140 ft-lb)
E: INSPECTION
1) Check the transverse link for wear, damage and
cracks, and correct or replace if defective.
2) Check the bushings for cracks, fatigue or damage.
3) Check the rear bushing for oil leaks.
G4M0494
2. REAR BUSHING
1) Scribe an aligning mark on the transverse link
and rear bushing.
2) Loosen the nut and remove rear bushing.
G4M0495
FS-17
FRONT BALL JOINT

FRONT SUSPENSION
4. Front Ball Joint
C: INSPECTION
A: REMOVAL
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
2 1.
1) Remove the wheel.

2) Pull out the cotter pin from ball stud, remove the
castle nut, and extract the ball stud from transverse
link.
3) Remove the bolt securing ball joint to housing.
G4M0500
G4M0499
(2) With 686 N (70 kgf, 154 lb) loaded in opposite direction shown in the figure, measure the
dimension 22.
4) Extract the ball joint from housing.
B: INSTALLATION
1) Install the ball joint onto housing.
Tightening torque (Bolt):
50 Nm (5.1 kgf-m, 37 ft-lb)
CAUTION:
Do not apply grease to tapered portion of ball
stud.
2) Connect the ball joint to transverse link.
Tightening torque (Castle nut):
Sedan turbo model:
30 Nm (3.1 kgf-m, 22 ft-lb)
Except sedan turbo model:
40 Nm (4.1 kgf-m, 30 ft-lb)
3) Retighten the castle nut further within 60 until a
slot in castle nut is aligned with the hole in ball stud
end, then insert a new cotter pin and bend it around
castle nut.
4) Install the front wheel.
G4M0501
(3) Calculate plays from the following formula.

S = 22 21
(4) When plays are larger than the following value, replace with a new one.
FRONT BALL JOINT
Specified play for replacement: S
2) When the play is smaller than specified value, visually inspect the dust cover.
3) The ball joint and cover that have been removed
must be checked for wear, damage or cracks, and
any defective part must be replaced.
4) If the dust cover is damaged, replace with a new
ball joint.
FS-18
FRONT STRUT
FRONT SUSPENSION
5. Front Strut
6) Remove the three nuts securing strut mount to

body.
A: REMOVAL
1) Remove the wheel.
2) Remove the bolt securing brake hose from strut.
B4M1788
3) Scribe an alignment mark on the camber adjusting bolt which secures strut to housing.
4) Remove the bolt securing ABS sensor harness.
SU0011
B4M1784
5) Remove the two bolts securing housing to strut.

CAUTION:
While holding the head of adjusting bolt, loosen
self-locking nut.
FS-19
FRONT STRUT
FRONT SUSPENSION
B: INSTALLATION
C: DISASSEMBLY
1) Install the strut mount at upper side of strut to

body, and then tighten with nuts.
1) Using a coil spring compressor, compress the

coil spring.
Tightening torque:
20 Nm (2.0 kgf-m, 14.5 ft-lb)
2) Position the aligning mark on camber adjustment bolt with aligning mark on lower side of strut.
CAUTION:
While holding the head of adjusting bolt,
tighten self-locking nut.
Be sure to use a new self-locking nut.
Tightening torque:
175 Nm (17.8 kgf-m, 129 ft-lb)
3) Install the ABS sensor harness to strut.
S4M0095
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
4) Install the bolts which secure brake hose to strut.
2) Using the ST, remove the self-locking nut.

ST 927760000
STRUT MOUNT SOCKET
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
5) Install the wheels.
NOTE:
S4M0096A
3) Remove the strut mount, upper spring seat and

rubber seat from strut.
4) Gradually decreasing the compression force,
and then remove the coil spring.
5) Remove the dust cover and helper spring.
FS-20
FRONT STRUT
FRONT SUSPENSION
D: ASSEMBLY
1) Before installing the coil spring, strut mount, etc.,
on the strut, check for the presence of air in the
damping force generating mechanism of the strut
since air prevents proper damping force from being
produced.
2) Checking for the presence of air
(1) Place the strut vertically with piston rod facing up.
(2) Move the piston rod to 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 piston rod facing up.
(2) Fully extend the piston rod.
(3) With the piston rod fully extended, place the
piston rod side down. The strut must stand vertically.
(4) Fully contract the piston rod.
(5) Repeat three or four times from the first
step.
5) Set the coil spring correctly so that its end face

fits well into the spring seat as shown in the figure.
S4M0353A
(1) Coil spring end face
6) Install the helper and dust cover to the piston

rod.
7) Pull the piston rod fully upward, and install the
rubber seat and spring seat.
NOTE:
Ensure that upper spring seat is positioned as
NOTE:
After completely purging air from the strut, be sure
to place the strut with piston rod facing up. If it is
laid down, check for entry of air in the strut as outlined under Checking for the presence of air.
4) Using a coil spring compressor, compress the
coil spring.
S4M0097B
NOTE:
Make sure that the vertical installing direction of coil
spring is as shown in the figure.
(1) Outside of body
8) Install the strut mount to the piston rod, and then

tighten the self-locking nut temporarily.
CAUTION:
Be sure to use a new self-locking nut.
B4M0568B
(1) Flat (top side)

(2) Identification paint
(3) Inclined (bottom side)
FS-21
FRONT STRUT
FRONT SUSPENSION
9) Using a hexagon wrench to prevent strut rod

from turning, tighten the self-locking nut with ST.
ST 927760000
STRUT MOUNT SOCKET
Tightening torque:
54 Nm (5.5 kgf-m, 39.8 ft-lb)
2. STRUT MOUNT
Check the rubber part for creep, cracks and deterioration, and replace it with a new one if defective.
3. DUST COVER
If any cracks or damage are found, replace it with a
new one.
4. COIL SPRING
One having permanent strain should be replaced
with a new one. When the vehicle posture is uneven, although there are no considerable reasons
like tire puncture, uneven loading, etc., check the
coil spring for its free length referring to specifications, cracks, etc., and replace it with a new one if
defective.
S4M0096A
10) Loosen the coil spring carefully.
5. HELPER
E: INSPECTION
Replace it with a new one if cracked or damaged.
Check the disassembled parts for cracks, damage

and wear, and replace with new parts if defective.
F: DISPOSAL
1. DAMPER STRUT
1) Check for oil leakage.
2) Move the piston rod up and down to check that it
operates smoothly without any binding.
3) Play of piston rod
Measure the play as follows:
Fix outer shell and fully extend the rod. Set a dial
gauge at the end of rod: L [10 mm (0.39 in)], then
apply a force of W [20 N (2 kgf, 4 lb)] to threaded
portion. With the force of 20 N (2 kgf, 4 lb) applied,
read dial gauge indication: P1. Apply a force of 20 N
(2 kgf, 4 lb) in the opposite direction of W, then
read dial gauge indication: P2.
CAUTION:
Before handling gas filled struts, be sure to
wear goggles to protect eyes from gas, oil and/
or filings.
Do not disassemble the strut damper or place
into a fire.
Drill holes before disposing of gas filled
struts.
1) Place the gas filled strut on a flat and level surface with piston rod fully extended.
2) Using a 2 to 3 mm (0.08 to 0.12 in) dia. drill,
make holes in areas shown in the figure.
B4M1202A
G4M0508
The free play is determined by the following equation:

Play = P1, P2
Limit of play:
If the play is greater, replace the strut.
FS-22
FRONT STABILIZER
FRONT SUSPENSION
6. Front Stabilizer
B: INSTALLATION
A: REMOVAL
1) Jack-up the front part of the vehicle and support

it with safety stands (rigid racks).
2) Remove the jack-up plate from lower part of
crossmember.
4) Remove the bolts which secure stabilizer to
crossmember.
NOTE:
Install the bushing (on front crossmember side)
while aligning it with paint mark on stabilizer.
Ensure that bushing and stabilizer have the
same identification colors when installing.
SU0012
(1) Mark stamped on stabilizer

(2) Bushing identification color
B4M1846
5) Remove the bolt which secures stabilizer link to

front transverse link.
2) Always tighten the rubber bushing location when

wheels are in full contact with the ground and vehicle is curb weight.
Tightening torque (Sedan turbo model):
Jack-up plate to crossmember:
20 Nm (2.0 kgf-m, 14.5 ft-lb)
Stabilizer link to front transverse link:
45 Nm (4.6 kgf-m, 33 ft-lb)
Stabilizer to crossmember:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
S4M0355
Tightening torque (Except sedan turbo model):

Jack-up plate to crossmember:
20 Nm (2.0 kgf-m, 14.5 ft-lb)
Stabilizer link to front transverse link:
30 Nm (3.1 kgf-m, 22 ft-lb)
Stabilizer to crossmember:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
C: INSPECTION
1) Check the bushing for cracks, fatigue or damage.
2) Check the stabilizer link for deformities, cracks,
or damage, and bushing for protrusions from the
hole of stabilizer link.
FS-23
FRONT CROSSMEMBER
FRONT SUSPENSION
7. Front Crossmember
B: INSTALLATION
A: REMOVAL

2) Lift-up the vehicle, and then remove the front
tires and wheels.
4) Remove both the stabilizer and jack-up plate.
S4M0534A
(1) Front stabilizer

(2) Front crossmember
5) Disconnect the tie-rod end from housing.

6) Remove the front exhaust pipe.
7) Remove the front transverse link from front
crossmember and body.
CAUTION:
Always tighten the rubber bushing when
wheels are in full contact with the ground and
vehicle is curb weight.
Tightening torque:
Transverse link bushing to crossmember:
100 Nm (10.2 kgf-m, 74 ft-lb)
Stabilizer to bushing:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
Tie-rod end to housing:
27.0 Nm (2.75 kgf-m, 19.9 ft-lb)
Front cushion rubber to crossmember:
85 Nm (8.7 kgf-m, 62.7 ft-lb)
Universal joint to pinion shaft:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
Crossmember to body:
100 Nm (10.2 kgf-m, 74 ft-lb)
2) Purge air from the power steering system.
NOTE:
C: INSPECTION
Check the crossmember for wear, damage and
SU0010
8) Remove the nuts attaching engine mount cushion rubber to crossmember.

9) Remove the steering universal joint.
10) Disconnect the power steering pipe from steering gear box.
11) Lift the engine by approx. 10 mm (0.39 in) by
using chain block.
12) Support the crossmember with a jack, remove
nuts securing crossmember to body and lower the
crossmember gradually along with steering gearbox.
CAUTION:
When removing the crossmember downward,
be careful that tie-rod end does not interfere
with SFJ boot.
FS-24
SUB FRAME
FRONT SUSPENSION
8. Sub Frame
B: INSTALLATION
A: REMOVAL

NOTE:
Replace the M12 bolt with a new one.

3) Remove the bolt cover.
Tightening torque:
T1: 34 Nm (3.5 kgf-m, 25 ft-lb)
T2: 55 Nm (5.6 kgf-m, 41 ft-lb)
T3: 71 Nm (7.2 kgf-m, 52 ft-lb)
T4: 105 Nm (10.7 kgf-m, 77 ft-lb)
(1)
(2)
(3)
T2
(4)
T3
T2
(4)
T3
(2)
(3)
(4)
T4
T1
SU0022
T4
4) Remove the clip.
(1)
(1)
(2)
(3)
(4)
SU0023

NOTE:
Loosen bolt (1) and leave a few threads caught,
then remove the bolts in the order of (2), (3), (4),
(5), and (6).
(6)
(5)
(6)
(4)
(3)
(2)
(1)
(5)
(4)
(3)
(2)
(1)
SU0024
FS-25
M8 bolt
M12 bolt (with max)
M12 bolt (with oil)
M10 bolt
(4)
SU0032
SUB FRAME
FRONT SUSPENSION
C: INSPECTION
1) Check that there is no damage and distortion at
the sub frame.
2) Check that the bolts are tightened with the specified torque. If there is looseness, tighten to the
specified torque.
NOTE:
The tightening torque differs by the color for bolt
(3). Always verify the bolt color before checking
tightening torque.
Tightening torque:
T1: 34 Nm (3.5 kgf-m, 25 ft-lb)
T2: 55 Nm (5.6 kgf-m, 41 ft-lb)
T3: 71 Nm (7.2 kgf-m, 52 ft-lb)
T4: Dark green bolt
105 Nm (10.7 kgf-m, 77 ft-lb)
T4: Except dark green bolt
55 Nm (5.6 kgf-m, 41 ft-lb)
(2)
(3)
T2
(4)
T3
T2
(4)
T3
(2)
(3)
(4)
(1)
T4
T1
T4
(1)
(1)
(2)
(3)
(4)
(4)
SU0032
M8 bolt
M12 bolt
M12 bolt
M10 bolt
FS-26

FRONT SUSPENSION
9. General Diagnostic Table

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
Possible causes
(1) Permanent distortion or breakage of coil spring
(2) Unsmooth operation of damper strut and/or shock absorber
(3) Installation of wrong strut and/or shock absorber
(4) Installation of wrong coil spring
Countermeasures
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/or hump.
3) Large shock in bumping
Possible causes
(1) Breakage of coil spring
(2) Overinflation pressure of tire
(3) Improper wheel arch height
(4) Fault in operation of damper strut and/or shock absorber
(5) Damage or deformation of strut mount and/or shock absorber mount
(6) Unsuitability of maximum and/or minimum length of damper strut and/or
shock absorber
(7) Deformation or loss of bushing
(8) Deformation or damage of helper in strut assembly and/or shock
absorber
(9) Oil leakage of damper strut and/or shock absorber
Countermeasures
Replace.
Adjust.
Adjust or replace the coil springs with new ones.
Replace.
Replace.
Replace.
Replace.
Replace.
3. NOISE
Possible causes
(1) Wear or damage of damper strut and/or shock absorber component parts
(2) Loosening of suspension link installing bolt
shock absorber
(6) Wear or damage of ball joint
(7) Deformation of stabilizer clamp
FS-27
Countermeasures
Replace.
Retighten to the specified torque.
Replace.
Replace.
Replace.
Replace.

FRONT SUSPENSION
FS-28
REAR SUSPENSION
RS
1.
2.
3.
4.
5.
6.
7.
8.
Page
Wheel Alignment .........................................................................................9
Rear Stabilizer...........................................................................................10
Rear Trailing Link ......................................................................................11
Rear Strut..................................................................................................15
Lateral link.................................................................................................17
Rear Crossmember...................................................................................21
GENERAL DESCRIPTION
REAR SUSPENSION
A: SPECIFICATIONS
Item
Turbo
130
Sedan
Non-turbo
125
Toe-in
Wheel arch height
Thrust angle
376 mm
(14.80 in)
381 mm
(15.0 in)
20 mm
(0.79 in)
NOTE:
Front and rear toe-ins and front camber can be
adjusted. If toe-in or camber tolerance exceeds
specifications, adjust toe-in and camber to the middle value of specification.
The other items indicated in the specification table cannot be adjusted. If the other items exceeds
specifications, check suspension parts and connections for deformities; replace with new ones as
required.
B4M2250C
(1) Front
A B = Positive: Toe-in, Negative: Toe-out
1, 2: Each toe-in angle
RS-2
Wagon
Turbo
Non-turbo
120
115
12 mm (0.0390.079 in)
Each toe-in angle: 00730
376 mm
381 mm
(14.80 in)
(15.0 in)
020
17 mm
(0.67 in)
OUTBACK
110
386 mm
(15.20 in)
GENERAL DESCRIPTION
REAR SUSPENSION
RS-3
GENERAL DESCRIPTION
REAR SUSPENSION
B: COMPONENT
1. REAR SUSPENSION
SU0013
RS-4
GENERAL DESCRIPTION
REAR SUSPENSION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Stabilizer (Turbo model)

Stabilizer bracket (Turbo model)
Stabilizer bushing (Turbo model)
Clamp (Turbo model)
Floating bushing
Stopper
Stabilizer link (Turbo model)
Rear lateral link (Turbo model)
Bushing (C)
Bushing (A)
Front lateral link
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
Trailing link bracket

Cap (Protection)
Washer
Rear crossmember
Strut mount cap
Strut mount
Rubber seat upper
Dust cover
Coil spring
Helper
Rubber seat lower

T1: 20 (2.0, 14.5)
T2: 25 (2.5, 18.1)
T3: 45 (4.6, 33.2)
T4: 55 (5.6, 41)
T5: 70 (7.1, 52)
T6: 90 (9.2, 66)
T7: 100 (10.2, 74)
T8: 115 (11.7, 85)
T9: 130 (13.3, 96)
T10: 135 (13.8, 100)
(12)
Bushing (B)
(27)
Damper strut
T11: 220 (22.4, 162)
(13)
(14)
(15)
Trailing link rear bushing

Trailing link
Trailing link front bushing
(28)
(29)
(30)
Self-locking nut
Rear differential member rear
Rear lateral link (Non-turbo
model)
RS-5
GENERAL DESCRIPTION
REAR SUSPENSION
C: CAUTION
points.
Before disposing shock absorbers, be sure to
bleed gas completely. Also, do not throw away in
fire.
RS-6
GENERAL DESCRIPTION
REAR SUSPENSION
D: PREPARATION TOOL
1. SPECIAL TOOLS
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
927720000
INSTALLER &
REMOVER
Used for replacing front bushing.
927730000
INSTALLER &
REMOVER
Used for replacing rear bushing.
REMOVER
Used for removing DOJ.
B4M2378A
SU0014
SU0015
28099PA100
SU0016
RS-7
GENERAL DESCRIPTION
REAR SUSPENSION
ILLUSTRATION
TOOL NUMBER
927710000
DESCRIPTION
INSTALLER &
REMOVER
REMARKS
Used for replacing lateral link bushing.
92770000
INSTALLER &
REMOVER
927690000
HELPER SOCKET
WRENCH
SU0015
SU0015
SU0015

TOOL NAME
Alignment gauge
Turning radius gauge
Toe-in gauge
Transmission jack
Bearing puller
REMARKS
Used for toe-in measurement.
Used for suspension assembly/disassembly.
Used for removing bushings.
RS-8
WHEEL ALIGNMENT
REAR SUSPENSION
2. Wheel Alignment
A: INSPECTION
NOTE:
The front and rear wheel alignment must be measured and/or adjusted at once to obtain accuracy.
Measure and/or adjust the rear wheel alignment together with the front. Follow the procedure in "FS"
section "Wheel Alignment" for measurement and/or
adjustment of wheel alignment. <Ref. to FS-8, INSPECTION, Wheel Alignment.>
RS-9
REAR STABILIZER
REAR SUSPENSION
3. Rear Stabilizer
B: INSTALLATION
A: REMOVAL
1) Jack-up the rear part of the vehicle, support it

with safety stands (rigid racks).
2) Remove the bolt which secures stabilizer link to
rear lateral link.
NOTE:
Install the bushing while aligning it with paint
mark on stabilizer.
Ensure that bushing and stabilizer have the
same identification colors when installing.
SU0017
SU0012
3) Remove the bolt and nut which secure stabilizer

to stabilizer bracket.
(1) Mark stamped on stabilizer

(2) Bushing identification color
2) Always tighten the rubber bushing location when

wheels are in full contact with the ground and vehicle is curb weight.
SU0018
Tightening torque:
Stabilizer link to rear lateral link
45 Nm (4.6 kgf-m, 33.2 ft-lb)
Stabilizer to stabilizer bracket
25 Nm (2.5 kgf-m, 18.1 ft-lb)
C: INSPECTION
1) Check the bushing for cracks, fatigue or damage.
2) Check the stabilizer links for deformities, cracks,
or damage, and bushing for protrusions from the
hole of stabilizer link.
RS-10
REAR TRAILING LINK

REAR SUSPENSION
4. Rear Trailing Link
B: INSTALLATION
A: REMOVAL
1) Loosen the rear wheel nuts.

2) Jack-up the vehicle, support it with safety stands
(rigid racks), and then remove the rear wheels.
3) Remove both the rear parking brake clamp and
ABS sensor harness. (Models equipped with ABS)
4) Remove the bolt which secures trailing link to
trailing link bracket.
CAUTION:
Always tighten the rubber bushing location
when wheels are in full contact with the ground
and vehicle is at curb weight condition.
NOTE:
S4M0103B
(1) Trailing link
5) Remove the bolt which secures trailing link to

rear housing.
RS-11
REAR TRAILING LINK

REAR SUSPENSION
C: DISASSEMBLY
2. REAR BUSHING
1. FRONT BUSHING
1) Remove the housing. <Ref. to DS-24, REMOVAL, Rear Axle.>

2) Using the ST, press the rear bushing out of
place.
ST 927730000
INSTALLER & REMOVER
SET
Using the ST, press the front bushing out of place.

ST 927720000
INSTALLER & REMOVER
SET
S4M0358A
S4M0359A
(1) Press
(2) Trailing link
(1) Press
(2) Housing
RS-12
REAR TRAILING LINK

REAR SUSPENSION
D: ASSEMBLY
2. REAR BUSHING
1. FRONT BUSHING
1) Using the ST, press the bushing into trailing link.

ST 927730000
INSTALLER & REMOVER
SET
Using the ST, press the bushing into trailing link.

ST 927720000
INSTALLER & REMOVER
SET
CAUTION:
When installing the bushing, turn the ST plunger upside down and press it until the plunger
end surface contacts trailing link end surface.
NOTE:
If it is difficult to press the bushing into trailing link,
apply water-diluted TIRE LUBE to the inner surface
of ST as a lubricant.
SPECIFOED lubricant:
TIRE LUBE: water = 1 : 3
S4M0360A
B4M0224B
(1) Press
(2) Front bushing
(3) Trailing link
(1) Press
CAUTION:
Install the front bushing in the proper direction,
S4M0361A
(1) Front
RS-13
REAR TRAILING LINK

REAR SUSPENSION
2) Press the ST plunger until bushing flange protrudes beyond trailing link.
ST 927730000
INSTALLER & REMOVER
SET
3) Turn the trailing link upside down. Press the ST

plunger in the opposite direction that outlines in the
former procedure until bushing is correctly positioned in trailing link.
ST 927730000
INSTALLER & REMOVER
SET
B4M0195B
(1) Plunger
(2) Flange
B4M0196B
(1) Press
(2) Plunger
4) Install the housing. <Ref. to DS-27, INSTALLATION, Rear Axle.>
E: INSPECTION
Check the trailing links for bends, corrosion or damage.
RS-14
REAR STRUT
REAR SUSPENSION
5. Rear Strut
8) Remove the bolts which secure rear strut to

housing.
A: REMOVAL
1) Depress the brake pedal and secure it in that position using a wooden block, etc. (Drum brake only)
2) Remove the rear seat cushion and backrest.
(Sedan model)
3) Remove the strut cap of quarter trim. (Wagon
model)
4) Loosen the rear wheel nuts.
(rigid racks) and remove rear wheels.
6) Drum brake models:
Remove the brake hose clip.
Disconnect the brake hose from brake pipe from
strut, and then disconnect the brake pipe from
drum brake.
H4M1070
9) Remove the nuts securing strut mount to body.
G4M0399
7) Disc brake models:

Remove the brake hose clip, and then remove the
brake hose from rear strut.
SU0019
(1) Brake hose clip

(2) Brake hose
RS-15
REAR STRUT
REAR SUSPENSION
B: INSTALLATION
E: INSPECTION
1) Tighten the self-locking nut used to secure strut

mount to vehicle body.
Refer to Front Strut as a guide for inspection procedures.

<Ref. to FS-22, INSPECTION, Front Strut.>
CAUTION:
Discard the loosened self-locking nut, and replace with a new one.
F: DISPOSAL
Tightening torque:
20 Nm (2.0 kgf-m, 14.5 ft-lb)
2) Tighten the bolts which secure rear strut to housing.
Refer to Front Strut as a guide for disposal procedures. <Ref. to FS-22, DISPOSAL, Front Strut.>
Tightening torque:
220 Nm (22.4 kgf-m, 162 ft-lb)
CAUTION:
Discard the loosened self-locking nut, and replace with a new one.
3) Disc brake model:
Install the brake hose to lower side of strut, then insert brake hose clip.
Drum brake model:
Connect the brake hose to brake pipe.
Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
Insert the brake hose clip between brake hose and
lower side of strut.
CAUTION:
Check that the hose clip is positioned properly.
Check the brake hose for twisting, or excessive tension.
Do not subject the ABS sensor harness to excessive tension. (Model equipped with ABS)
4) Be sure to bleed air from the brake system.
5) Lower the vehicle and tighten wheel nut.
Tightening torque:
90 Nm (9.2 kgf-m, 66 ft-lb)
6) Sedan model:
Install the rear seat backrest and rear seat cushion.
Wagon model:
Install the strut cap to rear quarter trim.
NOTE:
C: DISASSEMBLY
For disassembly of rear strut, refer to procedures
outlined under front strut as a guide. <Ref. to FS20, DISASSEMBLY, Front Strut.>
D: ASSEMBLY
Refer to Front Strut as a guide for assembly procedures.
<Ref. to FS-21, ASSEMBLY, Front Strut.>
RS-16
LATERAL LINK
REAR SUSPENSION
6. Lateral link
A: REMOVAL
1) Loosen the wheel nuts. Lift-up the vehicle and
remove wheel.
2) Remove the stabilizers. (Turbo model)
3) Remove the ABS sensor harness from trailing
link.
(Models equipped with ABS)
4) Remove the bolt securing trailing link to housing.
7) Remove the DOJ from rear differential using tire

lever.
(Except for 2.0 L MT model)
NOTE:
The side spline shaft circlip comes out together
with the shaft.
S4M0363A
(1) Tire lever
CAUTION:
When removing the DOJ from rear differential,
fit tire lever to the bolt as shown in the figure so
as not to damage axle shaft holder.
B4M0573B
(1) Rear housing

(2) Trailing link
5) Remove the bolts which secure lateral link assembly to rear housing.
6) Remove the DOJ from rear differential using ST.
(2.0 L MT model)
ST 28099PA100 DRIVE SHAFT REMOVER
NOTE:
with the shaft.
S4M0364A
(1) Axle shaft holder
8) Scribe an alignment mark on the rear lateral link

adjusting bolt and crossmember.
9) Remove the bolts securing front and rear lateral
links to crossmember, detach lateral links.
CAUTION:
To loosen the adjusting bolt, always loosen the
nut while holding head of adjusting bolt.
S4M0362A
(1) Bolt
(2) DOJ
CAUTION:
Be careful not to damage the side bearing retainer. Always use bolt shown in the figure, as
supporting point for ST during removal.
RS-17
LATERAL LINK
REAR SUSPENSION
B: INSTALLATION
Install in the reverse order of removal. Observe the
following instructions.
Installation of DOJ to differential: <Ref. to DS-39,
INSTALLATION, Rear Drive Shaft.>
CAUTION:
Do not allow the DOJ splines to damage side
oil seal.
Always tighten the rubber bushing location
when wheels are in full contact with the ground
and vehicle is curb weight.
Tighten the nut when installing adjusting
bolt.
Replace the self-locking nut and DOJ circlip
with new ones.
NOTE:
C: DISASSEMBLY
Using the ST, press the bushing out of place.
NOTE:
Using the following table as a guide, verify the
type of bushings.
Select the ST according to type of bushings
used.
Bushing
Bushing A
Bushing B
Bushing C
ST: INSTALLER & REMOVER SET

927700000
927690000
927700000
S4M0100B
(1)
(2)
(3)
(4)
(5)
Bushing A
Bushing B
Bushing C
Front
Outside of body
S4M0365A
(1) Press
(2) Lateral link
RS-18
LATERAL LINK
REAR SUSPENSION
D: ASSEMBLY
1) Using the ST, press the bushing into place.
2) Press the ST plunger until bushing flange protrudes beyond lateral link.
CAUTION:
Select the ST according to type of bushings
used.
NOTE:
Using the same ST as that used during disassembly.
NOTE:
Using the same ST as that used during disassembly.
If it is difficult to press the bushing into trailing
link, apply water-diluted TIRE LUBE to the inner
surface of ST as a lubricant.
Specified lubricant:
TIRE LUBE: water = 1 : 3
B4M0197B
(1)
(2)
(3)
(4)
S4M0366A
(1) Press
(2) Bushing
(3) Lateral link
RS-19
Press
Plunger
Lateral link
Flange
LATERAL LINK
REAR SUSPENSION
3) Turn the lateral link upside down. Press the ST

plunger in opposite direction that outlined in the
former procedure until bushing is correctly positioned in trailing link.
NOTE:
Using the same ST as that used during dissassembly.
B4M0198B
(1) Press
(2) Plunger
(3) Lateral link
E: INSPECTION
Visually check the lateral links for damage or
bends.
RS-20
REAR CROSSMEMBER
REAR SUSPENSION
7. Rear Crossmember
B: INSTALLATION
A: REMOVAL
CAUTION:
Discard the loosened self-locking nut and replace it with a new one.
Always tighten the nut (not adjusting bolt),
when tightening adjusting bolt.
2) For installation and tightening torque of rear differential;
T-type
<Ref. to DI-26, INSTALLATION, Rear Differential
for T-type.>
VA-type
for VA-type.>
3) Always tighten the rubber bushing when wheels
are in full contact with the ground and vehicle is
curb weight.
CAUTION:
Do not subject the ABS sensor harness to excessive tension. (Models equipped with ABS)
1) Separate the front exhaust pipe and rear exhaust pipe.
3) Remove the rear differential.
T-type
<Ref. to DI-25, REMOVAL, Rear Differential for Ttype.>
VA-type
<Ref. to DI-41, REMOVAL, Rear Differential for
VA-type.>
4) Place the transmission jack under rear
crossmember.
NOTE:
C: INSPECTION
Check the removed parts for wear, damage and
G4M0544
5) Remove the bolts securing crossmember to vehicle body, and then remove the crossmember.
G4M0545
6) Scribe an alignment mark on the rear lateral link

cam bolt and crossmember.
7) Remove the front and rear lateral links by loosening nuts.
RS-21

REAR SUSPENSION

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
Possible causes
(1) Permanent distortion or breakage of coil spring
(2) Unsmooth operation of damper strut and/or shock absorber
(3) Installation of wrong strut and/or shock absorber
(4) Installation of wrong coil spring
Countermeasures
Replace.
Replace.
2. POOR RIDE COMFORT

1) Large rebound shock
2) Rocking of the vehicle continues too long after running over bump and/or hump.
3) Large shock in bumping
Possible causes
(2) Overinflation pressure of tire
(3) Improper wheel arch height
(4) Fault in operation of damper strut and/or shock absorber
(5) Damage or deformation of strut mount and/or shock absorber mount
shock absorber
(8) Deformation or damage of helper in strut assembly and/or shock
absorber
(9) Oil leakage of damper strut and/or shock absorber
Countermeasures
Replace.
Adjust.
Adjust or replace the coil springs with new ones.
Replace.
Replace.
Replace.
Replace.
Replace.
3. NOISE
Possible causes
(1) Wear or damage of damper strut and/or shock absorber component parts
(2) Loosening of suspension link installing bolt
shock absorber
(6) Wear or damage of ball joint
(7) Deformation of stabilizer clamp
RS-22
Countermeasures
Replace.
Retighten to the specified torque.
Replace.
Replace.
Replace.
Replace.
WT
1.
2.
3.
4.
5.
6.
7.
8.
Page
Tire ..............................................................................................................4
Steel Wheel.................................................................................................5
Aluminum Wheel .........................................................................................6
Wheel Balancing .........................................................................................7
T-type Tire ................................................................................................8
Full Wheel Cap............................................................................................9
General Diagnostics Table........................................................................10
GENERAL DESCRIPTION
A: SPECIFICATIONS
S4M0367A
(1) Offset
(2) P.C.D.
Front and rear
Except
OUTBACK
OUTBACK
T-Type tire
Tire size
185/70R14 88H
195/60R15 88H
205/50 R16 87V
215/45 R17 87W
P205/55 R16 89V
T125/70 D15 95M
T135/70 D16 100M
Rim size
14 5 1/2JJ
15 6JJ
16 6 1/2JJ
17 7JJ
16 6 1/2JJ
15 4T
16 4T
Front and rear
OUTBACK
T-Type tire
P.C.D. mm (in)
55 (2.17)
100 (3.94) dia.
53 (2.09)
50 (1.97)
Tire inflation pressure kPa (kg/cm2, psi)

Light load
Full load
Tire size
Except
OUTBACK
Rim offset mm (in)
185/70 R14 88H

195/60 R15 88H
205/50 R16 87V
215/45 R17 87W
P205/55 R16 89V
T125/70 D15 95M
T135/70 D16 100M
Fr: 220 (2.2, 32)

Rr: 200 (2.0, 29)
Fr: 220 (2.2, 32)

Rr: 220 (2.2, 32)
Fr: 220 (2.2, 32) Rr: 200 (2.0, 29)

Fr: 230 (2.3, 33) Rr: 220 (2.2, 32)
Fr: 220 (2.2, 32) Rr: 200 (2.0, 29)
420 (4.2, 60)
NOTE:
T-type tire for temporary use is supplied as a spare tire.
At trailer towing, rear inflation pressure is 250 kPa (2.5 kg/cm2, 36 psi).
WT-2
GENERAL DESCRIPTION
B: PREPARATION TOOL
1. SERVICE DATA
Item
Steel wheel
Aluminum wheel
Axial runout
Radial runout
1.5 mm (0.059 in)
1.0 mm (0.039 in)

TOOL NAME
Air pressure gauge
Dial gauge
2. ADJUSTING PARTS
Wheel balancing
Dynamic unbalance
Balance weight part number
(For steel wheel)
723141290
723141300
723141310
723141320
723141330
723141340
723141350
723141360
723141370
723241380
723241580
723241590
(For aluminum wheel)
23141GA462
23141GA472
23141GA482
23141GA492
23141GA502
23141GA512
23141GA522
23141GA532
23141GA542
23141GA552
23141GA572
Standard
Service limit
Less than 5 g (0.18 oz)
Weight
5 g (0.18 oz)
10 g (0.35 oz)
15 g (0.53 oz)
20 g (0.71 oz)
25 g (0.88 oz)
30 g (1.06 oz)
35 g (1.23 oz)
40 g (1.41 oz)
45 g (1.59 oz)
50 g (1.76 oz)
55 g (1.94 oz)
60 g (2.12 oz)
Weight
5 g (0.18 oz)
10 g (0.35 oz)
15 g (0.53 oz)
20 g (0.71 oz)
25 g (0.88 oz)
30 g (1.06 oz)
35 g (1.23 oz)
40 g (1.41 oz)
45 g (1.59 oz)
50 g (1.76 oz)
55 g (1.94 oz)
60 g (2.12 oz)
WT-3
REMARKS
Used for measuring tire air pressure.
Used for measuring wheel runout.
TIRE
2. Tire
A: INSPECTION
1) Take stone, glass, nail etc. off the tread groove.
2) Replace the tire:
CAUTION:
When replacing a tire, make sure to use only
the same size, construction and load range as
originally installed.
Avoid mixing radial, belted bias or bias tires
on the vehicle.
(1) When large crack on the side wall, damage
or crack on tread is found.
(2) When the tread wear indicator appears as
a solid band across the tread.
S4M0377A
(1) Tread wear indicator

(2) Tire tread
1. TIRE ROTATION
If tires are maintained at the same positions for a
long period of time, uneven wear results. Therefore, they should be periodically rotated.
This lengthens service life of tires.
CAUTION:
When rotating the tires, replace unevenly worn
or damaged tires with new ones.
B4M1765
WT-4
STEEL WHEEL
3. Steel Wheel
C: INSPECTION
A: REMOVAL
1) Deformation or damage on the rim can cause air

leakage. Check the rim flange for deformation,
crack, or damage, and repair or replace as necessary.
2) Jack-up the vehicle until wheels clear the floor.
3) Slowly rotate the wheel to check rim runout using a dial gauge.
1) Apply parking brake, and position the select lever to P or LOW.

2) Set shop jacks or a lift to the specified point, and
support the vehicle with its wheels slightly contacting the floor.
3) Loosen 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:
While removing the wheels, prevent hub bolts
from damage.
NOTE:
Place the wheels with their outer sides facing upward to prevent wheels from damage.
G4M0298
B: INSTALLATION
1) Attach the wheel to hub by aligning the wheel
bolt hole with hub bolt.
2) Temporarily attach the wheel nuts to hub bolts.
(In the case of aluminum wheel, use SUBARU genuine wheel nut for aluminum wheel.)
3) Manually tighten the nuts making sure the wheel
hub hole is aligned correctly to guide portion of hub.
4) Tighten the wheel nuts in a diagonal selection to
specified torque. Use a wheel nut wrench.
Axial runout limit

Radial runout limit
1.5 mm (0.059 in)
Wheel nut tightening torque:

90 Nm (9.1 kgf-m, 65.7 ft-lb)
CAUTION:
Tighten the wheel nuts in two or three steps
by gradually increasing the torque and working
diagonally, until the specified torque is
reached. For drum brake models, excess tightening of wheel nuts may cause wheels to judder.
Do not depress the wrench with foot; Always
use both hands when tightening.
Make sure the bolt, nut and nut seating surface of the wheel are free from oils.
5) If a wheel is removed for replacement or for repair of a puncture, retighten the wheel nuts to the
specified torque after running 1,000 km (600
miles).
G4M0299
4) If the rim runout exceeds specifications, remove

the tire from rim and check runout while attaching
dial gauge to positions shown in the figure.
5) If 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 limit
Radial runout limit
1.0 mm (0.039 in)
D: CAUTION
Aluminum wheels are easily scratched. To maintain their appearance and safety, do the following:
1) Do not damage the aluminum wheels during removal, disassembly, installation, wheel balancing,
etc. After removing the aluminum wheels, place
them on a rubber mat, etc.
2) While the vehicle is being driven, be careful not
to ride over sharp obstacles or allow the aluminum
wheels to contact the shoulder of the road.
3) When installing a tire chain, be sure to install it
properly not to have slack; otherwise it may hit the
wheel while driving.
4) 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
B: INSPECTION
A: REPLACEMENT
1) Proper wheel balance may be lost if the tire is repaired or if it wears. Check the tire for dynamic balance, and repair as necessary.
2) To check for dynamic balance, use a dynamic
balancer. Drive in the balance weight on both the
top and rear sides of the rim.
3) Some types of balancer can cause damage to
the wheel. Use an appropriate balancer when adjusting the wheel balance.
4) Use genuine balance weights.
1) Remove the balance weights.

2) Using dynamic balancing, measure the wheel
balance.
3) Select a weight close to the value measured by
dynamic balancing.
(For steel wheel)
723141290
723141300
723141310
723141320
723141330
723141340
723141350
723141360
723141370
723241380
723241580
723241590
(For aluminum wheel)
23141GA462
23141GA472
23141GA482
23141GA492
23141GA502
23141GA512
23141GA522
23141GA532
23141GA542
23141GA552
23141GA572
Weight
5 g (0.18 oz)
10 g (0.35 oz)
15 g (0.53 oz)
20 g (0.71 oz)
25 g (0.88 oz)
30 g (1.06 oz)
35 g (1.23 oz)
40 g (1.41 oz)
45 g (1.59 oz)
50 g (1.76 oz)
55 g (1.94 oz)
60 g (2.12 oz)
CAUTION:
55 g (1.94 oz) weight used with the aluminum
wheel is not available.
Balance weights are available for use with
any of 14- to 16-inch wheels.
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)
B4M0053B
4) Install the selected weight to the point designated by dynamic balancing.

5) Using dynamic balancing, measure the wheel
balance again. Check that the wheel balance is
correctly adjusted.
(1) Weight for aluminum wheel

(2) Weight for steel wheel
Service limit: A
Weight for steel wheel;
2.16 mm (0.085 in)
Weight for aluminum wheel;
4.5 mm (0.177 in)
WT-7
T-TYPE TIRE
6. T-type Tire
A: NOTE
T-type tire for temporary use is prepared as a
spare tire.
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 80 km/h
(50 MPH).
Drive as slowly as possible and avoid passing over bumps.
B: REPLACEMENT
Refer to Removal and Installation of Steel Wheel
for removal/installation of T-type tires. <Ref. to
WT-5, Steel Wheel.>
CAUTION:
Replace with a conventional tire as soon as
possible since the T-type tire is only for temporary use.
C: INSPECTION
1) Check the tire inflation pressure.
Specification:
420 kPa (4.2 kg/cm2, 60 psi)
2) Take 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.
WT-8
FULL WHEEL CAP

7. Full Wheel Cap

A: REMOVAL
Pry off the full wheel cap with a wheel cap remover
inserted between openings on the cap.
SU0007
B: INSTALLATION
Align the valve hole in wheel cap with the valve on
wheel and secure the wheel cap by tapping four
points by hand.
C: INSPECTION
1) Check the wheels for missing wheel caps.
2) Check the pawls of wheel caps for damage or
bend.
3) Check the wheel caps for cracks.
WT-9
GENERAL DIAGNOSTICS TABLE

8. General Diagnostics Table

A: INSPECTION
Symptom
Front wheel shimmy
Abnormal tire wear
Sways/pitches
Wander/pulls
Possible cause
Worn or improperly inflated of tire.
Wheel is out of balance.
Improperly inflated of tire.
WT-10
Remedy
Replace
Adjustment
Replace
Replace
Replace
DIFFERENTIALS
DI
1.
2.
3.
4.
5.
6.
7.
8.
9.
Page
Differential Gear Oil...................................................................................23
Front Differential........................................................................................24
Rear Differential for T-type........................................................................25
Rear Differential for VA-type .....................................................................41
Rear Differential Front Oil Seal .................................................................56
Rear Differential Side Oil Seal ..................................................................58
Rear Differential Member ..........................................................................63
GENERAL DESCRIPTION
DIFFERENTIALS
A: SPECIFICATIONS
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 abnormal noise
when AWD is selected.
1.6 L
MODEL
Rear differential type
Identification
Type of gear
Gear ratio (Number of gear
teeth)
AT
2.0 L
MT
VA type without LSD
XP
XN
Hypoid gear
4.444 (40/9)
4.111 (37/9)
AT
3.900 (39/10)
0.82 (0.8 US qt, 0.7 Imp qt)
Oil capacity
Rear differential gear oil
GL-5
2.5 L
MODEL
2.0 L Turbo
MT
AT
MT
Except
Australia
AT
Australia
Rear differential type
Except
Australia
Australia
T type with LSD

EJ
ER
EJ
Hypoid gear
EF
SURETRAC
EM
4.111 (37/9)
3.700 (37/10)
4.111 (37/9)
3.545 (39/11)
4.444 (40/9)
LSD type
Identification
Type of gear
Gear ratio (Number of gear
teeth)
MT
T type without LSD
EG
Viscous coupling
0.82 (0.8 US qt, 0.7 Imp qt)
Oil capacity
GL-5
Identification

Recommended oil
CAUTION:
DR0001
H3M1272A
DI-2
GENERAL DESCRIPTION
DIFFERENTIALS
1. SERVICE DATA
Front and rear bearing preload at companion
flange bolt hole N (kgf, lb)
Side gear backlash
mm (in)
Side bearing standard width
New bearing
Used bearing
T-type
VA-type
T-type
T-type
VA-type
mm (in)
Crown gear to drive pinion backlash mm (in)
T-type
VA-type
Crown gear runout on its back surface mm (in)
19 26 (1.9 2.6, 4.3 5.8)

12.7 32.4 (1.3 3.3, 2.9 7.3)
8 16 (0.8 1.6, 1.8 3.6)
0.10 0.20 (0.0039 0.0079)
0.05 0.15 (0.0020 0.0059)
20.00 (0.7874)
0.10 0.20 (0.0039 0.0079)
0.10 0.15 (0.0039 0.0059)
Less than 0.05 (0.0020)
2. ADJUSTING PARTS
VA-type
Front and rear bearing preload at companion flange bolt hole
Preload adjusting spacer
Preload adjusting washer
New bearing
Part No.
32288AA040
32288AA050
31454AA100
32288AA060
31454AA110
32288AA070
31454AA120
32288AA080
32288AA090
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
DI-3
12.7 32.4 N
(1.3 3.3 kgf, 2.9 7.3 lb)
Length
52.3 mm (2.059 in)
52.5 mm (2.067 in)
52.6 mm (2.071 in)
52.7 mm (2.075 in)
52.8 mm (2.079 in)
52.9 mm (2.083 in)
53.0 mm (2.087 in)
53.1 mm (2.091 in)
53.3 mm (2.098 in)
Thickness
1.500 mm (0.0591 in)
1.513 mm (0.0596 in)
1.525 mm (0.0600 in)
1.538 mm (0.0606 in)
1.550 mm (0.0610 in)
1.563 mm (0.0615 in)
1.575 mm (0.0620 in)
1.588 mm (0.0625 in)
1.600 mm (0.0630 in)
1.613 mm (0.0635 in)
1.625 mm (0.0640 in)
1.638 mm (0.0645 in)
1.650 mm (0.0650 in)
1.663 mm (0.0655 in)
1.675 mm (0.0659 in)
1.688 mm (0.0665 in)
1.700 mm (0.0669 in)
1.713 mm (0.0674 in)
1.725 mm (0.0679 in)
1.738 mm (0.0684 in)
1.750 mm (0.0689 in)
1.763 mm (0.0694 in)
1.775 mm (0.0699 in)
GENERAL DESCRIPTION
DIFFERENTIALS
Pinion height adjusting shim
Side gear backlash
Side gear thrust washer
Crown gear to drive pinion backlash

Crown gear runout on its back surface
Part No.
Thickness
32295AA200
0.150 mm (0.0059 in)
32295AA210
0.175 mm (0.0069 in)
32295AA220
0.200 mm (0.0079 in)
32295AA230
0.225 mm (0.0089 in)
32295AA240
0.250 mm (0.0098 in)
32295AA250
0.275 mm (0.0108 in)
0.05 0.15 mm (0.0020 0.0059 in)
0.925 0.950 mm
803135011
(0.0364 0.0374 in)
0.950 0.975 mm
803135012
(0.0374 0.0384 in)
0.975 1.000 mm
803135013
(0.0384 0.0394 in)
1.000 1.025 mm
803135014
(0.0394 0.0404 in)
1.025 1.050 mm
803135015
(0.0404 0.0413 in)
0.10 0.15 mm (0.0039 0.0059 in)
Limit
0.05 mm (0.0020 in)
T-type
Front and rear bearing preload at companion flange bolt hole
Preload adjusting spacer
Preload adjusting washer
New bearing
Used bearing
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
DI-4
19 26 N
(1.9 2.6 kgf, 4.3 5.8 lb)
8 16 N
(0.8 1.6 kgf, 1.8 3.6 lb)
Length
56.2 mm (2.213 in)
56.4 mm (2.220 in)
56.6 mm (2.228 in)
56.8 mm (2.236 in)
57.0 mm (2.244 in)
57.2 mm (2.252 in)
Length
2.59 mm (0.1020 in)
2.57 mm (0.1012 in)
2.55 mm (0.1004 in)
2.53 mm (0.0996 in)
2.51 mm (0.0988 in)
2.49 mm (0.0980 in)
2.47 mm (0.0972 in)
2.45 mm (0.0965 in)
2.43 mm (0.0957 in)
2.41 mm (0.0949 in)
2.39 mm (0.0941 in)
2.37 mm (0.0933 in)
2.35 mm (0.0925 in)
2.33 mm (0.0917 in)
2.31 mm (0.0909 in)
GENERAL DESCRIPTION
DIFFERENTIALS
Side gear backlash

(Model without LSD)
Side bearing standard width
Side bearing retainer shim
Crown gear to drive pinion backlash

Crown gear runout on its back surface
Part No.
Thickness
383495200
3.09 mm (0.1217 in)
383505200
3.12 mm (0.1228 in)
383515200
3.15 mm (0.1240 in)
383525200
3.18 mm (0.1252 in)
383535200
3.21 mm (0.1264 in)
383545200
3.24 mm (0.1276 in)
383555200
3.27 mm (0.1287 in)
383565200
3.30 mm (0.1299 in)
383575200
3.33 mm (0.1311 in)
383585200
3.36 mm (0.1323 in)
383595200
3.39 mm (0.1335 in)
383605200
3.42 mm (0.1346 in)
383615200
3.45 mm (0.1358 in)
383625200
3.48 mm (0.1370 in)
383635200
3.51 mm (0.1382 in)
383645200
3.54 mm (0.1394 in)
383655200
3.57 mm (0.1406 in)
383665200
3.60 mm (0.1417 in)
383675200
3.63 mm (0.1429 in)
383685200
3.66 mm (0.1441 in)
0.1 0.2 mm (0.0039 0.0079 in)
Part No.
Thickness
383445201
0.75 0.80 mm (0.0295 0.0315 in)
383445202
0.80 0.85 mm (0.0315 0.0335 in)
383445203
0.85 0.90 mm (0.0335 0.0354 in)
20.00 mm (0.7874 in)

Part No.
Thickness
383475201
0.20 mm (0.0079 in)
383475202
0.25 mm (0.0098 in)
383475203
0.30 mm (0.0118 in)
383475204
0.40 mm (0.0157 in)
383475205
0.50 mm (0.0197 in)
0.10 0.20 mm (0.0039 0.0079 in)
Limit
0.05 mm (0.0020 in)
DI-5
GENERAL DESCRIPTION
DIFFERENTIALS
B: COMPONENT
1. REAR DIFFERENTIAL FOR T-TYPE WITHOUT LSD
B3M0130D
(1)
Pinion crown gear and drive pinion set
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Pinion height adjusting washer

Rear bearing
Bearing preload adjusting spacer
Bearing preload adjusting washer
Differential carrier
Front bearing
Spacer
Pilot bearing
Front oil seal
Companion flange
Self-locking nut
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
Side bearing
O-ring
Side bearing retainer
Side oil seal
Side gear
Pinion mate gear
Pinion mate gear washer
Pinion shaft lock pin
Circlip
Pinion mate shaft
Air breather cap
DI-6
(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 FOR T-TYPE WITH LSD
(1)
(2)
(3)
(4)
(5)
(25)
(1)
(21)
(22)
(23)
T3
(20)
T1
(15)
T4
(19)
(24)
(13)
T3
(17)
(18)
T2
(6)
(16)
(14)
(14)
(15)
(7)
(13)
T1
(16)
(17)
(8)
(10)
T5
(12)
(9)
(11)
TR0913
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)

Rear bearing
Front bearing
Collar
Pilot bearing
Front oil seal
Companion flange
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
Self-locking nut
Side bearing
O-ring
Side bearing retainer
Side oil seal
Gasket
Differential case (Viscous coupling type)
(20)
(21)
(22)
Rear cover
Air breather cap
Stud bolt
DI-7
(23)
(24)
(25)
Oil filler plug

Oil drain plug
Differential case (SURETRAC
type)

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 FOR VA-TYPE
H3M1663D
(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-8
(26)
(27)
(28)
(29)
(30)
Gasket
Oil filler plug
Oil drain plug
Rear cover
Gasket

T1: 25 (2.5, 18.1)
T2: 25 (2.5, 18.1)
T3: 34 (3.5, 25.3)
T4: 62 (6.3, 45.6)
T5: 188 (19.2, 139)
GENERAL DESCRIPTION
DIFFERENTIALS
4. REAR DIFFERENTIAL MOUNTING SYSTEM
DR0002
(1)
(2)
(3)
(4)
(5)
Differential front member

Plate
Crossmember
Differential rear member
Differential mount lower bracket
(2.5 L and Turbo model)
(6)
Differential mount lower bracket

(1.6 L and 2.0 L Non-turbo model)
(7)
(8)
(9)
(10)
Stopper
Dynamic damper
Differential mount bracket
Differential mount front cover
DI-9

T1: 20 (2.0, 14.5)
T2: 33 (3.4, 24.3)
T3: 65 (6.6, 47.9)
T4: 70 (7.1, 51.6)
T5: 90 (9.2, 66.4)
T6: 100 (10.2, 73.8)
GENERAL DESCRIPTION
DIFFERENTIALS
C: CAUTION
points.
Before installing O-rings or snap rings, apply sufficient amount of gear oil to avoid damage and deformation.
Avoid damaging the mating face of the case.
DI-10
GENERAL DESCRIPTION
DIFFERENTIALS
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
398477701
DESCRIPTION
HANDLE
REMARKS
Used for installing front and rear bearing cone.
398477702
DRIFT
Used press-fitting the bearing cone of differential

carrier (rear).
398217700
ATTACHMENT SET
Stand for rear differential carrier disassembly

and assembly.
498447120
DRIFT
Used for installing front oil seal.
B3M1893
B3M1894
B3M1895
B3M1896
DI-11
GENERAL DESCRIPTION
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
498427200
DESCRIPTION
FLANGE WRENCH
REMARKS
Used for stopping rotation of companion flange
when loosening and tightening self-lock nut.
398467700
DRIFT
Used for removing pinion, pilot bearing and front

bearing cone.
399780104
WEIGHT
Used for installing front bearing cone, pilot bearing companion flange.
899580100
INSTALLER
Used for press-fitting the front bearing cone, pilot

bearing.
B3M1897
B3M1898
B3M1899
B3M1900
DI-12
GENERAL DESCRIPTION
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
899904100
DESCRIPTION
STRAIGHT PIN
REMOVER
REMARKS
Used for driving out differential pinion shaft lock
pin.
498247001
MAGNET BASE

Used with DIAL GAUGE (498247100).
498247100
DIAL GAUGE
Used measuring backlash between side gear

and pinion, hypoid gear.
Used with MAGNET BASE (498247001).
398507704
BLOCK
Used for adjusting pinion height and preload.
B3M1901
B3M1902
B3M1903
B3M1904
DI-13
GENERAL DESCRIPTION
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
398177700
DESCRIPTION
INSTALLER
REMARKS
Used for installing rear bearing cone.
For T-type.
398457700
ATTACHMENT
Used for removing side bearing retainer.

For T-type.
398477703
DRIFT2
Used for press-fitting the bearing race (rear) of

differential carrier.
For T-type.
398437700
DRIFT
Used for installing side oil seal.

For T-type.
B3M1905
B3M1906
B3M1907
B3M1908
DI-14
GENERAL DESCRIPTION
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
398507702
DESCRIPTION
DUMMY SHAFT
REMARKS
For T-type.
398507703
DUMMY COLLAR

For T-type.
398517700
REPLACER
Used for removing rear bearing cone.

For T-type.
398487700
DRIFT
Used for press-fitting the side bearing cone.

For T-type.
B3M1909
B3M1910
B3M1911
B3M1912
DI-15
GENERAL DESCRIPTION
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
398507701
DESCRIPTION
DIFFERENTIAL
CARRIER GAUGE
REMARKS
Used for adjusting pinion height.
For T-type.
398527700
PULLEY ASSY
Used for removing front oil seal.

Used for removing side bearing cup. (T-type)
398527700
PULLER SET
Used for extracting side bearing cone.

(1) BOLT (899521412)
(2) PULLER (399527702)
(3) HOLDER (399527703)
(4) ADAPTER (398497701)
(5) BOLT (899520107)
(6) NUT (021008000)
For T-type.
398227700
WEIGHT
Used for installing side bearing.

For T-type.
B3M1913
B3M1914
B3M1915A
B3M1916
DI-16
GENERAL DESCRIPTION
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
28099PA090
DESCRIPTION
REMARKS
OIL SEAL PROTEC- Used for installing rear drive shaft into rear difTOR
ferential.
For protecting oil seal.
B3M1917
398237700
GAUGE
Used for installing side bearing.

For T-type.
DRIVE SHAFT
REMOVER
Used for removing rear drive shaft from rear

differential.
For T-type.
INSTALLER
Used for installing rear bearing cone.

For VA-type.
B3M1918
28099PA100
B3M1919
498175500
B3M1920
DI-17
GENERAL DESCRIPTION
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
499785500
DESCRIPTION
WRENCH ASSY
REMARKS
Used for removing and installing side oil seal
holder.
For VA-type.
498447100
DRIFT
Used for installing oil seal.

For VA-type.
399520105
SEAT
Used for removing side bearing cone.

Used with PULLER SET (899524100).
For VA-type.
399703602
PULLEY ASSY
Used for removing companion flange
B3M1921
B3M1922
B3M1923
B3M1930
DI-18
GENERAL DESCRIPTION
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
498485400
DESCRIPTION
DRIFT
REMARKS
Used for installing side bearing cone.
For VA-type.
498505501
DIFFERENTIAL
CARRIER GAUGE
Used for adjusting pinion height.

For VA-type.
498447110
DRIFT
Used for press-fitting the bearing race (front)

of differential carrier.
For VA-type.
498447150
DUMMY SHAFT
Used for adjusting pinion height and Pre-load.

For VA-type.
B3M1924
B3M1925
B3M1926
B3M1927
DI-19
GENERAL DESCRIPTION
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
498515500
DESCRIPTION
REPLACER
REMARKS
Used for removing rear bearing cone.
For VA-type.
32285AA000
DUMMY COLLAR
Used for adjusting pinion height and Pre-load.

For VA-type.
499705404
SEAT
Used for removing side bearing race.

Used with PULLEY ASSY (499705401).
For VA-type.
499705401
PULLEY ASSY
Used for removing side bearing race.

Used with SEAT (499705404).
For VA-type.
B3M1911
B3M1977
B3M1928
B3M1930
DI-20
GENERAL DESCRIPTION
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
899874100
DESCRIPTION
INSTALLER
REMARKS
Used for installing companion flange.
PULLER SET
Used for removing side bearing cone of differential.

For VA-type.
(1) Puller
(2) Cap
B3M1931
899524100
B3M1932A
DI-21
GENERAL DESCRIPTION
DIFFERENTIALS

TOOL NAME
Transmission jack
Puller
Thickness gauge
Tire lever
REMARKS
Used for assembly/disassembly of rear differential.
Used for removal of side bearing retainer. (T-type)
Used for measuring clearance.
Used for removal of rear drive shaft. (VA-type)
DI-22
DIFFERENTIAL GEAR OIL

DIFFERENTIALS
2. Differential Gear Oil

A: INSPECTION
1) Take out the filler plug, and replace the gear oil if
it is contaminated or deteriorated. <Ref. to DI-23,
REPLACEMENT, Differential Gear Oil.>
2) Check the gear oil level is up to the bottom part
of filler bolt. If the level is low, refill up to the bottom
of filler bolt.
3) Tighten the oil drain plug.

NOTE:
Apply fluid packing to the drain plug for T-type.
Use a new aluminum gasket for VA-type.
Fluid packing:
Tightening torque:
T-type;
49 Nm (5.0 kgf-m, 36.2 ft-lb)
VA-type;
34 Nm (3.5 kgf-m, 25.3 ft-lb)
4) Fill the differential carrier with gear oil to the upper plug level.
NOTE:
Carefully refill oil while watching the level. Excess
or insufficient oil must be avoided.
Oil capacity:
0.8 2 (0.8 US qt, 0.7 Imp qt)
S3M0527A
(A) Filler plug

(B) Drain plug
B: REPLACEMENT
racks.
2) Remove the oil drain plug and filler plug, and
drain the gear oil.
(A)
CAUTION:
Be careful not to burn your hands, because
gear oil becomes extremely hot after running.
(B)
DR0017
(A) Filler plug

(B) Drain plug
5) Install the filler plug.

NOTE:
Apply fluid packing to the filler plug for T-type.
Fluid packing:
DR0003
(A) Filler plug

(B) Drain plug
Tightening torque:
T-type;
49 Nm (5.0 kgf-m, 36.2 ft-lb)
VA-type;
34 Nm (3.5 kgf-m, 25.3 ft-lb)
DI-23
FRONT DIFFERENTIAL
DIFFERENTIALS
3. Front Differential
A: NOTE
1. AT MODEL
Refer to AUTOMATIC TRANSMISSION in separate publication AUTOMATIC TRANSMISSION
for Front Differential. (Pub No. G0864ZE)
2. MT MODEL
For front differential of manual transmission, refer
to MT section. <Ref. to MT-95, Front Differential
Assembly.>
DI-24
REAR DIFFERENTIAL FOR T-TYPE

DIFFERENTIALS
4. Rear Differential for T-type

A: REMOVAL
3) Move the select lever or gear shift lever to N.
4) Release the parking brake.
racks.
7) Remove the wheels.
<Ref. to EX(w/oOBD)-13, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(w/oOBD)-14, REMOVAL, Muffler.>
<Ref. to EX-11, REMOVAL, Rear Exhaust Pipe.>
and <Ref. to EX-12, REMOVAL, Muffler.>
Turbo model
10) Remove the front cover of rear differential
mount.
13) Remove the DOJ of rear drive shaft from rear

differential using ST. <Ref. to DI-58, REPLACEMENT, Rear Differential Side Oil Seal.>
B3M1628B
(A) Bolt
14) Secure the rear drive shaft to rear crossmember using wire.
S3M0500
15) Remove the lower differential bracket.
S3M0503

12) Remove the clamps and bracket of parking
brake cable.
S3M0529
16) Support the rear differential with transmission

jack.
DR0018
S3M0505
DI-25

DIFFERENTIALS
17) Remove the self-locking nuts and bolts.
21) Remove the rear differential from front member.
DR0019
18) Remove the bolts which secure rear differential

front member to body.
Loosen the bolt A first, then remove the bolts B.
NOTE:
Support the front member with use of a helper to
prevent it from dropping.
G3M1030
B: INSTALLATION
1) Install the air breather cap tapping with a plastic
hammer.
NOTE:
Be sure to install a new air breather cap.
2) Position the front member on body by passing it
under the parking brake cable and securing to rear
differential.
NOTE:
When installing the rear differential front member,
do not confuse the installation sequence of the upper and lower stoppers.
3) Install the DOJ of drive shaft into rear differential.<Ref. to DI-58, REPLACEMENT, Rear Differential Side Oil Seal.>
ST 28099PA090 SIDE OIL SEAL PROTECTOR
B3M0657C
(A) Bolt A
(B) Bolt B
19) Remove the bolt A.

20) While slowly lowering the transmission jack,
move the rear differential forward and remove front
member and rear differential from body.
G3M1026
G3M1029
4) Installing procedure hereafter is in the reverse

order of removal.
5) After installation, fill the differential carrier with
gear oil to the filler plug level. <Ref. to DI-23, Differential Gear Oil.>
DI-26

DIFFERENTIALS
C: DISASSEMBLY
To detect the real cause of trouble, inspect the following items before disassembling.
Tooth contact of crown gear and pinion, and
backlash
Runout of crown gear at its back surface
Turning resistance of drive pinion
1) Set the ST on vise and install the differential assembly to ST.
ST 398217700
ATTACHMENT
4) Remove the rear cover by loosening the retaining bolts.
S3M0531A
(A) Rear cover

(B) Differential carrier
5) Make right and left side bearing retainers in order to identify them at reassembly. Remove the
side bearing retainer attaching bolts, set the ST to
differential case, and extract right and left side
bearing retainers with a puller.
G3M1031
2) Drain the gear oil by removing the plug.

3) Remove the air breather cap.
NOTE:
Do not attempt to replace the air breather cap unless necessary.
NOTE:
Each shim, which is installed to adjust the side
bearing preload, should be kept together with its
mating retainer.
ST 398457700
ATTACHMENT
S3M0532A
S3M0530A
(A) Air breather cap

(B) Rear cover
6) Pull out the differential case assembly from differential carrier.

NOTE:
Be careful not to hit the teeth against the case.
S3M0533
DI-27

DIFFERENTIALS
7) When replacing the side bearing, pull the bearing cup from side bearing retainer using ST.
ST 398527700
PULLER ASSY
10) Drive out the pinion shaft lock pin from crown
gear side. (Without LSD)
NOTE:
The lock pin is staked at the pin hole end on the differential carrier; do not drive it out forcibly before
unstaking it.
ST 899904100
S3M0534A
8) Extract the bearing cone with ST.

NOTE:
Do not attempt to disassemble the parts unless
necessary.
Set the puller so that its claws catch the edge of
bearing cone.
Never mix up the right and left hand bearing races and cones.
ST 398527700
PULLER SET
B3M0133
11) Draw out the pinion mate shaft and remove the
pinion mate gears, side gears and thrust washers.
(Without LSD)
NOTE:
The gears as well as thrust washers should be
marked or kept separated right and left, front and
rear.
G3M0068
9) Remove the crown gear by loosening the crown

gear bolts.
NOTE:
Further disassembling is not allowed.
S3M0510A
(A)
(B)
(C)
(D)
(E)
S3M0509
DI-28
Side gear
Pinion mate gear
Thrust washer
Differential case
Pinion mate shaft

DIFFERENTIALS
12) Hold the companion flange with ST and remove

the drive pinion nut.
ST 498427200
FLANGE WRENCH
15) Remove the rear bearing cone from drive pinion by supporting the cone with ST.
NOTE:
Place the replacer so that its center-recessed side
faces the pinion gear.
ST 398517700
REPLACER
G3M1052
13) Extract the companion flange with a puller.

S3M0512A
16) Remove the front oil seal from differential carrier using ST.
ST 398527700
PULLER ASSY
S3M0511
14) Press the end of drive pinion shaft and extract it

together with the rear bearing cone, preload adjusting spacer and washer.
NOTE:
Hold the drive pinion so as not to drop it.
ST 398467700
DRIFT
S3M0513
17) Remove the pilot bearing together with front

bearing cone using ST.
ST 398467700
DRIFT
G3M0074
S3M0514A
(A) Pinion bearing

(B) Front bearing
(C) Rear bearing cup
DI-29

DIFFERENTIALS
18) When replacing the bearings, tap the front

bearing cup and rear bearing cup in this order out of
case by using a brass bar.
(1) Press the rear bearing race into differential

carrier using ST1 and ST2.
ST2 398477703 DRIFT 2
S3M0515A
G3M1037
(A) 2 cutouts along diagonal lines

(B) Tap alternately with brass bar.
(2) Insert the ST1 into carrier with pinion height

adjusting washer and rear bearing cone fitted
onto it.
D: ASSEMBLY
1) Precautions for assembling
Assemble in the reverse order of disassembling.
Check and adjust each part during assembly.
Keep the shims and washers in order, so that
they are not improperly installed.
Thoroughly clean the surfaces on which the
shims, washers and bearings are to be installed.
Apply gear oil when installing the bearings and
thrust washers.
Be careful not to mix up the right and left hand
races of the bearings.
Replace the oil seal with a new one at every disassembly. Apply chassis grease between the lips
when installing the oil seal.
NOTE:
Re-use the used washer if not deformed.
Use a new rear bearing cone.
(3) Then install the preload adjusting spacer
and washer, front bearing cone, ST2, companion flange, and washer and drive pinion nut.
ST1 398507702 DUMMY SHAFT
ST2 398507703 DUMMY COLLAR
S3M0516A
(A) Pinion height adjusting shim

(B) Preload adjusting spacer
(C) Preload adjusting washer
G3M0079
2) Adjusting preload for front and rear bearings

Adjust the bearing preload with spacer and washer
between front and rear bearings. Pinion height adjusting washer are not affected by this adjustment.
The adjustment must be carried out without oil seal
inserted.
DI-30

DIFFERENTIALS
(4) Turn the ST1 with hand to make it seated,

and tighten the drive pinion nut while measuring
the preload with spring balance. Select the preload adjusting washer and spacer so that the
specified preload is obtained when nut is tightened to the specified torque.
Part No.
NOTE:
Use a new lock nut.
NOTE:
Be careful not to give excessive preload.
When tightening the drive pinion nut, lock ST1
with ST2 as shown in the figure.
ST1 398507704 BLOCK
Preload adjusting
washer
Tightening torque:
181 Nm (18.5 kgf-m, 134 ft-lb)
Preload adjusting
spacer
G3M1038
Front and rear bearing preload

For new bearing:
19 26 N (1.9 2.6 kgf, 4.3 5.8 lb)
at companion flange bolt hole
For used bearing:
8 16 N (0.8 1.6 kgf, 1.8 3.6 lb)
383705200
383715200
383725200
383735200
383745200
383755200
383765200
383775200
383785200
383795200
383805200
383815200
383825200
383835200
383845200
Part No.
383695201
383695202
383695203
383695204
383695205
383695206
Thickness mm
(in)
2.59 (0.1020)
2.57 (0.1012)
2.55 (0.1004)
2.53 (0.0996)
2.51 (0.0988)
2.49 (0.0980)
2.47 (0.0972)
2.45 (0.0965)
2.43 (0.0957)
2.41 (0.0949)
2.39 (0.0941)
2.37 (0.0933)
2.35 (0.0925)
2.33 (0.0917)
2.31 (0.0909)
Length mm (in)
56.2 (2.213)
56.4 (2.220)
56.6 (2.228)
56.8 (2.236)
57.0 (2.244)
57.2 (2.252)
3) Adjusting drive pinion height

Adjust the drive pinion height with shim installed
between the rear bearing cone and back of pinion
gear.
(1) Install the ST1, ST2 and ST3, as shown in
the figure, and apply specified preload on the
bearings.
For new bearing:
19 26 N (1.9 2.6 kgf, 4.3 5.8 lb)
For used bearing:
8 16 N (0.8 1.6 kgf, 1.8 3.6 lb)
Adjusting preload for front and rear bearings

NOTE:
At this time, install a pinion height adjusting shim
which is temporarily selected or the same as that
used before. Measure and record the thickness.
S3M0518A
DI-31

DIFFERENTIALS
ST1
ST2
398507702
398507701
ST3
398507703
DUMMY SHAFT
DIFFERENTIAL CARRIER
GAUGE
DUMMY COLLAR
(Example of calculation)
To = 2.20 + 1.20 = 3.40 mm
N = 0.23 mm H = + 1,
T = 3.40 + 0.23 0.01 0.20 = 3.42
Result: Thickness = 3.42 mm
Therefore use the shim 383605200.
Part No.
Thickness mm (in)
383495200
3.09 (0.1217)
383505200
3.12 (0.1228)
383515200
3.15 (0.1240)
383525200
3.18 (0.1252)
383535200
3.21 (0.1264)
383545200
3.24 (0.1276)
383555200
3.27 (0.1287)
383565200
3.30 (0.1299)
383575200
3.33 (0.1311)
383585200
3.36 (0.1323)
383595200
3.39 (0.1335)
383605200
3.42 (0.1346)
383615200
3.45 (0.1358)
383625200
3.48 (0.1370)
383635200
3.51 (0.1382)
383645200
3.54 (0.1394)
383655200
3.57 (0.1406)
383665200
3.60 (0.1417)
383675200
3.63 (0.1429)
383685200
3.66 (0.1441)
S3M0518B
(2) Measure the clearance N between the end

of ST2 and end surface of ST1 by using a thickness gauge.
NOTE:
Make sure there is no clearance between the case
and ST2.
ST2 398507701 DIFFERENTIAL CARRIER
GAUGE
4) Install the selected pinion height adjusting shim

on drive pinion, and press the rear bearing cone
into position with ST.
ST 398177700
INSTALLER
H3M1309B
(3) Obtain the thickness of pinion height adjusting shim to be inserted from the following formula, and replace the temporarily installed shim
with this one.
T = To + N (H x 0.01) 0.20 mm (0.0079 in)
NOTE:
Use copies of this page.
T
To
N
H
Memo:
S3M0519A
Thickness of shim temporarily inserted

mm (in)
Thickness of pinion height adjusting
shim mm (in)
Reading of thickness gauge mm (in)
Figure marked on drive pinion head
DI-32

DIFFERENTIALS
5) Insert the drive pinion into differential carrier, install the previously selected bearing preload adjusting spacer and washer.
8) Fit a new oil seal with ST.

NOTE:
Press-fit until the end of oil seal is 1 mm (0.04 in)
inward from end of carrier.
Apply grease between the oil seal lips.
ST 498447120
DRIFT
B3M0560B
(A)
(B)
(C)
(D)
Drive pinion
Bearing adjusting spacer
Washer
G3M0087
6) Press-fit the front bearing cone into case with

ST1, ST2 and ST3.
ST1 398507703 DUMMY COLLAR
9) Press-fit the companion flange with ST1 and

ST2.
NOTE:
Be careful not to damage the bearing.
S3M0521A
G3M0085
7) Insert the spacer, then press-fit the pilot bearing

with ST1 and ST2.
10) Install the self-locking nut. Then tighten it with

the ST.
ST 498427200
FLANGE WRENCH
Tightening torque:
181 Nm (18.5 kgf-m, 134 ft-lb)
S3M0520A
G3M1052
DI-33

DIFFERENTIALS
11) Assembling differential case

Install the side gears and pinion mate gears, with
their thrust washers and pinion mate shaft, into differential case. (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.
(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 both sides of the hole to
prevent pin from falling off.
12) Install the crown gear on differential case.
NOTE:
Before installing the bolts, apply Lock Tite to bolt
threads.
Lock Tite:
NOTE:
Tighten diagonally while tapping the bolt heads.
Tightening torque:
105 Nm (10.7 kgf-m, 77.4 ft-lb)
S3M0509
13) Press the side bearing cone onto differential

case with ST.
ST 398487700
DRIFT
G3M0089
(1) Measure the side gear backlash.

Side gear back clearance:
0.10 0.20 mm (0.0039 0.0079 in)
G3M0091
B3M1933
(2) Adjust the backlash as specified by selecting the side gear thrust washer.
Part No.
383445201
383445202
383445203
14) Adjusting side bearing retainer shims

(1) The driven gear backlash and side bearing
preload can be determined by the side bearing
retainer shim thickness.

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)
DI-34

DIFFERENTIALS
(2) Install the differential case assembly into differential carrier in the reverse order of disassembly.
(5) Tighten the side bearing retainer bolts.

NOTE:
Before tightening the two side bearing retainer
bolts, apply Lock Tite to bolt threads.
Lock Tite:
Tightening torque:
10.3 Nm (1.05 kgf-m, 7.6 ft-lb)
S3M0533
(3) Install the side retainer shims and O-rings to

the right and left retainers from which they were
removed.
NOTE:
Replace the broken or cracked O-ring with new
one.
Replace the broken or corroded side retainer
shim with a new one of same thickness.
Part No.
Thickness mm (in)
383475201
0.20 (0.0079)
383475202
0.25 (0.0098)
383475203
0.30 (0.0118)
383475204
0.40 (0.0157)
383475205
0.50 (0.0197)
S3M0173
(6) Measure the crown gear-to-drive pinion

backlash. Set the magnet base on differential
carrier. Align the contact point of dial gauge with
tooth face of crown gear, and move the crown
gear while holding drive pinion still. Read the
value indicated on dial gauge.
Backlash:
0.10 0.20 mm (0.0039 0.0079 in)
(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.
G3M1047
(7) At the same time, measure the turning resistance of drive pinion. Compared with the resistance when differential case is not installed, if
the increase of the resistance is not within the
specified range, readjust the side bearing retainer shims.
S3M0172B
(A) Arrow mark
Turning resistance increase:

2.9 10.8 N (0.3 1.1 kgf, 0.7 2.4 lb)
DI-35

DIFFERENTIALS
15) Re-check the crown gear-to-pinion backlash.

Backlash:
0.10 0.20 mm (0.0039 0.0079 in)
G3M1047
16) Check the crown gear runout on its back surface, and make sure that pinion and crown gear rotate smoothly.
Limit of runout:
S3M0525
17) Checking and adjusting tooth contact of crown

gear
(1) Apply an even coat of red lead on both sides
of three or four teeth on the crown gear. Check
the contact pattern after rotating the crown gear
several revolutions back and forth until a definite
contact pattern appears on the crown gear.
(2) When the contact pattern is incorrect, readjust according to the instructions given in
TOOTH CONTACT PATTERN.
NOTE:
Be sure to wipe off red lead completely after adjustment is completed.
DI-36

DIFFERENTIALS
Condition
Correct tooth contact
Tooth contact pattern slightly shifted
towards toe under no load rotation.
(When loaded, contact pattern moves
toward heel.)
TOOTH CONTACT PATTERN

Contact pattern
Adjustment
G3M0098A
Face contact
Backlash is too large.
This may cause noise and chipping at

tooth ends.
Flank contact
Backlash is too small.
This may cause noise and stepped wear

on surfaces.
Toe contact
Contact area is small.
This may cause chipping at toe ends.
Heel contact
This may cause chipping at heel ends.
Increase thickness of drive pinion height

adjusting shim in order to bring drive pinion closer to crown gear center.
G3M0098B
G3M0098F
Reduce thickness of drive pinion height

adjusting shim in order to move drive
pinion away from crown gear.
G3M0098C
G3M0098G
Adjust as for flank contact.
G3M0098D
G3M0098E
: Adjusting direction of drive pinion

: Adjusting direction of crown gear
DI-37
G3M0098G
Adjust as for face contact.
G3M0098F

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.
(1) Drive pinion height
GAUGE
19) Install the rear cover and tighten the bolts to

specified torque.
Tightening torque:
29 Nm (3.0 kgf-m, 21.7 ft-lb)
G3M1050
E: INSPECTION
H3M1309B
T = To + N (H x 0.01) 0.20 (mm)

Where:
T = Thickness of pinion height adjusting shim
(mm)
To = Thickness of shim temporarily inserted
(mm)
N = Reading of thickness gauge (mm)
H = Figure marked on drive pinion head
(2) Hypoid gear backlash
Backlash:
0.10 0.20 mm (0.0039 0.0079 in)
G3M1047
Wash all the disassembled parts clean, and examine them for wear, damage, or other defects. Repair or replace defective parts as necessary.
1) Crown gear and drive pinion
If abnormal tooth contact is evident, find out the
cause and adjust to give correct tooth contact at assembly. Replace the gear if excessively worn or incapable of adjustment.
If crack, score, or seizure is evident, replace as a
set. Slight damage of tooth can be corrected by oil
stone or the like.
2) Side gear and pinion mate gear
Replace if crack, score, or other defects are evident on tooth surface.
Replace if thrust washer contacting surface is
worn or seized. Slight damage of the surface can
be corrected by oil stone or the like.
3) Bearing
Replace if seizure, peeling, wear, rust, dragging
during rotation, abnormal noise or other defect is
evident.
4) Thrust washers of side gear and pinion mate
gear
Replace if seizure, flaw, abnormal wear or other
defect is evident.
5) Oil seal
Replace if deformed or damaged, and at every disassembling.
6) Differential carrier
Replace if the bearing bores are worn or damaged.
7) Differential case
Replace if its sliding surfaces are worn or cracked.
8) Companion flange
Replace if the oil seal lip contacting surfaces have
flaws.
DI-38

DIFFERENTIALS
1. SIDE GEAR BACKLASH
3. CROWN GEAR RUNOUT
Using a dial gauge, check the backlash of the side

gear.
Using a dial gauge, check the crown gear runout.
Side gear backlash:

0.1 0.2 mm (0.004 0.008 in)
If the side gear backlash is not within the specification, adjust clearance as specified by selecting the
side gear thrust washer.
Crown gear runout:

If the crown gear runout exceeds 0.05 mm (0.0020
in), replace the crown gear.
S3M0525
4. TOOTH CONTACT BETWEEN CROWN

GEAR AND DRIVE PINION
B3M1934
2. CROWN GEAR BACKLASH

Using a dial gauge, check the backlash of the
crown gear.
Crown gear backlash:
0.1 0.2 mm (0.004 0.008 in)
If the crown gear backlash is not within the specification, adjust the side bearing preload or repair if
necessary.
Inspect the tooth contact between crown gear and

driven pinion. <Ref. to DI-30, ASSEMBLY, Rear
Differential for T-type.>
5. TOTAL PRELOAD
Using a gauge, check the turning resistance increase.
Turning resistance increase:
2.9 10.8 Nm (0.3 1.1 kgf, 0.7 2.4 lb)
If the increase of resistance is not within the specification, adjust the side bearing retainer shims.
G3M1047
B3M1935
DI-39

DIFFERENTIALS
F: ADJUSTMENT
Adjust the side gear backlash.
<Ref. to DI-30, ASSEMBLY, Rear Differential for Ttype.>

Adjust the crown gear backlash.

Adjust the tooth contact between crown gear and
drive pinion gear.
4. TOTAL PRELOAD
Adjust the side bearing shim.
DI-40
REAR DIFFERENTIAL FOR VA-TYPE

DIFFERENTIALS
5. Rear Differential for VA-type
13) Remove the DOJ of rear drive shaft from rear

differential.<Ref. to DI-58, REPLACEMENT, Rear
Differential Side Oil Seal.>
A: REMOVAL
racks.
10) Remove the front cover of rear differential
mount.
S3M0504A
(A) DOJ
(B) Tire lever
14) Secure the rear drive shaft to rear crossmember using wire.
S3M0500
15) Remove the lower differential bracket.

S3M0503

12) Remove the clamps and bracket of parking
brake cable.
H3M1273A
16) Support the rear differential with transmission

jack.
DR0018
G3M0055
DI-41

DIFFERENTIALS
17) Remove the self-locking nuts and bolts.
22) Remove the rear differential from body.
DR0019
G3M0059
18) Remove the bolts which secure rear differential

front member to bolts B.
NOTE:
Support the front member with use of a helper to
prevent it from dropping.
B: INSTALLATION
differential.
NOTE:
do not confuse the installation sequence of the upper and lower stoppers.
2) Install the DOJ of rear drive shaft into rear differential. <Ref. to DI-58, REPLACEMENT, Rear Differential Side Oil Seal.>
B3M0657C
(A) Bolt A
(B) Bolt B
19) Remove the bolt A.

20) While slowly lowering the transmission jack,
move the rear differential forward and remove bolts
from rear crossmember.
21) Remove the front member from body.
G3M1026

4) After installation, fill the differential carrier with
gear oil to the upper plug level. <Ref. to DI-24,
Front Differential.>
G3M0058
DI-42

DIFFERENTIALS
C: DISASSEMBLY
5) Remove the right and left lock plates.
To detect the real cause of trouble, inspect the following items before disassembling.
Tooth contact of crown gear and pinion, and
backlash
Runout of crown gear at its back surface
Turning resistance of drive pinion
1) Set the ST on vise and install the differential assembly to ST.
ST 398217700
ATTACHMENT
G3M0063
6) Remove the right and left holders with ST.

ST 499785500
WRENCH
G3M0060
2) Drain the gear oil by removing the plug.

3) Remove the rear cover by loosening the retaining bolts.
G3M0064
7) Pull out the differential assembly from differential

case.
NOTE:
Be careful not to hit the teeth against the case.
S3M0506
4) Replace the air breather cap.

NOTE:
Do not attempt to replace the air breather cap unless necessary.
G3M0065
S3M0507A
(A) Air breather cap

(B) Rear cover
DI-43

DIFFERENTIALS
8) Remove the bearing race from right and left

holders with ST1 and ST2.
ST1 499705401 PULLEY ASSY
ST2 499705404 SEAT
11) Remove the crown gear by loosening the

crown gear bolts.
S3M0509
12) Drive out the pinion shaft lock pin from crown
gear side.
S3M0508A
(A) Bearing race

(B) Holder
9) Remove the oil seal from right and left holders

using screwdriver.
NOTE:
The lock pin is staked at the pin hole end on the differential case; do not drive it out forcibly before
unstaking it.
ST 899904100
NOTE:
Perform this operation only when changing oil seal.
B3M0133
13) Draw out the pinion mate shaft and remove the
pinion mate gears, side gears and thrust washers.
B3M0132
10) Extract the bearing cone with ST1 and ST2.

NOTE:
Do not attempt to disassemble the parts unless
necessary.
Set the Puller so that its claws catch the edge of
bearing cone.
Never mix up the right and left hand bearing races and cones.
ST1 899524100 PULLER SET
ST2 399520105 SEAT
NOTE:
The gears as well as thrust washers should be
marked or kept separated right and left, front and
rear.
S3M0510A
(A)
(B)
(C)
(D)
(E)
H3M1970A
DI-44
Side gear
Pinion mate gear
Thrust washer
Differential case
Pinion mate shaft

DIFFERENTIALS
14) Hold the companion flange with ST and remove

the self-locking nut.
ST 498427200
FLANGE WRENCH
17) Remove the rear bearing cone from drive pinion by supporting the cone with ST.
NOTE:
Place the replacer so that its center-recessed side
faces the pinion gear.
ST 498515500
REPLACER
G3M0072
15) Extract the companion flange with a puller.

S3M0512A
18) Remove the front oil seal from differential carrier using ST.
ST 398527700
PULLER SET
S3M0511A
(A) Companion
(B) Puller
16) Press the end of drive pinion shaft and extract it

together with the rear bearing cone, preload adjusting spacer and washer.
NOTE:
Hold the drive pinion so as not to drop it.
ST 398467700
DRIFT
S3M0513A
(A) Differential carrier

(B) Front oil seal
19) Remove the pilot bearing together with front

bearing cone using ST.
ST 398467700
DRIFT
G3M0074
S3M0514A
(A) Pilot bearing

(B) Front bearing
(C) Rear bearing cup
DI-45

DIFFERENTIALS
20) When replacing the bearings, tap the front

bearing cup and rear bearing cup in this order out of
case by using a brass bar.
(2) Press the front bearing race into differential

ST2 498447110 DRIFT
S3M0515A
G3M0080
(A) 2 cutouts along diagonal lines

(B) Tap alternately with brass bar.
(3) Insert the front bearing cone.
D: ASSEMBLY
1) Precautions for assembling
Assemble in the reverse order of disassembling.
Check and adjust each part during assembly.
Keep the shims and washers in order, so that
they are not improperly installed.
Thoroughly clean the surfaces on which the
shims, washers and bearings are to be installed.
Apply gear oil when installing the bearings and
thrust washers.
Be careful not to mix up the right and left hand
races of the bearings.
Replace the oil seal with a new one at every disassembly. Apply chassis grease between the lips
when installing the oil seal.
NOTE:
Use a new front bearing cone.
(4) Insert the ST1 into case with pinion height
adjusting shim and rear bearing cone fitted onto
it.
NOTE:
Re-use the used washer if not deformed.
Use a new rear bearing cone.
(5) Then install the preload adjusting spacer
and washer, front bearing cone, ST2, companion flange, and washer and self-locking nut.
ST2 32285AA000 DUMMY COLLAR
S3M0516A
G3M0079
2) Adjust preload for front and rear bearings.

Adjust the bearing preload with spacer and washer
between front and rear bearings. Pinion height adjusting washer are not affected by this adjustment.
The adjustment must be carried out without oil seal
inserted.
(1) Press the rear bearing race into differential
ST2 398477702 DRIFT
DI-46

(B) Preload adjusting spacer
(C) Preload adjusting washer

DIFFERENTIALS
(6) Turn the ST1 with hand to make it seated,

and tighten the drive pinion nut while measuring
the preload with spring balance. Select the preload adjusting washer and spacer so that the
specified preload is obtained when nut is tightened to the specified torque.
NOTE:
Use a new self-locking nut.
Be careful not to give excessive preload.
When tightening the drive pinion nut, lock ST1
with ST2 as shown in the figure.
ST1 398507704 BLOCK
Tightening torque:
188 Nm (19.2 kgf-m, 139 ft-lb)
Preload adjusting
washer
G3M1038

For new bearing:
12.7 32.4 N (1.3 3.3 kgf, 2.9 7.3 lb)
Preload adjusting
spacer
S3M0517
DI-47
Part No.
38336AA000
38336AA120
38336AA010
38336AA130
38336AA020
38336AA140
38336AA030
38336AA150
38336AA040
38336AA160
38336AA050
38336AA170
38336AA060
38336AA180
38336AA070
38336AA190
38336AA080
38336AA200
38336AA090
38336AA210
38336AA100
38336AA220
38336AA110
Part No.
32288AA040
32288AA050
31454AA100
32288AA060
31454AA110
32288AA070
31454AA120
32288AA080
32288AA090
Thickness mm (in)
1.500 (0.0591)
1.513 (0.0596)
1.525 (0.0600)
1.538 (0.0606)
1.550 (0.0610)
1.563 (0.0615)
1.575 (0.0620)
1.588 (0.0625)
1.600 (0.0630)
1.613 (0.0635)
1.625 (0.0640)
1.638 (0.0645)
1.650 (0.0650)
1.663 (0.0655)
1.675 (0.0659)
1.688 (0.0665)
1.700 (0.0669)
1.713 (0.0674)
1.725 (0.0679)
1.738 (0.0684)
1.750 (0.0689)
1.763 (0.0694)
1.775 (0.0699)
Length mm (in)
52.3 (2.059)
52.5 (2.067)
52.6 (2.071)
52.7 (2.075)
52.8 (2.079)
52.9 (2.083)
53.0 (2.087)
53.1 (2.091)
53.3 (2.098)

DIFFERENTIALS
3) Adjusting drive pinion height

Adjust the drive pinion height with shim installed
between the rear bearing cone and back of pinion
gear.
(1) Install the ST1, ST2 and ST3, as shown in
the figure, and apply specified preload on the
bearings.
For new bearing:
12.7 32.4 N (1.3 3.3 kgf, 2.9 7.3 lb)
Adjusting preload for front and rear bearings

NOTE:
At this time, install an original pinion height adjusting shim.
GAUGE
(3) Obtain the thickness of pinion height adjusting washer to be inserted from the following formula, and replace the temporarily installed shim
with this one.
NOTE:
Use 1 to 3 shims as required for adjustment.
T = To + N 0.05 (mm)
where
(mm)
To = Thickness of shim originally installed
(mm)
H = Figure marked on drive pinion head
(Example of calculation)
To = 0.15 mm
N = 0.1 mm
T = 0.15 + 0.1 0.05 = 0.2 mm
Result: Thickness = 0.2 mm
Therefore use the 32295AA220.
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)
S3M0518A
(2) Measure the clearance N between the end

of ST3 and end surface of ST1 by using a thickness gauge.
4) Install the selected pinion height adjusting shim

on drive pinion, and press the rear bearing cone
into position with ST.
ST 498175500
INSTALLER
NOTE:
Make sure there is no clearance between the case
and ST3.
GAUGE
S3M0519A
H3M1309B
DI-48

DIFFERENTIALS
5) Insert the drive pinion into differential carrier, install the previously selected bearing preload adjusting spacer and washer.
8) Fit a new oil seal with ST.

NOTE:
Press-fit until the end of oil seal is 1 mm (0.04 in)
inward from end of carrier.
Apply grease between the oil seal lips.
ST 498447120
DRIFT
H3M1666A
(A)
(B)
(C)
(D)
Drive pinion
G3M0087
6) Press-fit the front bearing cone into carrier with

ST1, ST2 and ST3.
9) Press-fit the companion flange with ST1 and

ST2.
NOTE:
Be careful not to damage the bearing.
S3M0521A
G3M0085
7) Insert the spacer, then press-fit the pilot bearing

with ST1 and ST2.
10) Install the self-locking nut. Then tighten it with

the ST.
ST 498427200
FLANGE WRENCH
Tightening torque:
188 Nm (19.2 kgf-m, 139 ft-lb)
S3M0520A
G3M0721
DI-49

DIFFERENTIALS
11) Assembling differential case

Install the side gears and pinion mate gears, with
their thrust washers and pinion mate shaft, into differential case.
(2) Adjust the side gear backlash as specified

by selecting the side gear thrust washer.
Part No.
803135011
803135012
803135013
803135014
803135015
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.

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 driving in the pinion shaft lock pin,
stake both sides of the hole to prevent pin from
falling off.
(5) Install the crown gear on differential case.
NOTE:
Before installing the bolts, apply Lock Tite to bolt
threads.
Lock Tite:
NOTE:
Tighten diagonally while tapping the bolt heads.
Tightening torque:
62 Nm (6.3 kgf-m, 45.6 ft-lb)
G3M0089
(1) Measure the side gear backlash.

Side gear back clearance:
0.05 0.15 mm (0.0020 0.0059 in)
S3M0509
12) Press the side bearing cone onto differential

case with ST.
ST 498485400
DRIFT
B3M1933
G3M0091
DI-50

DIFFERENTIALS
13) Assemble holders.

(1) Install the oil seal into right and left holders.
ST 498447100
DRIFT
(1) Turn the drive pinion with ST for better fitting

of differential side bearing.
ST 498427200
FLANGE WRENCH
G3M0094
S3M0522A
(2) Install the bearing race into right and left

holders.
ST 398477702
BEARING OUTER RACE
DRIFT
(2) Screw in the side (left-side) holder until light

contact is made with ST.
ST 499785500
WRENCH
G3M0064
G3M0093
(3) Back off the side (left-side) holder approx. 1

1/2 teeth of holder, and tighten the left-side holder by approx. 2 teeth (approx. 1 1/2 + 1/2 teeth).
[Back off amount of side (left-side) holder + 1/2
tooth.]
This + 1/2 tooth gives preload.
(4) Temporarily tighten the lock plate.
(3) Install the differential case assembly into differential carrier in the reverse order of disassembly.
NOTE:
Turn over the lock plate to displace the holder 1/2
tooth.
G3M0065
14) Perform the backlash adjustment of pinion

crown gear set and preload adjustment of differential side bearing.
G3M0063
(5) Measure the crown gear-to-drive pinion

backlash. Set the magnet base on differential
carrier. Align the contact point of dial gauge with
tooth face of crown gear, and move the crown
gear while holding drive pinion still. Read the
value indicated on dial gauge.
DI-51

DIFFERENTIALS
NOTE:
If measured backlash is not within specified range,
repeat the procedures for pinion crown gear set
backlash adjustment and differential side bearing
preload adjustment.
17) Re-check the crown gear-to-pinion backlash.

Backlash:
0.10 0.15 mm (0.0039 0.0059 in)
Backlash:
0.10 0.15 mm (0.0039 0.0059 in)
S3M0523
18) Check the crown gear runout on its back surface, and make sure that pinion and crown gear rotate smoothly.
S3M0523
15) Draw a matching mark on both differential carrier and holder. Remove the holder one side at a
time.
Replace in the original position after inserting an Oring and applying grease to threaded portion.
Limit of runout:
0.05 mm (0.0020 in)
S3M0525
S3M0524A
(A) Matching mark

(B) Holder
16) Tighten the bolt of lock plate to specified

torque.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
19) Checking and adjusting tooth contact of crown

gear.
(1) Apply an even coat of red lead on both sides
of three or four teeth on the crown gear. Check
the contact pattern after rotating the crown gear
several revolutions back and forth until a definite
contact pattern appears on the crown gear.
(2) When the contact pattern is incorrect, readjust according to the instructions given in
TOOTH CONTACT PATTERN.
NOTE:
Be sure to wipe off red lead completely after adjustment is completed.
G3M0063
DI-52

DIFFERENTIALS
Condition
Correct tooth contact
Tooth contact pattern slightly shifted
towards toe under no load rotation.
(When loaded, contact pattern moves
toward heel.)
TOOTH CONTACT PATTERN

Contact pattern
Adjustment
G3M0098A
Face contact
Backlash is too large.
This may cause noise and chipping at

tooth ends.
Flank contact
Backlash is too small.
This may cause noise and stepped wear

on surfaces.
Toe contact

This may cause chipping at toe ends.
Increase thickness of drive pinion height

adjusting washer in order to bring drive
pinion closer to crown gear center.
G3M0098B
G3M0098F
Reduce thickness of drive pinion height

adjusting washer in order to move drive
pinion away from crown gear.
G3M0098C
G3M0098G
Adjust as for flank contact.
G3M0098D
Heel contact

This may cause chipping at heel ends.
G3M0098E
: Adjusting direction of drive pinion

: Adjusting direction of crown gear
DI-53
G3M0098G
Adjust as for face contact.
G3M0098F

DIFFERENTIALS
20) If proper tooth contact is not obtained, once

again adjust the drive pinion height and the differential side bearing preload (already mentioned)
and the hypoid gear backlash.
(1) Drive pinion height
ST2 498505501 DIFFERENTIAL GAUGE
(3) Hypoid gear backlash

Backlash:
0.10 0.15 mm (0.0039 0.0059 in)
S3M0523
21) Install the rear cover and tighten the bolts to

specified torque.
H3M1309B
T = To + N 0.05 (mm)
where
(mm)
To = Thickness of shim originally installed
(mm)
(2) Differential side bearing preload
Screw in side (left-side) holder until light contact
is made with ST.
Back off the side (left-side) holder approx. 1 1/2
teeth of holder, and tighten the left-side holder
by approx. 2 teeth (approx. 1 1/2 + 1/2 teeth).
[Back off amount of side (left-side) holder + 1/2
tooth.]
This + 1/2 tooth gives preload.
ST 499785500
WRENCH
G3M0064
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
S3M0526A
(A) Rear cover
E: INSPECTION
Wash all the disassembled parts clean, and examine them for wear, damage, or other defects. Repair or replace defective parts as necessary.
1) Crown gear and drive pinion
If abnormal tooth contact is evident, find out the
cause and adjust to give correct tooth contact at assembly. Replace the gear if excessively worn or incapable of adjustment.
If crack, score, or seizure is evident, replace as a
set. Slight damage of tooth can be corrected by oil
stone or the like.
2) Side gear and pinion mate gear
Replace if crack, score, or other defects are evident on tooth surface.
Replace if thrust washer contacting surface is
worn or seized. Slight damage of the surface can
be corrected by oil stone or the like.
3) Bearing
Replace if seizure, peeling, wear, rust, dragging
during rotation, abnormal noise or other defect is
evident.
DI-54

DIFFERENTIALS
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.
3. CROWN GEAR RUNOUT

Using a dial gauge, check the crown gear runout.
Crown gear runout:
If the crown gear runout exceeds 0.05 mm (0.0020
in), replace the crown gear.

Using a dial gauge, check the backlash of the side
gear.
Side gear backlash:
0.05 0.15 mm (0.0020 0.0059 in)
If the side gear backlash is not within the specification, adjust clearance as specified by selecting the
side gear thrust washer.
S3M0525

Inspect the tooth contact between crown gear and
drive pinion.
<Ref. to DI-46, ASSEMBLY, Rear Differential for
VA-type.>
F: ADJUSTMENT
Adjust the side gear backlash.
VA-type.>

Adjust the crown gear backlash.
VA-type.>
B3M1934

Using a dial gauge, check the backlash of the
crown gear.
Crown gear backlash:
0.10 0.15 mm (0.0039 0.0059 in)
If the crown gear backlash is not within the specification, adjust the side bearing preload or repair if
necessary.

Adjust the tooth contact between crown gear and
drive pinion gear.
VA-type.>
G3M1047
DI-55
REAR DIFFERENTIAL FRONT OIL SEAL

DIFFERENTIALS
6. Rear Differential Front Oil

Seal
11) Remove the tank cover.
A: REPLACEMENT
5) Remove the oil drain plug, and drain the gear oil.
B3M1643
12) Extract the companion flange using ST.

ST 399703602
PULLEY ASSY
DR0003
(A) Filler plug

(B) Drain plug
6) Install the oil drain plug.

NOTE:
Apply fluid packing to the drain plug for T-type.
B3M1644B
13) Remove the oil seal using ST.

ST 499705401
PULLER ASSY
Tightening torque:
T-type;
49 Nm (5.0 kgf-m, 36.2 ft-lb)
VA-type;
34 Nm (3.5 kgf-m, 25.3 ft-lb)
7) Jack-up the rear wheels and support the vehicle
body with sturdy racks.
9) Remove the propeller shaft from body. <Ref. to
DS-15, REMOVAL, Propeller Shaft.>
10) Remove the self-locking nut while holding the
companion flange with ST.
ST 498427200
FLANGE WRENCH
B3M1609B
14) Fit a new oil seal using ST.

ST 498447120
DRIFT
G3M0037
B3M1608A
DI-56
REAR DIFFERENTIAL FRONT OIL SEAL

DIFFERENTIALS
15) Install the companion flange.

NOTE:
Use a plastic hammer to install the companion
flange.
16) Tighten the self-locking nut within the specified
torque range so that the turning resistance of companion flange becomes the same as that before replacing oil seal.
ST 498427200
FLANGE WRENCH
NOTE:
Tightening torque:
181 Nm (18.5 kgf-m, 134 ft-lb)
G3M0034
17) Hereafter, reassemble in the reverse order of

disassembly.
DI-57
REAR DIFFERENTIAL SIDE OIL SEAL

DIFFERENTIALS
7. Rear Differential Side Oil Seal

A: INSPECTION
(2) Remove the ABS sensor cable clamp from

trailing link.
Make sure that there is no oil leakage from side oil

seal.
If there is any oil leakage, replace the oil seal.
B: REPLACEMENT
1. T-TYPE
4) Loosen both wheel nuts.
5) Jack-up the vehicle and support it with rigid
racks.
Turbo model
8) Remove the DOJ of rear drive shaft from rear differential.
(1) Remove the ABS sensor cable clamp and
parking brake cable clamp from bracket.
H3M1398

parking brake cable guide from trailing link.
H3M1399B
(A) Parking brake cable guide

(B) ABS sensor cable clamp
(4) Remove the rear stabilizer link.
SU0017
(5) Remove the bolts which secure trailing link

to housing.
H3M1397B
(A) ABS sensor cable clamp

(B) Parking brake cable guide
G3M0042
DI-58

DIFFERENTIALS
(6) Remove the bolts which secure front and

rear lateral link to rear housing.
9) Remove the rear drive shaft to the rear crossmember using wire.
S3M0500
G3M0043
(7) Remove the DOJ from the rear differential

by using ST.
10) Remove the nut of protector.

ST 398527700
PULLER ASSY
NOTE:
When removing the DOJ from rear differential, fit
ST to the bolts as shown in the figure so as not to
damage the side bearing retainer.
G3M1023
11) Drive in a new side oil seal using ST.

CAUTION:
Apply chassis grease between the oil seal lips.
ST 398437700
DRIFT
G3M1024
DR0006
(A) Bolt
DI-59

DIFFERENTIALS
12) Insert the DOJ into rear differential.

(1) Install the ST to rear differential.
8) Remove the DOJ of rear drive shaft from rear differential.

parking brake cable clamp from bracket.
H3M1397B
DR0007
(2) Install the spline shaft until the spline portion

is inside the side oil seal using ST.
(A) ABS sensor cable clamp

(B) Parking brake cable guide
(2) Remove the ABS sensor cable clamp from

trailing link.
G3M1026
(3) Remove the ST.

disassembly.
H3M1398

parking brake cable guide from trailing link.
2. VA-TYPE
4) Loosen both wheel nuts.
5) Jack-up the vehicle and support it with rigid
racks.
DI-60
H3M1399B
(A) Parking brake cable guide

(B) ABS sensor cable clamp

DIFFERENTIALS
(4) Remove the rear stabilizer link.
(7) Remove the DOJ from the rear differential

using tire lever.
NOTE:
When removing the DOJ from rear differential, fit
tire lever to the bolt as shown in the figure so as not
to damage the axle shaft holder.
NOTE:
with the shaft.
SU0017
(5) Remove the bolts which secure trailing link

to housing.
G3M0042
(6) Remove the bolts which secure front and

rear lateral link to rear housing.
H3M1664B
(A) Tire lever

(B) Axle shaft holder
9) Secure the rear drive shaft to rear crossmember

using wire.
G3M0043
S3M0500
DI-61

DIFFERENTIALS
10) Remove the oil seal with screwdriver.
(2) Install the spline shaft until the spline portion

is inside the side oil seal.
S3M0501A
G3M0049
(A) Side oil seal

(B) Screwdriver
ST
11) Drive in a new side oil seal using ST.

NOTE:
Apply chassis grease between the oil seal lips.
ST 498447100
OIL SEAL INSTALLER
(3) Remove the ST.

28099PA090 SIDE OIL SEAL PROTECTOR
(4) Completely insert the DOJ into rear differential by pressing rear housing.
NOTE:
Make sure that the oil seal lip is not folded over inward.
G3M0048
12) Insert the DOJ into rear differential.
H4M1095
NOTE:
Before inserting, replace the circlip at the end of
spline shaft with a new one.
(1) Install the ST to rear differential.

disassembly.
G3M0256
DI-62
REAR DIFFERENTIAL MEMBER

DIFFERENTIALS
8. Rear Differential Member
B: INSTALLATION
A: REMOVAL

differential.

3) Move the selector lever or gear shift lever to N.
6) Jack-up the vehicle and support it with study
racks.
Turbo model
9) Remove the rear differential front member.
NOTE:
When removing the rear differential front member,
work the removal procedure as rear differential.
T-type
VA-type
VA-type.>
10) Remove the differential rear member.
NOTE:
do not confuse the installation sequence of the
stopper.
G3M1029
2) Insert the DOJ of rear drive shaft into rear differential.<Ref. to DI-58, REPLACEMENT, Rear Differential Side Oil Seal.>
NOTE:
Before inserting, replace the differential side oil
seal with a new one.
ST 28099PA090 SIDE OIL SEAL PROTEXTOR
G3M1026
3) Hereafter, install in the reverse order of removal.
C: INSPECTION
1) Check the rear differential member for damage,
bend, or corrosion.
If damage, bend, or corrosion is excessive, replace
the rear differential member.
2) Check the bushings of rear differential member
for cracking, hardening, or damage.
If cracking, hardening, or damage is excessive, replace the rear differential member.
DI-63

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 crown
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 disassembly.
(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-64
Remedy
Repair or replace.
Clean, repair or replace.

Tighten the bolts to specified torque.
Replace the O-ring.
Tighten the bolts to specified torque.
Replace the gasket and apply liquid packing.
Retighten and apply liquid packing.
Repair or replace.
Readjust or replace.
Replace the seized part and fill with specified oil to specified level.
Replace.
Replace the gear or thrust washer.
Retighten.
Replace.
Readjust.
Replace the gear or thrust washer.
Readjust.
Tighten to specified torque.
Tighten to specified torque.
Replace.
Replace.
Replace.
Replace.

DIFFERENTIALS
Symptom or trouble
6. Gear noises
NOTE:
Since noises from engine, muffler, transmission, propeller shaft, wheel bearings,
tires, and body are sometimes mistaken
for noises from differential assembly, be
careful in checking them. Inspection
methods to locate noises include coasting, accelerating, cruising, and jacking-up
all four wheels. Perform these inspections
according to condition of trouble. When
listening to noises, shift gears into four
wheel drive and fourth speed position, trying to pick up only differential noise.
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-65
Remedy
Readjust or replace the hypoid gear set.
Readjust.
Replace the hypoid gear set.
Replace the hypoid gear set.
Readjust.
Replace.
Replace.
Replace.

DIFFERENTIALS
DI-66
TRANSFER CASE
TC
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Page
Transfer Case and Extension for MT ..........................................................3
Transfer Clutch and Extension for AT .........................................................4
Oil Seal........................................................................................................5
Transfer Drive Gear (MT)............................................................................6
Transfer Driven Gear (MT)..........................................................................7
Reduction Drive Gear without VTD .............................................................8
Reduction Drive Gear with VTD ..................................................................9
Reduction Driven Gear without VTD .........................................................10
Reduction Driven Gear with VTD ..............................................................11
Center Differential .....................................................................................12
Transfer Clutch Pressure Test ..................................................................13
Transfer Duty Solenoid and Valve Body ...................................................14
GENERAL DESCRIPTION
TRANSFER CASE
A: NOTE
For general description refer to AUTOMATIC
TRANSMISSION (a separate publication: Pub.
No. G0864ZE) and AT or MT section.
AT model:
<Ref. to AT-2, General Description.>
MT model:
<Ref. to MT-2, General Description.>
TC-2
TRANSFER CASE AND EXTENSION FOR MT

TRANSFER CASE
2. Transfer Case and Extension

for MT
A: NOTE
For removal, installation and inspection work, refer
to MT section. <Ref. to MT-48, Transfer Case and
Extension Case Assembly.>
TC-3
TRANSFER CLUTCH AND EXTENSION FOR AT

TRANSFER CASE
3. Transfer Clutch and Extension for AT

A: NOTE
to AUTOMATIC TRANSMISSION (a separate
publication: Pub. No. G0864ZE).
TC-4
OIL SEAL
TRANSFER CASE
4. Oil Seal
A: NOTE
to AT or MT section.
AT model:
<Ref. to AT-27, Extension Case Oil Seal.>
MT model:
<Ref. to MT-42, Oil Seal.>
TC-5
TRANSFER DRIVE GEAR (MT)

TRANSFER CASE
5. Transfer Drive Gear (MT)

A: NOTE
to MT section. <Ref. to MT-52, Transfer Drive
Gear.>
TC-6
TRANSFER DRIVEN GEAR (MT)

TRANSFER CASE
6. Transfer Driven Gear (MT)

A: NOTE
to MT section. <Ref. to MT-54, Transfer Driven
Gear.>
TC-7
REDUCTION DRIVE GEAR WITHOUT VTD

TRANSFER CASE
7. Reduction Drive Gear without

VTD
A: NOTE
TC-8
REDUCTION DRIVE GEAR WITH VTD

TRANSFER CASE
8. Reduction Drive Gear with

VTD
A: NOTE
publication: Pub. No. G0864ZE)
TC-9
REDUCTION DRIVEN GEAR WITHOUT VTD

TRANSFER CASE
9. Reduction Driven Gear without VTD

A: NOTE
TC-10
REDUCTION DRIVEN GEAR WITH VTD

TRANSFER CASE
10.Reduction Driven Gear with

VTD
A: NOTE
publication: Pub. No. G0864ZE)
TC-11
CENTER DIFFERENTIAL
TRANSFER CASE
11.Center Differential
A: NOTE
to MT section. <Ref. to MT-56, Center Differential.>
TC-12
TRANSFER CLUTCH PRESSURE TEST

TRANSFER CASE
12.Transfer Clutch Pressure

Test
A: NOTE
For inspection work, refer to AT section. <Ref. to
AT-18, Transfer Clutch Pressure Test.>
TC-13
TRANSFER DUTY SOLENOID AND VALVE BODY

TRANSFER CASE
13.Transfer Duty Solenoid and

Valve Body
A: NOTE
to AT section. <Ref. to AT-40, Shift Solenoids,
Duty Solenoids and ATF Temperature Sensor.>
TC-14
DRIVE SHAFT SYSTEM
DS
1.
2.
3.
4.
5.
6.
7.
Page
Propeller Shaft ..........................................................................................15
Front Axle..................................................................................................18
Rear Axle ..................................................................................................24
Front Drive Shaft .......................................................................................33
Rear Drive Shaft........................................................................................39
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
A: SPECIFICATIONS
1. PROPELLER SHAFT
Model
Propeller shaft type
Front propeller shaft Joint-to-joint length: L1
mm (in)
Rear propeller shaft Joint-to-joint length: L2

Outside diameter of tube:
(A)
mm (in)
AT
MT
mm (in)
Non-turbo
UJ type
584 (22.99)
643 (25.32)
713 (28.07)
708 (27.87)
D1
63.5 (2.500)
D2
57.0 (2.244)
D1
D2
L1
(B)
Turbo
DOJ type
579 (22.79)
638 (25.12)
L2
D1
D2
L1
L2
DR0008
(A)
UJ type (Non-turbo model)
(B)
DOJ type (Turbo model)
DS-2
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
2. FRONT DRIVE SHAFT ASSEMBLY

Type of drive shaft assembly
EBJ87+SFJ82
SHAFT
Shaft diameter
Non-turbo 26 mm (1.02 in)
Turbo
28 mm (1.10 in)
B4M2218E
(A)
EBJ87+SFJ82
(B)
Measuring point
DS-3
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
3. REAR DRIVE SHAFT ASSEMBLY

Size
A
B
C
D
E
F
G
H
I
J
EBJ82/DOJ82 Sedan RH
EBJ82/DOJ82 Sedan LH
BJ79/DOJ79 Sedan R160RH
BJ79/DOJ79 Sedan R160LH
BJ79/DOJ79 Sedan R152R/L
BJ79/DOJ79 Wagon R152R/L
EBJ82/DOJ82 Wagon RH
EBJ82/DOJ82 Wagon LH
BJ79/DOJ79 Wagon R160RH
BJ79/DOJ79 Wagon R160LH
Model
Sedan Turbo
Sedan 2.0 L NA MT
Sedan 1.6 L, 2.0 L NA AT
Wagon 1.6 L, 2.0 L NA AT
Wagon Turbo
Wagon 2.0 L NA MT
No. of identification
protrusion on shaft
2 (Two)
1 (One)
2 (Two)
1 (One)
3 (Three)
None
2 (Two)
1 (One)
2 (Two)
1 (One)
L1
(mm)
363
353
368
358
363
355
353
343
358
348
D
(mm)
24
24
23
23
23
23
24
24
23
23
DR0009
DS-4
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
(A)
(B)
(C)
(D)
EBJ82/DOJ82 Sedan RH
EBJ82/DOJ82 Sedan LH
BJ79/DOJ79 Sedan R160RH
BJ79/DOJ79 Sedan R160LH
(E)
(F)
(G)
(H)
BJ79/DOJ79 Sedan R152R/L

BJ79/DOJ79 Wagon R152R/L
EBJ82/DOJ82 Wagon RH
EBJ82/DOJ82 Wagon LH
DS-5
(I)
(J)
(K)
BJ79/DOJ79 Wagon R160RH

BJ79/DOJ79 Wagon R160LH
Identification protrusion
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
B: COMPONENT
1. PROPELLER SHAFT
DR0024
(1)
(2)
(3)
Propeller shaft (Turbo model)

Propeller shaft (Non-Turbo model)
Rear differential (VA-type)
(4)
(5)
Rear differential (T-type)

Bush
DS-6

T1: 31 (3.2, 23.1)
T2: 52 (5.3, 38.3)
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
2. FRONT AXLE
B4M2213A
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Baffle plate (SFJ)

Spring pin
Outer race (SFJ)
Snap ring
Trunnion
Free ring
Circlip
Boot band
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Boot (SFJ)
Boot (EBJ)
EBJ ASSY
Tone wheel (With ABS)
Baffle plate
Oil seal (IN)
Snap ring
Bearing
DS-7
(17)
(18)
(19)
(20)
(21)
Housing
Oil seal (OUT)
Hub bolt
Hub
Axle nut

T: 186 (19, 137)
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
3. REAR AXLE
DR0011
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Circlip
Baffle plate (DOJ)
Outer race (DOJ)
Snap ring
Inner race
Ball
Cage
Circlip
Boot band
Boot (DOJ)
Boot (*)
(12)
Non-Turbo: BJ ASSY
Turbo: EBJ ASSY
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
Baffle plate (*)

Oil seal (IN. No. 2)
Oil seal (IN. No. 3)
Housing
Bearing
Snap ring
Oil seal (OUT)
Tone wheel (With ABS)
Hub bolt
DS-8
(22)
(23)
Hub
Axle nut

T1: 13 (1.3, 9.4)
T2: 186 (19, 137)
*
Non-Turbo model: BJ
Turbo model: EBJ
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
C: CAUTION
points.
DS-9
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
D: PREPARATION TOOL
1. SPECIAL TOOLS
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.
927060000
HUB REMOVER
Used for removing front hub.

Used with HUB STAND (927080000).
B4M2386
B4N2387A
B4M2388
B4M2389
DS-10
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
ILLUSTRATION
TOOL NUMBER
927420000
DESCRIPTION
HUB REMOVER
REMARKS
Used for removing rear hub.
Used with HUB STAND (927080000).
927080000
HUB STAND
Used for disassembling and assembling hub bolt

in hub.
927100000
BEARING PULLER
Used for disassembling and assembling front

housing bearing.
Used with HOUSING STAND (927400000).
927140000
AXLE SHAFT
PULLER PLATE
Same as plate 2 included in AXLE SHAFT

PULLER (926470000).
H5M0981
B4M2390
B4M2391
B4M2392
DS-11
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
ILLUSTRATION
TOOL NUMBER
927390000
DESCRIPTION
ADAPTER
REMARKS
Used as an adapter for AXLE SHAFT
927400000
HOUSING STAND
Used for disassembling and assembling front

housing bearing.
Used with BEARING PULLER (927100000).
927410000
OIL SEAL
INSTALLER
Used for installing oil seal into front housing.

927430000
HOUSING STAND
Used for disassembling and assembling rear

housing bearing.
Used with BEARING PULLER (927440000).
B4M2393
B4M2394
B4M2395
H5M0982
DS-12
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
ILLUSTRATION
TOOL NUMBER
927120000
DESCRIPTION
HUB INSTALLER
REMARKS
Used for installing hub.
927440000
BEARING
REMOVER
Used for disassembling and assembling rear

housing bearing.
927460000
OIL SEAL
INSTALLER
Used for installing outer bearing and sub bearing into holding.
927450000
HUB INSTALLER
Used for installing hub unit into hub ASSY.

Used with BEARING SPACER (28499AE000)
and HUB STAND (927080000).
B4M2399
H5M0983
H5M0984
B4M2400
DS-13
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
ILLUSTRATION
TOOL NUMBER
28099PA090
DESCRIPTION
REMARKS
OIL SEAL PROTEC- Used for installing rear drive shaft into rear difTOR
ferential.
For protecting oil seal.
B4M2401
28099PA100
DRIVE SHAFT
REMOVER
Used for removing rear drive shaft from rear differential.
28099AC000
BOOT BAND PLIERS
Used for tightening front BJ boot band.
B4M2402
B4M2403

TOOL NAME
Puller
Dial gauge
Snap ring pliers
REMERKS
Used for removing ball joint from knuckle arm.
Used for inspecting propeller shaft run-out.
Used for installing and removing snap ring.
DS-14
PROPELLER SHAFT
DRIVE SHAFT SYSTEM
2. Propeller Shaft
8) Remove the four bolts which hold propeller shaft

to rear differential.
A: REMOVAL
NOTE:
Before removing the propeller shaft, wrap the
metal parts with a cloth or rubber material.
In case of DOJ type, before removing the propeller shaft, wrap the 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.
NOTE:
Put matching marks on affected parts before removal.
Remove all but one bolt.
B3M1587C
(A) Matching mark
9) Remove the two bolts which hold center bearing

to vehicle body.
S3M0030

racks.
5) Remove the center exhaust pipes.
7) Remove the differential mount front cover.
S3M0028
DR0004
DS-15
PROPELLER SHAFT
DRIVE SHAFT SYSTEM
10) Remove the propeller shaft from transmission.
B: INSTALLATION
CAUTION:
Be careful not to damage the 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 the propeller shaft.
1) Insert the sleeve yoke into transmission, and

then attach the center bearing to body.
Tightening torque:
52 Nm (5.3 kgf-m, 38.3 ft-lb)
NOTE:
Be sure to use an empty oil can to catch oil flowing out when removing the propeller shaft.
Be sure to plug the opening in transmission after
removal of propeller shaft.
S3M0028
2) Align the matching marks, and then connect the

flange yoke and rear differential.
Tightening torque:
31 Nm (3.2 kgf-m, 23.1 ft-lb)
G3M0025
11) Install the extension cap to transmission.

NOTE:
If the extension cap is not available, place a vinyl
bag over opening and fasten with string to prevent
gear oil or ATF from leaking.
B3M1587C
(A) Matching mark
3) Install the differential mount front cover.

Tightening torque:
88 Nm (9.0 kgf-m, 65 ft-lb)
S3M0498A
(A) Extension cap
DR0004
4) Install the center exhaust pipes.

DS-16
PROPELLER SHAFT
DRIVE SHAFT SYSTEM
C: INSPECTION
3. RUNOUT OF PROPELLER SHAFT
NOTE:
Do not disassemble the propeller shaft. Check the
following and replace if necessary.
1) Tube surfaces for dents or cracks
2) Splines for deformation or abnormal wear
3) Joints for non-smooth operation or abnormal
noise
4) Center bearing for free play, noise or nonsmooth operation
5) Oil seals for abnormal wear or damage
6) Center bearing for breakage
Check the following points with propeller shaft installed in vehicle.

4) Turn the rear wheels by hand to check for
runout of propeller shaft.
NOTE:
Measure the runout with a dial gauge at the center
of front and rear propeller shaft tubes.
Runout:
Limit 0.6 mm (0.024 in)
1. JOINTS AND CONNECTIONS

3) Check for any looseness of the yoke flange connecting bolts and center bearing retaining bolts.
2. SPLINES AND BEARING LOCATIONS

4) Turn the propeller shaft by hand to see if abnormal free play exists at splines. Also move the yokes
to see if abnormal free play exists at spiders and
bearings.
B3M1603A
(A) Propeller shaft

(B) Dial gauge
4. CENTER BEARING FREE PLAY

4) While holding the propeller shaft near center
bearing with your hand, move it up and down, and
left and right to check for any abnormal bearing free
play.
B3M1602
B3M1604
DS-17
FRONT AXLE
DRIVE SHAFT SYSTEM
3. Front Axle
A: REMOVAL
1) Jack-up the vehicle, support it with safety
stands, and remove the front wheels.
2) Unlock the axle nut.
6) Remove the front drive shaft assembly from hub.

If it is hard to remove, use the STs.
ST1 926470000 AXLE SHAFT PULLER
PLATE
CAUTION:
Be careful not to damage the oil seal lip when
removing front drive shaft.
When replacing the front drive shaft, also replace inner oil seal.
G4M0214
3) Remove the axle nut using a socket wrench.

CAUTION:
Be sure to loose and retighten the axle nut after
removing wheel from the vehicle. Failure to follow this rule may damage the wheel bearings.
4) Remove the stabilizer link.
G4M0216
7) Remove the disc rotor from hub.

If the disc rotor seizes up within hub, drive disc rotor
out by installing an 8-mm bolt in screw hole on the
rotor.
G4M0215
5) Remove the disc brake caliper from housing,

and suspend it from strut using a wire.
B4M1678
8) Remove the cotter pin and castle nut which secure tie-rod end to housing knuckle arm.
B4M2214A
(A) Cotter pin

(B) Castle nut
(C) Tie-rod
DS-18
FRONT AXLE
DRIVE SHAFT SYSTEM
9) Using a puller, remove the tie-rod ball joint from

knuckle arm.
B: INSTALLATION
1) Install the transverse link ball joint to housing.
Tightening torque:
49 Nm (5.0 kgf-m, 36 ft-lb)
2) While aligning the alignment mark on the camber adjusting bolt head, connect housing and strut.
CAUTION:
B4M2215
10) On ABS equipped models, remove the ABS

sensor assembly and harness in advance.
B4M2209
11) Remove the transverse link ball joint from

housing.
Tightening torque:
152 Nm (15.5 kgf-m, 112 ft-lb)
3) Install the ABS sensor on housing (only vehicle
equipped with ABS).
Tightening torque:
32 Nm (3.3 kgf-m, 23.9 ft-lb)
4) Install the disc rotor on hub.
5) Install the disc brake caliper on housing.
Tightening torque:
78 Nm (8 kgf-m, 57.9 ft-lb)
6) Install the front drive shaft. <Ref. to DS-33, INSTALLATION, Front Drive Shaft.>
7) Connect the stabilizer link.
8) Connect the tie-rod end ball joint and knuckle
arm with a castle nut, and then insert the cotter pin
into tie-rod end.
Tightening torque:
27.0 Nm (2.75 kgf-m, 19.9 ft-lb)
B4M2216
12) After scribing an alignment mark on the camber

adjusting bolt head, remove the bolts which connect housing and strut, and disconnect housing
from strut.
B4M1970
DS-19
B4M2214A
(A) Cotter pin

(B) Castle nut
(C) Tie-rod
FRONT AXLE
DRIVE SHAFT SYSTEM
9) While depressing the brake pedal, tighten the

axle nut and lock it securely.
Tightening torque:
186 Nm (19 kgf-m, 137 ft-lb)
CAUTION:
Use a new axle nut.
Always tighten the axle nut before installing
wheel on the vehicle. If the wheel is installed
and comes in contact with ground when axle
nut is loose, wheel bearings may be damaged.
Be sure to tighten the axle nut to specified
torque. Do not overtighten it as this may damage wheel bearing.
10) After tightening the axle nut, lock it securely.
C: DISASSEMBLY
1) Using the ST1, support the housing and hub securely.
2) Attach the ST2 to housing and drive hub out.
ST1 927060000 HUB REMOVER
ST2 927080000 HUB STAND
G4M0238
11) Install the wheel and tighten wheel nuts to

specified torque.
Tightening torque:
88 Nm (9 kgf-m, 65 ft-lb)
G4M0223
If inner bearing race remains in the hub, remove it

with a suitable tool (commercially available).
CAUTION:
Be careful not to scratch the polished area of
hub.
Be sure to install the inner race on the side of
outer race from which it was removed.
G4M0224
DS-20
FRONT AXLE
DRIVE SHAFT SYSTEM
3) Remove the disc cover from housing.
8) Using the ST and a hydraulic press, drive the

hub bolts out.
ST 927080000
HUB STAND
CAUTION:
Be careful not to hammer the hub bolts. This
may deform the hub.
G4M0225
4) Using a standard screwdriver, remove the outer

and inner oil seals.
CAUTION:
Do not use old oil seals.
5) Using a flat bladed screwdriver, remove the
snap ring.
CAUTION:
Be careful not to damage the housing at removal.
G4M0228
D: ASSEMBLY
CAUTION:
When the hub is to be removed from housing,
replace the bearing set and oil seal with new
ones.
1) Attach the hub to ST securely.
ST 927080000
HUB STAND
H4M1001
6) Using the ST1, support the housing securely.

7) Using the ST2, press the inner race to drive out
outer bearing.
ST1 927400000 HOUSING STAND
ST2 927100000 BEARING PULLER
CAUTION:
Do not remove the outer race unless it is
faulty.
Discard the outer race after removal.
Do not replace the inner or outer race separately; always replace as a unit.
G4M0230
2) Using a hydraulic press, press the new hub bolts

into place.
CAUTION:
Be sure to press the hub bolts until their seating surfaces contact the hub.
NOTE:
Use 12 mm (0.47 in) dia. holes in HUB STAND to
prevent bolts from tilting.
3) Clean dust or foreign particles from inside the
housing.
G4M0227
DS-21
FRONT AXLE
DRIVE SHAFT SYSTEM
4) Using the ST1 and ST2, press a new bearing

into place.
ST2 927100000 BEARING PULLER
7) Using the ST1 and ST2, press the inner oil seal
until it contacts circlip.
CAUTION:
Always press the outer race when installing
bearing.
Be careful not to remove the plastic lock from
inner race when installing bearing.
Charge the bearing with new grease when
outer race is not removed.
Specified grease:
SHELL 6459N
G4M0234
8) Invert the ST and housing.

ST 927400000
HOUSING STAND
9) Apply sufficient grease to the oil seal lip.
Specified grease:
SHELL 6459N
CAUTION:
If specified grease is not available, remove
the bearing grease and apply Auto Rex A instead.
Do not mix different types of grease.
10) Install the disc cover to housing the three bolts.
G4M0232
5) Using pliers, install the snap ring in its groove.

CAUTION:
Make sure to install it firmly to groove.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
11) Attach the hub to ST1 securely.
12) Clean dust or foreign particles from the polished surface of hub.
13) Using the ST2, press the bearing into hub by
driving inner race.
ST2 927120000 HUB INSTALLER
G4M0226
6) Using the ST1 and ST2, press the outer oil seal
until it contacts the bottom of housing.
G4M0235
G4M0233
DS-22
FRONT AXLE
DRIVE SHAFT SYSTEM
E: INSPECTION
1) Moving the front tire up and down by hand,
check that there is no backlash in the bearing, and
check that the wheel rotates smoothly.
S4M0572
2) Inspect the removed parts for wear and damage.

If defective, replace with new ones.
DS-23
REAR AXLE
DRIVE SHAFT SYSTEM
4. Rear Axle
8) Disconnect the parking brake cable end.
A: REMOVAL
1. DISC BRAKE
2) Jack-up the vehicle, and remove the rear wheel
cap and wheels.
CAUTION:
Be sure to loosen and retighten the axle nut after removing the wheel from vehicle. Failure to
follow this rule may damage the wheel bearings.
5) Return the parking brake lever and loosen adjusting nut.
S4M0368A
(1) Cable end
9) Disconnect the rear stabilizer from rear lateral

link.
10) Remove the bolts which secure trailing link assembly to rear housing.
CAUTION:
Discard the old self-locking nut. Replace with a
new one.
BR0054
(1) Parking brake lever

(2) Lock nut
(3) Adjusting nut
S4M0109
6) Remove the disc brake caliper from back plate,

and suspend it from strut using a piece of wire.
11) Remove the bolts which secure lateral assembly to rear housing.
CAUTION:
new one.
G4M0240

NOTE:
If the disc rotor seizes up within hub, drive it out by
installing an 8-mm bolt into bolt hole in disc rotor.
DS-24
S4M0110
REAR AXLE
DRIVE SHAFT SYSTEM
12) Disengage the BJ from housing splines, and

then remove the rear drive shaft assembly.
PLATE
CAUTION:
removing rear drive shaft.
When the rear drive shaft is to be replaced,
also replace the inner oil seal with a new one.
2. DRUM BRAKE
2) Jack-up the vehicle, and remove rear wheel cap
and wheels.
CAUTION:
5) Return the parking brake lever and loosen adjusting nut.
G4M0247
13) Remove the rear ABS sensor from back plate

(only vehicle equipped with ABS).
BR0054

(2) Lock nut
(3) Adjusting nut
6) Remove the brake drum from hub.
H4M1139B
(1) ABS sensor
14) Remove the bolts which secure rear housing to

strut, and separate the two.
G4M0249
DS-25
REAR AXLE
DRIVE SHAFT SYSTEM
7) If it is difficult to remove the brake drum, remove

the adjusting hole cover from back plate, and then
turn the adjusting screw using a slot-type screwdriver until brake shoe separates from the drum.
9) Disconnect the parking brake cable end.
S4M0368A
(1) Cable end

S4M0369A
(1)
(2)
(3)
(4)
(5)
(6)
10) Disconnect the rear stabilizer from rear lateral

link.
11) Remove the bolts which secure trailing link assembly to rear housing.
Back plate
Wheel cylinder
Adjuster ASSY pawls
Adjusting lever
Tightening direction
Push
CAUTION:
new one.
NOTE:
If the brake drum is difficult to remove, drive it out
by installing an 8-mm bolt into bolt hole in brake
drum.
S4M0109
12) Remove the bolts which secure lateral link assembly to rear housing.
G4M0243
8) Using a flare-nut wrench, disconnect the brake

pipe from wheel cylinder.
CAUTION:
new one.
CAUTION:
Cover the open end of wheel cylinder to prevent
entry of foreign particles.
S4M0110
G4M0244
DS-26
REAR AXLE
DRIVE SHAFT SYSTEM
13) Disengage the BJ from housing splines, and remove the rear drive shaft assembly.
PLATE
CAUTION:
When the rear drive shaft is to be replaced,
also replace the inner oil seal with a new one.
B: INSTALLATION
1. DISC BRAKE
1) Connect the rear housing assembly and strut assembly.
CAUTION:
Tightening torque:
196 Nm (20 kgf-m, 145 ft-lb)
2) Fit the BJ (bell joint) to rear housing splines.
CAUTION:
Be careful not to damage the inner oil seal lip.
3) Connect the rear housing assembly to lateral link
assembly.
CAUTION:
Tightening torque:
137 Nm (14 kgf-m, 101 ft-lb)
G4M0247
14) Remove the rear ABS sensor from back plate

(only vehicle equipped with ABS).
S4M0110
4) Connect the rear housing assembly to trailing

link assembly.
CAUTION:
H4M1139B
(1) ABS sensor
15) Remove the bolts which secure rear housing to

strut, and separate the two.
Tightening torque:
113 Nm (11.5 kgf-m, 83 ft-lb)
S4M0109
G4M0249
5) Connect the rear stabilizer to rear lateral link.

CAUTION:
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
DS-27
REAR AXLE
DRIVE SHAFT SYSTEM
6) Connect the parking brake cable to parking

brake.
7) Install the disc rotor on rear housing assembly.
8) Install the disc brake caliper on back plate.
Tightening torque:
52 Nm (5.3 kgf-m, 38.3 ft-lb)
13) Install the wheel, and then tighten the wheel

nuts to specified torque.
Tightening torque:
88 Nm (9.0 kgf-m, 65 ft-lb)
2. DRUM BRAKE
1) Connect the rear housing assembly and strut assembly.
CAUTION:
Tightening torque:
196 Nm (20 kgf-m, 145 ft-lb)
2) Fit the BJ (bell joint) to rear housing splines.
G4M0240
9) Install the rear ABS sensor and brake cable

bracket (only vehicle equipped with ABS).
CAUTION:
Be careful not to damage the inner oil seal lip.
3) Connect the rear housing assembly to lateral link
assembly.
CAUTION:
Tightening torque:
137 Nm (14 kgf-m, 101 ft-lb)
H4M1139B
(1) ABS sensor
10) Bleed the air from brake system. <Ref. to BR55, REPLACEMENT, Brake Fluid.>
11) Adjust the parking brake lever stroke by turning
adjuster.
12) Move the brake lever back to apply brakes.
While depressing the brake pedal, tighten axle nut
using a socket wrench. Lock the axle nut after tightening.
Tightening torque:
186 Nm (19 kgf-m, 137 ft-lb)
S4M0110
4) Connect the rear housing assembly to trailing

link assembly.
CAUTION:
Tightening torque:
113 Nm (11.5 kgf-m, 83 ft-lb)
CAUTION:
Use a new axle nut.
torque. Do not overtighten it as this may damage the wheel bearing.
DS-28
S4M0109
REAR AXLE
DRIVE SHAFT SYSTEM
5) Connect the rear stabilizer to rear lateral link.
C: DISASSEMBLY
CAUTION:
1) Using the ST1 and ST2, remove the hub from

rear housing.
ST 927080000
HUB STAND
ST 927420000
HUB REMOVER
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
6) Connect the parking brake cable to parking
brake.
7) Clean the brake pipe connection. Using a flarenut wrench, connect the brake pipe to wheel cylinder.
8) Connect the rear ABS sensor to back plate (only
vehicle equipped with ABS).
G4M0250
2) Remove the back plate from rear housing

3) Using a standard screwdriver, remove the outer
and inner oil seals.
CAUTION:
Use new oil seals.
4) Using a flat bladed screwdriver, remove the
snap ring.
H4M1139B
(1) ABS sensor
9) Connect the parking brake cable to lever.

10) Install the brake drum on rear housing assembly.
11) Bleed the air from brake system. <Ref. to BR55, REPLACEMENT, Brake Fluid.>
12) Adjust the parking brake lever stroke by turning
adjuster.
13) Move the brake lever back to apply brakes.
While depressing the brake pedal, tighten axle nut
using a socket wrench. Lock the axle nut after tightening.
CAUTION:
Be careful not to damage the housing at removal.
H4M1003
Tightening torque:
186 Nm (19 kgf-m, 137 ft-lb)
CAUTION:
Use a new axle nut.
14) Install the wheel, and then tighten the wheel
nuts to specified torque.
Tightening torque:
88 Nm (9.0 kgf-m, 65 ft-lb)
DS-29
REAR AXLE
DRIVE SHAFT SYSTEM
5) Using the ST1 and ST2, remove the bearing by

pressing inner race.
ST2 927440000 BEARING REMOVER
CAUTION:
Do not remove the bearing unless damaged.
Do not re-use the bearing after removal.
D: ASSEMBLY
CAUTION:
When the hub is to be removed from housing,
replace the bearing set and oil seal with new
ones.
1) Using the ST, press the new hub bolt into place.
CAUTION:
Ensure the hub bolt closely contacts hub.
Use a 12 mm (0.47 in) hole in the ST to prevent the hub bolt from tilting during installation.
ST 927080000
HUB STAND
G4M0252
6) Remove the tone wheel bolts, and then remove

the tone wheel from hub (only vehicle equipped
with ABS).
7) Using the ST, press the hub bolt out.
ST 927080000
HUB STAND
CAUTION:
Be careful not to hammer the hub bolts. This
may deform the hub.
G4M0230
2) Remove foreign particles (dust, rust, etc.) from

mating surfaces of the hub tone wheel, and then install the tone wheel to hub (only vehicle equipped
with ABS).
CAUTION:
Ensure the tone wheel closely contacts hub.
Be careful not to damage the tone wheel
teeth.
G4M0228
S4M0370A
(1) Tone wheel
DS-30
REAR AXLE
DRIVE SHAFT SYSTEM
3) Clean the housing interior completely. Using the

ST1 and ST2, press the bearing into housing.
ST2 927440000 BEARING REMOVER
7) Using the ST2, press the inner oil seal into housing until it touches bottom.
CAUTION:
Always press the outer race when installing
bearing.
Be careful not to remove the plastic lock from
inner race when installing bearing.
Charge bearing with new grease when outer
race is not removed.
S4M0268A
8) Using the ST1 and ST2, press the sub seal into
place.
S4M0266A
4) Using pliers, install the snap ring.

CAUTION:
Ensure the snap ring fits in groove properly.
S4M0269A
9) Apply sufficient grease to oil seal lip.

Specified grease:
SHELL 6459N
S4M0371A
(1) Pliers
5) Using the ST1 and ST2, press the outer oil seal
unit it comes in contact with snap ring.
CAUTION:
If specified grease is not available, remove
the bearing grease and apply Auto Rex A instead.
Do not mix different types of grease.
10) Install the back plate to rear housing.
Tightening torque:
52 Nm (5.3 kgf-m, 38.3 ft-lb)
S4M0267A
6) Invert both ST1 and housing.
DS-31
REAR AXLE
DRIVE SHAFT SYSTEM
11) Using the ST1 and ST2, press the baring into
hub.
ST2 927450000 HUB INSTALLER
S4M0270A
E: INSPECTION
1) Moving the front tire up and down by hand,
check that there is no backlash in the bearing, and
check that the wheel rotates smoothly.
S4M0572
2) Inspect the removed parts for wear and damage.

If defective, replace with new ones.
DS-32
FRONT DRIVE SHAFT

DRIVE SHAFT SYSTEM
5. Front Drive Shaft
B: INSTALLATION
A: REMOVAL
1) Insert the BJ into hub splines.

(rigid racks), and then remove the front wheel cap
and wheels.
3) Depress the brake pedal and remove axle nut
using a socket wrench.
CAUTION:
4) Remove the stabilizer link from transverse link.
5) Disconnect the transverse link from housing.
6) Remove the spring pin which secures transmission spindle to SFJ.
CAUTION:
Be careful not to damage the inner oil seal lip
and tone wheel.
2) Using the ST1 and ST2, pull the drive shaft into
place.
ST1 922431000 AXLE SHAFT INSTALLER
CAUTION:
Do not hammer the drive shaft when installing
it.
CAUTION:
Use a new spring pin.
G4M0291
3) Tighten the axle nut temporarily.

4) Install the SFJ on transmission spindle and drive
spring pin into place.
CAUTION:
Always use a new spring pin.
G4M0279
7) Remove the front drive shaft assembly. If it is

hard to remove, use the ST1 and ST2.
PLATE
CAUTION:
Be careful not to damage the oil seal lip and
tone wheel when removing front drive shaft.
When the front drive shaft is to be replaced,
also replace inner oil seal.
G4M0279
5) Connect the transverse link to housing.

Tightening torque (self-locking nut):
49 Nm (5.0 kgf-m, 36 ft-lb)
CAUTION:
6) Install the stabilizer bracket.
G4M0216
DS-33
FRONT DRIVE SHAFT

DRIVE SHAFT SYSTEM

axle nut to the specified torque.
3) Remove the circlip from SFJ outer race using

screwdriver.
Tightening torque:
186 Nm (19 kgf-m, 137 ft-lb)
CAUTION:
Use a new axle nut.
C: DISASSEMBLY
1) Place alignment marks on the shaft and outer
race.
B4M0776
4) Remove the SFJ outer race from shaft assembly.

5) Wipe off the grease.
CAUTION:
The grease is a special grease. Do not confuse
with other greases.
6) Place alignment marks on the free ring and trunnion.
B4M0774
2) Remove the SFJ boot band and boot.

CAUTION:
Be careful not to damage the boot.
B4M0777
B4M0775
7) Remove the free ring from trunnion.

CAUTION:
Be careful with the free ring position.
DS-34
FRONT DRIVE SHAFT

DRIVE SHAFT SYSTEM
8) Place an alignment mark on the trunnion and

shaft.
12) Raise the boot band claws by means of screwdriver and hammer.
B4M0778
9) Remove the snap ring and trunnion.
B4M2220B
B4M0779
CAUTION:
Be sure to wrap the shaft splines with vinyl tape
to prevent boot from scratches.
10) Remove the SFJ boot.
11) Place the drive shaft in a vise between wooden
blocks.
(A) Boot band claws
13) Cut and remove the boot.

CAUTION:
The boot must be replaced with a new one
whenever it is removed.
CAUTION:
Do not place the drive shaft directly in the vise;
use wooden block.
B4M0690
14) Thus, disassembly of axle is completed, but the

BJ cannot be disassembled.
DS-35
FRONT DRIVE SHAFT

DRIVE SHAFT SYSTEM
D: ASSEMBLY
7) Install the boot projecting portion to shaft groove.
CAUTION:
Use specified grease.
BJ side:
NTG2218 (Part No. 28093AA000)
SFJ side:
SSG6003 (Part No. 28093TA000)
1) Place the BJ boot and small boot band on BJ
side of shaft.
B4M1297C
CAUTION:
2) Place the drive shaft in a vise.
CAUTION:
Do not place the drive shaft directly in the vise;
use wooden blocks.
3) Apply a coat of specified grease [60 to 70 g (2.12
to 2.47 oz)] to BJ.
4) Apply an even coat of specified grease [20 to 30
g (0.71 to 1.06 oz)] to the entire inner surface of
boot. Also apply grease to the shaft.
(A) Boot
(B) Small boot band
(C) Shaft
8) Tighten the boot bands using ST, torque wrench

and socket flex handle.
ST 28099AC000 BOOT BAND PLIER
NOTE:
The inside of the larger end of BJ boot and boot
groove shall be cleaned so as to be free from
grease and other substances.
5) Install the boot projecting portion to BJ groove.
B4M0693C
(A)
(B)
(C)
(D)
(E)
B4M2217B
(A) BJ
(B) Large boot band
(C) Boot
6) Set the large boot band in place.
Large boot band

Boot
Torque wrench
Socket flex handle
BJ
Tightening torque:
Large boot band
157 Nm (16.0 kgf-m, 116 ft-lb) or more
Small boot band
133 Nm (13.6 kgf-m, 98 ft-lb) or more
9) Place the SFJ boot at the center of shaft.
10) Align the alignment marks, and then install the
trunnion on shaft.
B4M0778
DS-36
FRONT DRIVE SHAFT

DRIVE SHAFT SYSTEM
11) Install the snap ring to shaft.

CAUTION:
Confirm that the snap ring is completely fitted
in the shaft groove.
12) Fill 100 to 110 g (3.53 to 3.88 oz) of specified
grease into the interior of SFJ outer race.
13) Apply a coat of specified grease to the free ring
and trunnion.
14) Align the alignment marks on free ring and trunnion, and then install the free ring.
CAUTION:
Be careful with the free ring position.
17) Apply an even coat of the specified grease 30

to 40 g (1.06 to 1.41 oz) to the entire inner surface
of boot.
18) Install the SFJ boot taking care not to twist it.
CAUTION:
The inside of the larger end of SFJ boot and
boot groove shall be cleaned so as to be free
from grease and other substances.
When installing the SFJ boot, position the
outer race of SFJ at center of its travel.
19) Put a band through the clip and wind twice in
alignment with band groove of boot.
CAUTION:
Use a new band.
20) Pinch the end of band with pliers. Hold the clip
and tighten securely.
NOTE:
When tightening the boot, exercise care so that air
within the boot is appropriate.
21) Tighten the band by using ST.
ST 925091000
BAND TIGHTENING TOOL
NOTE:
Tighten the band until it cannot be moved by hand.
B4M0777
G4M0289
15) Align the alignment marks on shaft and outer

race, and then install the outer race.
22) Tap on the clip with punch provided at the end

of ST.
ST 925091000
CAUTION:
Tap to an extent that the boot underneath is not
damaged.
B4M0774
16) Install the circlip in the groove on SFJ outer

race.
CAUTION:
Pull the shaft lightly and assure that the circlip
is completely fitted in the groove.
DS-37
G4M0290
FRONT DRIVE SHAFT

DRIVE SHAFT SYSTEM
23) 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.
24) Fix up the boot on BJ in the same manner.
NOTE:
Extend and retract the SFJ to provide equal grease
coating.
E: INSPECTION
Check the removed parts for damage, wear, corrosion etc. If faulty, repair or replace.
1) DOJ (Double Offset Joint)
Check seizure, corrosion, damage, wear and excessive play.
2) SFJ (Shudder-less Freering tripod Joint)
Check seizure, corrosion, damage and excessive
play.
3) Shaft
Check excessive bending, twisting, damage and
wear.
4) BJ (Bell Joint)
play.
5) Boot
Check for wear, warping, breakage or scratches.
6) Grease
Check for discoloration or fluidity.
DS-38
REAR DRIVE SHAFT

DRIVE SHAFT SYSTEM
6. Rear Drive Shaft
B: INSTALLATION
A: REMOVAL
1) Insert the BJ into rear hub splines.

2) Lift-up the vehicle, and remove the rear wheel
cap and wheels.
CAUTION:
5) Remove the rear differential assembly.
With T-type
With VA-type
VA-type.>
6) Remove the axle nut and drive shaft. If it is hard
to remove, use the ST1 and ST2.
PLATE
CAUTION:
Be careful not to damage the tone wheel when
CAUTION:
Be careful not to damage the tone wheel.
2) Using the ST1 and ST2, pull the drive shaft into
place.
ST1 922431000 AXLE SHAFT INSTALLER
CAUTION:
Do not hammer the drive shaft when installing
it.
B4M1690A
3) Tighten the axle nut temporarily.

4) Install the rear differential.
With T-type
for T-type.>
With VA-type
for VA-type.>
axle nut using a socket wrench.
Tightening torque:
235 Nm (24 kgf-m, 174 ft-lb)
B4M1685A
CAUTION:
Use a new axle nut for rear use only.
DS-39
REAR DRIVE SHAFT

DRIVE SHAFT SYSTEM
C: DISASSEMBLY
7) Wipe off the grease, and then take out the balls.
1) Straighten the bent claw of larger end of DOJ

boot.
2) Loosen the band by means of screwdriver or pliers with care of not damaging boot.
CAUTION:
The grease is a special grease (grease for constant velocity joint). Do not confuse with other
greases.
NOTE:
Disassemble with exercising care not to lose balls
(6 pcs).
G4M0281
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 neck
of DOJ outer race with a screwdriver.
B4M0227E
(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, by using pliers.
10) Take out the DOJ inner race.
11) Take off the DOJ cage from shaft and remove
DOJ boot.
G4M0282
6) Take out the DOJ outer race from shaft assembly.
CAUTION:
12) Remove the BJ boot in same procedure as
DOJ boot.
13) Thus, disassembly of axle is completed, but the
BJ is unable to be disassembled.
DS-40
REAR DRIVE SHAFT

DRIVE SHAFT SYSTEM
D: ASSEMBLY
5) Install the cage, which was previously fitted, to

inner race fixed upon shaft.
CAUTION:
Use specified grease.
NOTE:
Fit the cage with protruded part aligned with the
track on inner race, and then turn by a half pitch.
BJ side:
Molylex No. 2 (Part No. 723223010)
DOJ side:
VU-3A702 (Yellow) (Part No. 23223GA050)
1) Install the BJ boot in specified position, and fill it
with 60 to 70 g (2.12 to 2.47 oz) of specified grease.
2) Place the DOJ boot at the center of shaft.
CAUTION:
3) Insert the DOJ cage onto shaft.
B4M0228E
NOTE:
Insert the cage with cut-out portion facing the shaft
end, since the cage has an orientation.
(A) Inner race

(B) Cage
6) Fill 80 to 90 g (2.82 to 3.17 oz) of specified

grease into the interior of DOJ outer race.
7) Apply a coat of specified grease to the cage
pocket and six balls.
8) Insert six balls into the cage pocket.
9) Align the outer race track and ball positions and
place in the part where shaft, inner race, cage and
balls are previously installed, and then fit outer
race.
S4M0376B
(A) Cage
(B) Cut-out portion
4) Install the DOJ inner race on shaft and fit snap

ring with pliers.
NOTE:
Confirm that the snap ring is completely fitted in
shaft groove.
B4M0227E
(A) Outer race

(B) Grease
G4M0285
DS-41
REAR DRIVE SHAFT

DRIVE SHAFT SYSTEM
10) Install the circlip in the groove on DOJ outer

race.
NOTE:
Assure that the balls, cage and inner race are
completely fitted in the outer race of DOJ.
Exercise care not to place the matched position
of circlip in the ball groove of outer race.
Pull the shaft lightly and assure that the circlip is
completely fitted in the groove.
16) 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.
G4M0290
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.
G4M0282
11) Apply an even coat of the specified grease [20

to 30 g (0.71 to 1.06 oz)] to the entire inner surface
of boot. Also apply grease to shaft.
12) Install the DOJ boot taking care not to twist it.
NOTE:
The inside of the larger end of DOJ boot and boot
groove shall be cleaned so as to be free from
grease and other substances.
When installing the DOJ boot, position the outer
race of DOJ at center of its travel.
13) Put a band through the clip and wind twice in
alignment with band groove of boot.
CAUTION:
Use a new band.
14) Pinch the end of band with pliers. Hold the clip
and tighten securely.
NOTE:
When tightening the boot, exercise care so that air
within the boot is appropriate.
15) Tighten the band by using ST.
ST 925091000
NOTE:
Tighten the band until it cannot be moved by hand.
CAUTION:
Be careful so that the end of the band is in close
contact with clip.
18) Fix up the boot on BJ in the same manner.
NOTE:
Extend and retract the DOJ to provide equal grease
coating.
E: INSPECTION
Check the removed parts for damage, wear, corrosion etc. If faulty, repair or replace.
1) DOJ (Double Offset Joint)
Check seizure, corrosion, damage, wear and excessive play.
2) SFJ (Shudder-less Freering tripod Joint)
play.
3) Shaft
Check excessive bending, twisting, damage and
wear.
4) BJ (Bell Joint)
play.
5) Boot
Check for wear, warping, breakage or scratches.
6) Grease
Check for discoloration or fluidity.
G4M0289
DS-42

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
1. Vibration of propeller shaft
NOTE:
Vibration is caused by propeller shaft during operation and is transferred to vehicle
body. Generally vibration increase in proportion to vehicle speed.
2. Tapping when starting and noise
while cruising, caused by propeller
shaft.
Possible cause
(1) Worn or damaged universal joint.
(2) Unbalanced propeller shaft due to
bend or dent.
(3) Loose installation of propeller shaft.
(4) Worn or damaged center bearing and
damaged center mounting rubber.
(1) Worn or damaged universal joint.
(2) Worn spline of sleeve yoke.
(3) Loose installation of propeller shaft.
(4) Loose installation of joint.
(5) Worn or damaged center bearing and
damaged center mounting rubber.
DS-43
Remedy
Replace.
Replace.
Retighten.
Replace.
Replace.
Replace.
Retighten.
Replace.
Replace.

DRIVE SHAFT SYSTEM
DS-44
ABS
ABS
1.
2.
3.
4.
5.
6.
7.
8.
Page
ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)................7
ABS Sequence Control .............................................................................11
Front ABS Sensor .....................................................................................14
Rear ABS Sensor......................................................................................17
Front Tone Wheel .....................................................................................20
Rear Tone Wheel ......................................................................................21
G Sensor ...................................................................................................22
GENERAL DESCRIPTION
ABS
A: SPECIFICATIONS
Item
ABS sensor gap
ABS sensor resistance
ABS sensor
Front
Marks of the harness
Rear
G sensor
G sensor voltage
ABS control module and

hydraulic control unit
(ABSCM&H/U) marks
Rear drum brake model

Rear disc brake model
Front
Rear
Front
Rear
RH
LH
RH
LH
AT
MT
AT
MT
ABS-2
Standard or remarks
0.3 0.8 mm (0.012 0.031 in)
0.7 1.2 mm (0.028 0.047 in)
1.250.25 k
1.00.2 k
White
Yellow
Light blue
Brown
2.30.2 V
CC
CD
CM
CN
GENERAL DESCRIPTION
ABS
B: COMPONENT
1. SENSOR
BR0001
(1)
(2)
(3)
G sensor
Rear ABS sensor RH
ABS spacer
(4)
(5)
(6)
Rear ABS sensor LH

Front ABS sensor LH
Front ABS sensor RH
ABS-3

T1: 7.4 (0.75, 5.4)
T2: 32 (3.3, 24)
GENERAL DESCRIPTION
ABS
2. ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
BR0092
(1)
(2)
(3)
Stud bolt
Damper
ABS control module and hydraulic control unit
(4)
(5)
Front-LH outlet
Secondary inlet
(6)
(7)
(8)
(9)
(10)
Front-RH outlet
Primary inlet
Rear-LH outlet
Rear-RH outlet
Bracket
ABS-4

T1:
18 (1.8, 13.0)
T2:
29 (3.0, 21.7)
T3:
32 (3.3, 24)
GENERAL DESCRIPTION
ABS
C: CAUTION
points.
cable from battery.
ABS-5
GENERAL DESCRIPTION
ABS
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
24082AA190
DESCRIPTION
CARTRIDGE
REMARKS
SELECT MONITOR
KIT

B2M3876
22771AA030
B2M3877

TOOL NAME
Circuit tester
Pressure gauge
Oscilloscope
REMARKS
Used for measuring oil pressure.
ABS-6
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) Remove the air intake duct from engine compartment to facilitate removal of ABSCM&H/U.
3) Use an air gun to get rid of water around the
ABSCM&H/U.
CAUTION:
Contact will be insufficient if the terminal gets
wet.
4) Pull off the lock of ABSCM&H/U connector to remove it.
8) Remove the ABSCM&H/U from engine compartment.

CAUTION:
ABSCM&H/U cannot be disassembled. Do
not attempt to loosen bolts and nuts.
Do not drop or bump the ABSCM&H/U.
Do not turn the ABSCM&H/U upside down or
place it on its side.
Be careful to prevent foreign particles from
getting into ABSCM&H/U.
Apply a coat of rust-preventive wax (Nippeco
LT or GB) to the bracket attaching bolt after
tightening.
Do not pull the harness when disconnecting
the connector.
B4M1222
B4M1224
5) Disconnect the connector from ABSCM&H/U.

CAUTION:
Be careful not to let water or other foreign matter contact the ABSCM&H/U terminal.
6) Unlock the cable clip.
7) Disconnect the brake pipes from ABSCM&H/U.
CAUTION:
Wrap brake pipes with vinyl bag to avoid spilling brake fluid on vehicle body.
ABS-7

ABS
B: INSTALLATION
C: INSPECTION
1) Install the ABSCM&H/U bracket.
1) Check the connected and fixed condition of connector.

2) Check specifications of the mark with
ABSCM&H/U.
Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
2) Install the ABSCM&H/U.
Mark
CC
CD
CM
CN
CAUTION:
Confirm that the specifications of the
ABSCM&H/U conforms to the vehicle specifications.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
Model
AT (Rear drum brake)
MT (Rear drum brake)
AT (Rear disc brake)
MT (Rear disc brake)
(1)
BR0051
B4M1222
(1) Mark
3) Connect the brake pipes to their correct

ABSCM&H/U connections.
Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
4) Using the cable clip, secure the ABSCM&H/U
harness to bracket.
5) Connect the connector to ABSCM&H/U.
CAUTION:
Be sure to remove all foreign matter from inside of the connector before connecting.
Ensure that the ABSCM&H/U connector is securely locked.
7) Bleed air from the brake system.
1. CHECKING THE HYDRAULIC UNIT ABS

OPERATION BY PRESSURE GAUGE
1) Lift-up the vehicle and 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 employ pressure gauge previously
used for transmission since the piston seal is
expanded which may lead to malfunction of the
brake.
NOTE:
Wrap sealing tape around the pressure gauge.
B4M1732
ABS-8

ABS
4) Bleed air from the pressure gauges.

5) Perform the ABS sequence control.
<Ref. to ABS-11, ABS Sequence Control.>
6) When the hydraulic unit begins to work, and first
the FL side performs decompression, holding, and
compression, and then the FR side performs decompression, holding, and compression.
7) Read values indicated on the pressure gauge
and check if the fluctuation of the values between
decompression and compression meets the standard values. Also check if any irregular brake pedal
tightness is felt.
Initial value
When
decompressed
When
compressed
Front wheel
3,432 kPa
(35 kgf/cm2, 498
psi)
490 kPa
(5 kgf/cm2, 71 psi)
or less
3,432 kPa
(35 kgf/cm2, 498
psi)
or more
Rear wheel
3,432 kPa
(35 kgf/cm2, 498
psi)
490 kPa
(5 kgf/cm2, 71 psi)
or less
3,432 kPa
(35 kgf/cm2, 498
psi)
or more
2. CHECKING THE HYDRAULIC UNIT ABS

OPERATION WITH BRAKE TESTER
1) In the case of AWD AT vehicles, install a spare
fuse with the FWD connector in the main fuse box
to simulate FWD vehicles.
BR0093
(1) Main fuse box

(2) FWD connector
8) Remove the pressure gauges from FL and FR

caliper bodies.
9) Remove the air bleeder screws from the RL and
RR caliper bodies.
10) Connect the air bleeder screws to the FL and
FR caliper bodies.
11) Connect two pressure gauges to the RL and
RR caliper bodies.
12) Bleed air from the pressure gauges and the FL
and FR caliper bodies.
14) When the hydraulic unit begins to work, at first
the RR side performs decompression, holding, and
compression, and then the RL side performs decompression, holding, and compression.
15) Read values indicated on the pressure gauges
and check if they meet the standard value.
16) After checking, remove the pressure gauges
from caliper bodies.
17) Connect the air bleeder screws to RL and RR
caliper bodies.
18) Bleed air from the brake line.
2) Prepare for operating the ABS sequence control.

3) Set the front wheels or rear wheels on the brake
tester and set the select levers position at N
range.
B4M1733B
B4M1730B
(1) Brake tester
4) Operate the brake tester.

6) Hydraulic unit begins to work; and check the following working sequence.
ABS-9

ABS
(1) The FL wheel performs decompression,

holding, and compression in sequence, and
subsequently the FR wheel repeats the cycle.
(2) The RR wheel performs decompression,
holding, and compression in sequence, and
subsequently the RL wheel repeats the cycle.
7) Read values indicated on the brake tester and
check if the fluctuation of values, when decompressed and compressed, meet the standard values.
Initial value
When
decompressed
When
compressed
Front wheel
981 N
(100 kgf, 221 lb)
490 N
(50 kgf, 110 lb)
or less
981 N
(100 kgf, 221 lb)
or more
Rear wheel
981 N
(100 kgf, 221 lb)
490 N
(50 kgf, 110 lb)
or less
981 N
(100 kgf, 221 lb)
or more
8) After checking, also check if any irregular brake

pedal tightness is felt.
ABS-10
ABS SEQUENCE CONTROL

ABS
3. ABS Sequence Control
2. ABS SEQUENCE CONTROL WITH SELECT MONITOR
A: OPERATION
1) Under the ABS sequence control, after the hydraulic unit solenoid valve is driven, the operation
of the hydraulic unit can be checked by means of
the brake tester or pressure gauge.
2) ABS sequence control can be started by diagnosis connector or select monitor.
1. ABS SEQUENCE CONTROL WITH DIAGNOSIS CONNECTOR

1) Connect the diagnosis terminals to terminals No.
3 and No. 6 of the diagnosis connector beside drivers seat.
(1)
(2)
(1)
(2)
(3)
(4)
(3)
(4)
BR0110
Diagnosis connector
Diagnosis terminals
Terminal 3
Terminal 6
2) Set the speed of all wheels at 4 km/h (2 MPH) or

less.
4) Within 0.5 seconds after the ABS warning light
goes out, depress the brake pedal and hold it immediately after ignition switch is turned to ON.
NOTE:
In the event of any trouble, the sequence control
may not be operative. In such a case, activate the
sequence control, referring to ABS SEQUENCE
CONTROL WITH DIAGNOSIS CONNECTOR.
<Ref. to ABS-11, ABS SEQUENCE CONTROL
WITH DIAGNOSIS CONNECTOR, ABS Sequence
Control.>
When the diagnosis terminal is connected to the
diagnosis connector, the sequence control will not
operate.
1) Connect the select monitor to data link connector under drivers seat instrument panel lower cover.
2) Turn the ignition switch to ON.
3) Turn the select monitor switch to ON.
4) Put the select monitor to BRAKE CONTROL
mode.
5) When Function check sequence is selected,
ABS sequence control will start.
6) The message Press Brake Pedal Firmly is displayed as follows:
(1) When using the brake tester, depress the
brake pedal with braking force of 981 N (100 kgf,
221 lb).
(2) When using the pressure gauge, depress
the brake pedal so as to make the pressure
gauge indicate 3,432 kPa (35 kg/cm2, 498 psi).
CAUTION:
Do not depress the clutch pedal.
7) When the message Press YES is displayed,
press the YES key.
8) Operation points will be displayed on select
monitor.
CAUTION:
Do not depress the clutch pedal.
NOTE:
When the ignition switch is set to on, the brake
pedal must not be depressed.
Engine must not operate.
5) After completion of ABS sequence control, turn
the ignition switch to OFF.
ABS-11

ABS
3. CONDITIONS FOR ABS SEQUENCE CONTROL
B4M1001A
NOTE:
When the select monitor is used, control operation starts at point A. The patterns from IGN key ON to the
point A show that operation is started by diagnosis connector.
HIGH means high voltage.
LOW means low voltage.
ABS-12

ABS
B: SPECIFICATION
1. CONDITIONS FOR COMPLETION OF
When the following conditions develop, the ABS
sequence control stops and ABS operation is returned to the normal control mode.
1) When the speed of at least one wheel reaches
10 km/h (6 MPH).
2) When terminal No. 3 or No. 6 are separated from
diagnosis terminals. (When the select monitor is
not used.)
3) When the brake pedal is released during sequence control and the braking lamp switch is set
to off.
4) When the brake pedal is depressed after ignition
key is turned to ON, and before ABS warning light
goes out. (When the select monitor is not used.)
5) When the brake pedal is not depressed after ignition key is turned to ON, and within 0.5 seconds
after ABS warning light goes out. (When the select
monitor is not used.)
6) After completion of the sequence control.
7) When malfunction is detected. (When the select
monitor is used.)
ABS-13
FRONT ABS SENSOR

ABS
4. Front ABS Sensor
B: INSTALLATION
A: REMOVAL
1) Temporarily install the front ABS sensor on

housing.

2) Disconnect the front ABS sensor connector located next to the front strut mounting house in engine compartment.
3) Remove the bolts which secure sensor harness
to strut.
CAUTION:
Be careful not to strike the ABS sensor's pole
piece and tone wheel's teeth against adjacent
metal parts during installation.
B4M2209
B4M1442
4) Remove the bolts which secure sensor harness

to body.
2) Install the front ABS sensor on strut and wheel

apron bracket.
Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
B4M1728C
B4M1728C
(1) To front ABS sensor connector

(2) Bracket
5) Remove the bolts which secure front ABS sensor to housing, and remove the front ABS sensor.
CAUTION:
Be careful not to damage the pole piece located at tip of the sensor and teeth faces during removal.
Do not pull the sensor harness during removal.
B4M2209
ABS-14
(1) To front ABS sensor connector

(2) Bracket
FRONT ABS SENSOR

ABS
3) Place a thickness gauge between ABS sensors

and tone wheels tooth face. After standard clearance is obtained over the entire perimeter, tighten
the ABS sensor on housing to specified torque.
ABS sensor standard clearance:
0.3 0.8 mm (0.012 0.031 in)
Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
C: INSPECTION
1. ABS SENSOR
1) Check the pole piece of ABS sensor for foreign
particles or damage. If necessary, clean the pole
piece or replace ABS sensor.
2) Measure the ABS sensor resistance.
B4M0248
B4M2209
CAUTION:
Check the marks on the harness to make sure
that no distortion exists.
RH: White
LH: Yellow
NOTE:
If the clearance is outside specifications, readjust.
4) After confirmation of the ABS sensor clearance,
connect the connector to ABS sensor.
Terminal No.
1 and 2
Standard
1.250.25 k
CAUTION:
If resistance is outside the standard value, replace the ABS sensor with a new one.
NOTE:
Check the ABS sensor cable for discontinuity. If
necessary, replace with a new one.
2. SENSOR GAP
1) Measure the distance A between ABS sensor
surface and sensor pole face.
B4M2482A
ABS-15
FRONT ABS SENSOR

ABS
2) Measure the distance B between surface

where the front axle housing meets the ABS sensor, and the tone wheel.
NOTE:
Measure so that the gauge touches the tone wheel
teeth top.
3. OUTPUT VOLTAGE
Output voltage can be checked by the following
method. Install the resistor and condenser, then rotate the wheel about 2.75 km/h (2 MPH) or equivalent.
NOTE:
Regarding terminal No., please refer to item 1. ABS
SENSOR.
S4M0510A
(1) Axle housing

(2) Tone wheel
3) Find the gap between the ABS sensor pole face

and the surface of the tone wheel teeth by putting
the measured values in the formula below and calculating.
ABS sensor clearance = B A
0.3 0.8 mm (0.012 0.031 in)
NOTE:
H4M1141A
D: ADJUSTMENT
Adjust the gap using spacer (Part No. 26755A000).
ABS-16
REAR ABS SENSOR

ABS
5. Rear ABS Sensor
B: INSTALLATION
A: REMOVAL
1) Install the rear tone wheel on hub, then rear

housing on hub.<Ref. to DS-30, ASSEMBLY, Rear
Axle.>
2) Temporarily install the rear ABS sensor on back
plate.

3) Remove the rear seat and disconnect the rear
ABS sensor connector.
4) Remove the rear sensor harness bracket from
the rear trailing link and bracket.
5) Remove the rear ABS sensor from back plate.
CAUTION:
Be careful not to strike the ABS sensor's pole
piece and tone wheel's teeth against adjacent
metal parts during installation.
BR0095
BR0095
(1) Rear ABS sensor
(1) Rear ABS sensor
6) Remove the rear tone wheel while removing the

hub from housing and hub assembly.<Ref. to DS24, REMOVAL, Rear Axle.>
CAUTION:
Be careful not to damage the pole piece located at tip of the sensor and teeth faces during removal.
Do not pull the sensor harness during removal.
3) Install the rear drive shaft to rear housing and

rear differential spindle.<Ref. to DS-27, INSTALLATION, Rear Axle.>
4) Install the rear sensor harness on rear trailing
link.
Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
BR0096
(1) Rear sensor harness

(2) Trailing link
ABS-17
REAR ABS SENSOR

ABS
5) Place a thickness gauge between ABS sensors

and tone wheels tooth face. After standard clearance is obtained over the entire perimeter, tighten
the ABS sensor on rear arm to specified torque.
0.7 1.2 mm (0.028 0.047 in)
Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
CAUTION:
that no distortion exists. (RH: white, LH: yellow)
NOTE:
6) After confirmation of the ABS sensor clearance,
connect the connector to ABS sensor.
2. SENSOR GAP
Clearances (sensor gaps) should be measured one
by one to ensure that tone wheel and speed sensor
are installed correctly.
NOTE:
If clearance is narrow, adjust by using spacer
(Part No. 26755AA000).
If clearance is wide, check the outputted voltage
then replace the ABS sensor or tone wheel if the
outputted voltage is outside specification.
ABS sensor clearance:
0.7 1.2 mm (0.028 0.047 in)
Tone wheel
C: INSPECTION
1. ABS SENSOR
1) Check the pole piece of ABS sensor for foreign
particles or damage. If necessary, clean the pole
piece or replace ABS sensor.
2) Measure the ABS sensor resistance.
ABS sensor
Sensor gap
BR0002
3. OUTPUT VOLTAGE
Output voltage can be checked by the following
method. Install the resistor and condenser, then rotate the wheel about 2.75 km/h (2 MPH) or equivalent.
NOTE:
Regarding terminal No., please refer to item 1. ABS
SENSOR.
B4M0248
Terminal No.
1 and 2
Standard
1.00.2 k
CAUTION:
If resistance is outside the standard value, replace the ABS sensor with a new one.
that no distortion exists.
RH: Light blue
LH: Brown
NOTE:
Check the ABS sensor cable for discontinuity. If
necessary, replace with a new one.
H4M1141A
ABS-18
REAR ABS SENSOR

ABS
D: ADJUSTMENT
Adjust the gap
26755AA000).
using
spacer
(Part
No.
ABS-19
FRONT TONE WHEEL

ABS
6. Front Tone Wheel

A: REMOVAL
Refer to Front Drive Shaft, because front tone
wheel is integrated with front drive shaft.
<Ref. to DS-33, REMOVAL, Front Drive Shaft.>
B: INSTALLATION
Refer to Front Drive Shaft, because front tone
wheel is integrated with front drive shaft.
<Ref. to DS-33, INSTALLATION, Front Drive
Shaft.>
C: INSPECTION
Visually check the tone wheels teeth (44 pieces)
for cracks or dents. If necessary, replace the tone
wheel with a new one.
NOTE:
Replace the BJ assembly with a new one as a single unit if there are any defects found on tone wheel
is unitized with BJ assembly of drive shaft.
ABS-20
REAR TONE WHEEL

ABS
7. Rear Tone Wheel

A: REMOVAL
Refer to Rear Drive Shaft, because rear tone wheel
is integrated with hub.
<Ref. to DS-39, REMOVAL, Rear Drive Shaft.>
B: INSTALLATION
Refer to Rear Drive Shaft, because rear tone wheel
is integrated with hub.
<Ref. to DS-39, INSTALLATION, Rear Drive
Shaft.>
C: INSPECTION
Visually check the tone wheels teeth (44 pieces)
for cracks or dents. If necessary, replace the tone
wheel with a new one.
ABS-21
G SENSOR
ABS
8. G Sensor
A: REMOVAL
G6M0095
2) Remove the console cover.

<Ref. to EI-40, 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.
BR0053
B: INSTALLATION
CAUTION:
Do not drop or bump the G sensor.
ABS-22
G SENSOR
ABS
C: INSPECTION
1
2
Step
CHECK SUBARU SELECT MONITOR.
CHECK G SENSOR.
2)Remove the G sensor from vehicle.
3)Connect the connector to G sensor.
5)Measure the voltage between G sensor connector terminals.
(R70) No. 2 (+) No. 3 ()
CHECK G SENSOR.
Measure the voltage between G sensor connector terminals.
(R70) No. 2 (+) No. 3 ()
CHECK G SENSOR.
(R70) No. 2 (+) No. 3 ()
CHECK G SENSOR.
2)Connect the select monitor connector to data
link connector.
3)Turn the select monitor into {BRAKE CONTROL} mode.
4)Set the display in the {Current Data Display
& Save} mode.
5)Read the G sensor output voltage.
CHECK G SENSOR.
1)Remove the console box.
2)Remove the G sensor from vehicle. (Do not
disconnect the connector.)
3)Read the select monitor display.
CHECK G SENSOR.
Read the select monitor display.
Check
Do you have SUBARU
SELECT MONITOR?
Is the voltage 2.30.2 V when
G sensor is horizontal?
Is the voltage 3.90.2 V when

G sensor is inclined forwards
to 90?
Yes
Go to step 5.
No
Go to step 2.
Go to step 3.
Replace the G
sensor.
Go to step 4.
Replace the G
sensor.
Is the voltage 0.70.2 V when G sensor is norG sensor is inclined backwards mal.
to 90?
Replace the G
sensor.
Is the indicated reading

2.30.2 V when the vehicle is
in horizontal position?
Go to step 6.
Replace the G
sensor.

3.90.2 V when G sensor is
inclined forwards to 90?
Go to step 7.
Replace the G
sensor.

0.70.2 V when G sensor is
inclined backwards to 90?
G sensor is normal.
Replace the G
sensor.
ABS-23
G SENSOR
ABS
ABS-24
ABS (DIAGNOSTICS)
ABS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Page
Control Module I/O Signal .........................................................................14
Inspection Mode........................................................................................21
ABS Warning Light Illumination Pattern ....................................................23
List of Diagnostics Trouble Code (DTC) ...................................................24
Diagnostics Chart with Diagnosis Connector ............................................28
Diagnostics Chart with Subaru Select Monitor..........................................92
General Diagnostics Table......................................................................179

ABS (DIAGNOSTICS)

A: PROCEDURE
CAUTION:
Remove foreign matter (dust, water, etc.) from the ABSCM&H/U connector during removal and installation.
NOTE:
To check the harness for broken wires or short circuits, shake it while holding it or the connector.
When the ABS warning light illuminates, read and record the diagnostic trouble code (DTC) indicated by
ABS warning light.
Step
Check
Yes
the ABS problem normal?
ABS-6, Check List for Interview.>
2)Before performing diagnosis, inspect the unit
which might influence ABS problem. <Ref. to
ABS-9, INSPECTION, General Description.>
Is any DTC readable?
Go to step 3.
TROUBLE CODE (DTC).
Calling up the DTC. <Ref. to ABS-20, Read

(DTC).
Is only the start code issued?
NOTE:
Record all DTCs.
PERFORM THE GENERAL DIAGNOSTICS. Is only the start code issued?
1)Inspect using General Diagnostics Table.
<Ref. to ABS-179, General Diagnostics
Table.>
ABS-22, WITHOUT SUBARU SELECT MONITOR, OPERATION, Clear Memory Mode.>
3)Perform the inspection mode. <Ref. to ABS21, Inspection Mode.>
Calling up the DTC. <Ref. to ABS-20, Read
ABS-2
Go to step 4.
Complete the
diagnosis.
No
Repair or replace
each unit.
Inspect using diagnostic chart for

ABS warning light
failure.<Ref. to
ABS-28, Diagnostics Chart with
Diagnosis Connector.>
NOTE:
Call up DTC again
after
inspecting
ABS warning light.
<Ref. to ABS-20,
Read Diagnostic
Trouble
Code
(DTC).>
Go to step 5.
Go to step 5.

ABS (DIAGNOSTICS)
Step
1)Inspect using Diagnostics Chart with Diagnostic Connector.<Ref. to ABS-28, Diagnostics Chart with Diagnosis Connector.>
Check
Is only the start code issued?
NOTE:
For DTC list, refer to List of Diagnostics Trouble Code (DTC).<Ref. to ABS-24, WITHOUT
SUBARU SELECT MONITOR, LIST, List of Diagnostics Trouble Code (DTC).>
2)Repair trouble cause.
ABS-22, WITHOUT SUBARU SELECT MONITOR, OPERATION, Clear Memory Mode.>
5)Calling up the DTC. <Ref. to ABS-20, Read
ABS-3
Yes
Complete the
diagnosis.
No
Inspect using
Diagnostics Chart
with Diagnostic
Connector. <Ref.
to ABS-28, Diagnostics Chart with

ABS (DIAGNOSTICS)

CAUTION:
Remove foreign matter (dust, water, etc.) from the ABSCM&H/U connector during removal and installation.
NOTE:
To check the harness for broken wires or short circuits, shake it while holding it or the connector.
Check list for interview. <Ref. to ABS-6, Check List for Interview.>
Step
ABS-6, Check List for Interview.>
2)Before performing diagnosis, inspect the unit
which might influence the ABS problem. <Ref.
to ABS-9, INSPECTION, General Description.>
TROUBLE CODE (DTC) DISPLAY.
2)Connect the SUBARU SELECT MONITOR
to data link connector.
3)Turn the ignition switch to ON and SUBARU
SELECT MONITOR to ON.
Check
Yes
the ABS problem normal?
No
Repair or replace
each unit.
Is the corresponding trouble

encoding?
Go to step 3.
Go to step 4.
NOTE:
If the communication function of select monitor
cannot be executed normally, check communication circuit. <Ref. to ABS-92, COMMUNICATION FOR INITIALIZING IMPOSSIBLE,
Diagnostics Chart with Subaru Select Monitor.>
4)Read the DTC. <Ref. to ABS-19, READ
CURRENT DATA, OPERATION, Subaru
Select Monitor.>
5)Record all DTCs and frame data.
PERFORM THE GENERAL DIAGNOSTICS. Is no DTC designated and
Complete the
1)Inspect using General Diagnostics Table. does the ABS warning light go diagnosis.
<Ref. to ABS-179, General Diagnostics
out after turning on?
Table.>
ABS-19, CLEAR MEMORY MODE, OPERATION, Subaru Select Monitor.>
4)Calling up the DTC. <Ref. to ABS-18, READ
DIAGNOSTIC TROUBLE CODE (DTC),
OPERATION, Subaru Select Monitor.>
Go to step 4.
ABS-4

ABS (DIAGNOSTICS)
Step
Check
Yes
Is no DTC designated and
Complete the
1)Inspect using Diagnostics Chart with Sub- does the ABS warning light go diagnosis.
aru Select Monitor.<Ref. to ABS-92, Diagnos- out after turning on?
tics Chart with Subaru Select Monitor.>
NOTE:
For DTC list, refer to List of Diagnostics Trouble Code (DTC).<Ref. to ABS-24, WITHOUT
SUBARU SELECT MONITOR, LIST, List of Diagnostics Trouble Code (DTC).>
2)Repair trouble cause.
ABS-19, CLEAR MEMORY MODE, OPERATION, Subaru Select Monitor.>
5)Calling up the DTC. <Ref. to ABS-18, READ
DIAGNOSTIC TROUBLE CODE (DTC),
OPERATION, Subaru Select Monitor.>
ABS-5
No
Inspect using
Diagnostics Chart
with Subaru Select
Monitor. <Ref. to
ABS-92, Diagnostics Chart with
Subaru Select
Monitor.>

ABS (DIAGNOSTICS)

A: CHECK
Check the following items about the vehicle's state.
1. STATE OF ABS WARNING LIGHT

ABS warning light
comes on.
Ignition key position
Timing
Always
Sometimes
Only once
Does not come on
When / how long does it come on?:
LOCK
ACC
ON (before starting engine)
START
On after starting (Engine is running)
On after starting (Engine is stop)
Immediately after ignition is ON.
Immediately after ignition starts.
When advancing
km/h to
MPH to
While traveling at a constant speed

When decelerating
When turning to right
km/h
km/h to
MPH to
Steering angle :
Steering time :
Steering angle :
Steering time :
When turning to left

When moving other electrical parts
Parts name :
Operating condition :
ABS-6
km/h
MPH
MPH
km/h
MPH
deg
sec
deg
sec

ABS (DIAGNOSTICS)
2. SYMPTOMS
ABS operating condi- Performs no work.
tion
Operates only when abruptly applying brakes.
How to step on brake pedal :
a) Operating time :
b) Operating noise : Produce / Does not produce
What kind of noise?
Vehicle speed :
sec
Knock
Gong gong
Bong
Buzz
Gong gong buzz
Others :
c) Reaction force of brake pedal
Behavior of vehicle
Stick
Press down once with a clunk
Press and released
Others :
a) Directional stability cannot be obtained or steering arm refuses to work when applying brakes :
Yes / No
When :
Vehicle turns to right
Vehicle turns to left
Spins
Others :
b) Directional stability cannot be obtained or steering arm refuses to work when accelerating :
Yes / No
When :
Vehicle turns to right
Vehicle turns to left
Spins
Others :
c) Brakes are out of order : Yes / No
What :
Braking distance is long
Brakes lock or drag
Pedal stroke is long
Pedal sticks
Others :
d) Poor acceleration : Yes / No
What :
Fails to accelerate
Engine stalls
Others :
e) Occurrence of vibration : Yes / No
Where
What kind :
f) Occurrence of abnormal noise : Yes / No
Where
What kind :
g) Occurrence of other phenomena : Yes / No
What kind :
ABS-7
km/h
MPH

ABS (DIAGNOSTICS)
3. CONDITIONS UNDER WHICH TROUBLE OCCURS

Environment
Fine
Cloudy
Rainy
Snowy
Various/Others :
a) Weather
F (C)
b) Ambient temperature
c) Road
Urban area
Suburbs
Highway
General road
Ascending slope
Descending slope
Paved road
Gravel road
Muddy road
Sandy place
Others :
Dry
Wet
New-fallen snow
Compressed snow
Frozen slope
Others :
Deceleration :
Continuous / Intermittent
Acceleration :
Continuous / Intermittent
km/h
Advancing
Accelerating
Reducing speed
Low speed
Turning
Others :
Front RH tire :
Front LH tire :
Rear RH tire :
Rear LH tire :
Front RH tire :
Front LH tire :
Rear RH tire :
Rear LH tire :
d) Road surface
Condition
a) Brakes
b) Accelerator
c) Vehicle speed
d) Tire inflation pressure
e) Degree of wear
f) Genuine parts are used. : Yes / No

g) Chain is passed around tires. : Yes / No
h) T tire is used. : Yes / No
i) Condition of suspension alignment :
j) Loading state :
k) Repair parts are used. : Yes / No
What :
l) Others :
ABS-8
g
g
MPH
kPa
kPa
kPa
kPa
GENERAL DESCRIPTION
ABS (DIAGNOSTICS)
B: INSPECTION
A: CAUTION

items which might affect ABS problems:
1. SUPPLEMENTAL RESTRAINT SYSTEM

AIRBAG
1. BATTERY
Airbag system wiring harness is routed near the

ABS sensor, ABS control module and hydraulic
control unit.
CAUTION:
wiring harness when servicing the ABS sensor,
ABS control module and hydraulic control unit.

electrolyte.
Standard voltage: 12 V, or more
2. BRAKE FLUID
1) Check the brake fluid level.
2) Check the brake fluid leakage.
3. HYDRAULIC UNIT
Check the hydraulic unit.
With brake tester <Ref. to ABS-9, CHECKING
THE HYDRAULIC UNIT ABS OPERATION WITH
BRAKE TESTER, INSPECTION, ABS Control
Module and Hydraulic Control Unit (ABSCM&H/
U).>
Without brake tester <Ref. to ABS-8, CHECKING THE HYDRAULIC UNIT ABS OPERATION
BY PRESSURE GAUGE, INSPECTION, ABS
Control Module and Hydraulic Control Unit (ABSCM&H/U).>
4. BRAKE DRAG
Check for brake drag.
5. BRAKE PAD AND ROTOR

Check the brake pad and rotor.
Front <Ref. to BR-23, INSPECTION, Front Brake
Pad.> and <Ref. to BR-26, INSPECTION, Front
Disc Rotor.>
Rear <Ref. to BR-34, INSPECTION, Rear Brake
Pad.> and <Ref. to BR-35, INSPECTION, Rear
Disc Rotor.> or <Ref. to BR-42, INSPECTION,
Rear Drum Brake Shoe.> and <Ref. to BR-43, INSPECTION, Rear Drum Brake Drum.>
6. TIRE
Check the tire specifications, tire wear and air pressure. <Ref. to WT-2, SPECIFICATIONS, General
Description.>
ABS-9
GENERAL DESCRIPTION
ABS (DIAGNOSTICS)
C: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
24082AA190
DESCRIPTION
CARTRIDGE
REMARKS
SELECT MONITOR
KIT

B2M3876
22771AA030
B2M3877

TOOL NAME
Circuit tester
Oscilloscope
REMARKS
ABS-10
GENERAL DESCRIPTION
ABS (DIAGNOSTICS)
ABS-11

ABS (DIAGNOSTICS)

A: LOCATION
BR0119
(1)
ABS control module and hydraulic control unit (ABSCM&H/U)
(6)
Transmission control module (only

AT vehicle)
(2)
(3)
(4)
(5)
Proportioning valve
Diagnosis connector
ABS warning light
Data link connector (for Subaru
Select Monitor)
(7)
(8)
(9)
(10)
Tone wheel
ABS sensor
Wheel cylinder
G sensor
ABS-12
(11)
(12)
(13)
Stop light switch

Master cylinder
Brake warning light

ABS (DIAGNOSTICS)
(13)
(4)
B4M1226B
BR0120
BR0056
B4M0231E
BR0033
BR0057
(5)
(7)
(8)
BR0058
ABS-13
CONTROL MODULE I/O SIGNAL

ABS (DIAGNOSTICS)
5. Control Module I/O Signal

BR0121
1) ABS control module and hydraulic control unit connector

2) Connector switch
NOTE:
The terminal numbers in ABS control module and hydraulic control unit connector are as shown in the figure.
When the connector is removed from ABSCM&H/U, the connector switch closes the circuit between terminal No. 22 and No. 23. The ABS warning light illuminates.
ABS-14

ABS (DIAGNOSTICS)
Contents
ABS sensor*2
(Wheel speed sensor)
Front left wheel

Front right wheel
Rear left wheel
Rear right wheel
Valve relay power supply

Motor relay power supply
G sensor*2
(AWD model only)
Power supply
Ground
Output
910
1112
78
1415
2423
2523
3028
28
628
Stop light switch*1
223
ABS warning light*2
2223
AT ABS signal*2
(AT model only)
3123
ABS operation signal monitor*2
323
Data is received.
Data is sent.
Terminal
No. 3
ABS diagnosis connector*2
Terminal No. 6
Power supply*1
Grounding line
Grounding line
2023
523
2923
423
123
23
26
Select monitor*2
Input/Output signal
Measured value and measuring conditions
Terminal No.
(+)()
0.12 1 V
(When it is 20 Hz.)
10 15 V
10 15 V
4.75 5.25 V
2.30.2 V when vehicle is in horizontal position.

Less than 1.5 V when the stop light is OFF and, 10 15 V
when the stop light is ON.
Less than 1.5 V during 1.5 seconds when ignition switch is ON,
and 10 15 V after 1.5 seconds.
Less than 1.5 V when the ABS control still operates and more
than 5.5 V when ABS does not operate.
Less than 1.5 V when the ABS control still operates and more
than 5.5 V when ABS does not operate.
Less than 1.5 V when no data is received.
4.75 5.25 V when no data is sent.
10 15 V when ignition switch is ON.
*1: Measure the I/O signal voltage after removing the connector from the ABSCM&H/U terminal.
*2: Measure the I/O signal voltage at connector (B200) or (F74).
ABS-15

ABS (DIAGNOSTICS)
B: SCHEMATIC
BR0122
(1)
(2)
(3)
Battery
IGN
ABS control module and hydraulic control unit (ABSCM&H/U)
(4)
(5)
(6)
(7)
(8)
(9)
ABS control module area

Valve relay
Motor relay
Motor
Front left inlet solenoid valve
Front left outlet solenoid valve
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Front right inlet solenoid valve

Front right outlet solenoid valve
Rear left inlet solenoid valve
Rear left outlet solenoid valve
Rear right inlet solenoid valve
Rear right outlet solenoid valve
Transmission control module (only
AT model)
(17)
(18)
Diagnosis connector
Data link connector
ABS-16
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
Brake warning light

ABS warning light
Stop light switch
Stop light
G sensor
Front left ABS sensor
Front right ABS sensor
Rear left ABS sensor
Rear right ABS sensor

ABS (DIAGNOSTICS)
C: WAVEFORM
B4M2526A
ABS-17

ABS (DIAGNOSTICS)

connector.
A: OPERATION
CAUTION:

(DTC)
S2M0285
S2M0288D

Monitor.
<Ref. to ABS-10, SPECIAL TOOLS, PREPARATION TOOL, General Description.>
S2M0286

connector.
(1)
(1) Power switch

screen, select the {Brake Control System} and
press [YES] key.
of engine type.
9) On the ABS Diagnosis display screen, select
the {Diagnostic Code(s) Display} and press [YES]
key.
NOTE:
For detailed concerning the DTC, refer to the
LIST OF DIAGNOSTICS TROUBLE CODE (DTC).
<Ref. to ABS-24, List of Diagnostics Trouble Code
(DTC).>
BR0034
(1) Data link connector
ABS-18

ABS (DIAGNOSTICS)
2. READ CURRENT DATA

1) On the Main Menu display screen, select the {Each System Check} and press YES key.
2) On the System Selection Menu display screen, select the {Brake Control System} and press YES
key.
3) Press the YES key after displayed the information of ABS type.
4) On the Brake Control Diagnosis display screen, select the {Current Data Display & Save} and press
YES key.
5) On the Data Display Menu display screen, select the {Data Display} and press YES key.
Display screen
FR Wheel Speed
FL Wheel Speed
RR Wheel Speed
RL Wheel Speed
Stop Light Switch
Stop Light Switch
G sensor output Signal
Valve Relay Signal
Motor Relay Signal
ABS Signal to TCM
ABS Warning Lamp
Motor Relay Monitor
Valve Relay Monitor
CCM Signal
Contents to be monitored
Wheel speed detected by Front Right ABS sensor is displayed
Wheel speed detected by Front Left ABS sensor is displayed
Wheel speed detected by Rear Right ABS sensor is displayed
Wheel speed detected by Rear Left ABS sensor is displayed
Stop light switch signal
Stop light switch monitor voltage is displayed.
Refers to vehicle acceleration detecting by analog G sensor. It
appears on the select monitor display in volts.
Valve Relay Signal
Motor Relay Signal
ABS operation signal from ABS control module to TCM
ON operation of ABS warning light is displayed.
Operating condition of motor relay is displayed.
Operating condition of the valve relay is displayed.
Unit of measure
km/h or MPH
km/h or MPH
km/h or MPH
km/h or MPH
ON or OFF
V
V
ON or OFF
ON or OFF
ON or OFF
ON or OFF
High or Low
ON or OFF
ON or OFF
NOTE:
3. CLEAR MEMORY MODE

1) On the Main Menu display screen, select the {2. Each System Check} and press YES key.
2) On the System Select Menu display screen, select the {Brake System} and press YES key.
3) Press the YES key after displayed the information of engine type.
4) On the Brake Control Diagnosis display screen, select the {Clear Memory} and press YES key.
5) When the Done and turn ignition switch to OFF are shown on display screen, turn the Subaru Select
NOTE:
ABS-19

ABS (DIAGNOSTICS)
7. Read Diagnostic Trouble

Code (DTC)
A: OPERATION
1) Take out the diagnosis connector from side of
driver's seat.
NOTE:
When there are no DTCs in memory, only the
start code (11) is shown.
When on-board diagnosis of the ABS control
module detects a problem, the information (up to a
maximum of three) will be stored in EEP ROM as a
DTC. When there are more than three, the most recent three will be stored. (Stored codes will stay in
memory until they are cleared.)
(1)
(3)
(2)
(1)
(2)
(3)
(4)

3) Connect the diagnosis connector terminal 6 to
diagnosis terminal.
5) ABS warning light is set in the diagnostic mode
and blinks to identify DTC.
6) After the start code (11) is shown, the DTCs will
be shown in order of the last information first.
These repeat for a maximum of 3 minutes.
(4)
BR0110
Diagnosis connector
Diagnosis terminal
Terminal 3
Terminal 6
Example of DTC indication

DTC: 21
OFF
ON
1.2 sec
2
1.0 sec 1.2 sec
0.3 sec
1.2 sec
0.3 sec
1.0 sec
0.3 sec
DTC: 21
DTC: 21
Start code
DTC: 22,31
ON
OFF
Start code
DTC: 22
DTC: 31
Start code
BR0081

Refer to SUBARU SELECT MONITOR for information about how to obtain and understand DTCs. <Ref. to
ABS-18, Subaru Select Monitor.>
ABS-20
INSPECTION MODE
ABS (DIAGNOSTICS)
8. Inspection Mode
A: OPERATION
Reproduce the condition under which the problem
has occurred as much as possible.
Drive the vehicle at a speed more than 40 km/h (25
MPH) for at least 1 minute.
ABS-21
CLEAR MEMORY MODE

ABS (DIAGNOSTICS)

A: OPERATION
1) After calling up a DTC, disconnect the diagnosis
connector terminal 6 from diagnosis terminal.
(1)
(2)
(1)
(2)
(3)
(4)
(3)
(4)
BR0110
Diagnosis connector
Diagnosis terminal
Terminal 3
Terminal 6
2) Repeat 3 times within approx. 12 seconds; connecting and disconnecting terminal 6 and diagnosis terminal for at least 0.2 seconds each time.
Diagnostic trouble code (DTC) indicatione mode
Memory erase mode
ABS warning lamp
GND(Low level)
GND open (High level)
Terminal 8
0.2 sec
or more
0.2 sec or more
1.5 sec
12 sec or less
BR0082
NOTE:
After the diagnostics is completed, make sure to clear memory. Make sure only start code (11) is shown after
memory is cleared.

Refer to SUBARU SELECT MONITOR for information about how to clear DTC. <Ref. to ABS-18, Subaru Select Monitor.>
ABS-22
ABS WARNING LIGHT ILLUMINATION PATTERN

ABS (DIAGNOSTICS)
10.ABS Warning Light Illumination Pattern

A: INSPECTION
B4M0781A
1) When the ABS warning light does not illuminate in accordance with this illumination pattern, there must be
an electrical malfunction.
2) When the ABS warning light remains constantly OFF, repair the ABS warning light circuit or diagnosis circuit. <Ref. to ABS-28, Diagnostics Chart with Diagnosis Connector.>
NOTE:
Even though the ABS warning light does not go out 1.5 seconds after it illuminates, the ABS system operates
normally when the warning light goes out while driving at approx. 12 km/h (7 MPH). However, the Anti-lock
brakes do not work while ABS warning light is illuminated.
ABS-23
LIST OF DIAGNOSTICS TROUBLE CODE (DTC)

ABS (DIAGNOSTICS)
11.List of Diagnostics Trouble Code (DTC)

A: LIST
DTC No.
11
Start code
DTC is shown after start code.
Only start code is shown in normal condition.
21
23
25
Abnormal ABS sensor

(Open circuit or input
voltage too high)
27
22
24
26
Abnormal ABS sensor

(Abnormal ABS sensor signal)
28
29
Any one of four
Index No.
<Ref. to ABS-39, DTC 21 ABNORMAL ABS SENSOR (OPEN

CIRCUIT OR INPUT VOLTAGE TOO HIGH) (FRONT RH) , Diagnostics Chart with Diagnosis Connector.>
CIRCUIT OR INPUT VOLTAGE TOO HIGH) (FRONT LH) , Diagnostics Chart with Diagnosis Connector.>
CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR RH) , Diagnostics Chart with Diagnosis Connector.>
CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR LH) , Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-46, DTC 22 ABNORMAL ABS SENSOR (ABNORMAL ABS SENSOR SIGNAL) (FRONT RH) , Diagnostics Chart
with Diagnosis Connector.>
<Ref. to ABS-46, DTC 24 ABNORMAL ABS SENSOR (ABNORMAL ABS SENSOR SIGNAL) (FRONT LH) , Diagnostics Chart
with Diagnosis Connector.>
<Ref. to ABS-46, DTC 26 ABNORMAL ABS SENSOR (ABNORMAL ABS SENSOR SIGNAL) (REAR RH) , Diagnostics Chart with
<Ref. to ABS-47, DTC 28 ABNORMAL ABS SENSOR (ABNORMAL ABS SENSOR SIGNAL) (REAR LH) , Diagnostics Chart with
<Ref. to ABS-52, DTC 29 ABNORMAL ABS SENSOR (ABNORMAL ABS SENSOR SIGNAL) (ANY ONE OF FOUR) , Diagnostics
Chart with Diagnosis Connector.>
ABS-24

ABS (DIAGNOSTICS)
DTC No.
31
Front right inlet valve
32
Front right outlet valve
33
Front left inlet valve
34
35
Abnormal solenoid
valve circuit(s) in ABS
control module and
hydraulic unit
Front left outlet valve
Rear right inlet valve
36
Rear right outlet valve
37
Rear left inlet valve
38
Rear left outlet valve
41
Abnormal ABS control module
42
Source voltage is abnormal.
44
A combination of AT control abnormal
51
Abnormal valve relay
52
Abnormal motor and/or motor relay
54
Abnormal stop light switch
56
Abnormal G sensor output voltage
Index No.
<Ref. to ABS-57, DTC 31 ABNORMAL INLET SOLENOID
VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT RH) , Diagnostics
<Ref. to ABS-61, DTC 32 ABNORMAL OUTLET SOLENOID
VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT RH) , Diagnostics
VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT LH) , Diagnostics
VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT LH) , Diagnostics
VALVE CIRCUIT(S) IN ABSCM&H/U (REAR RH) , Diagnostics
VALVE CIRCUIT(S) IN ABSCM&H/U (REAR RH) , Diagnostics
VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH) , Diagnostics
VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH) , Diagnostics
<Ref. to ABS-66, DTC 41 ABNORMAL ABS CONTROL MODULE , Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-68, DTC 42 SOURCE VOLTAGE IS ABNORMAL.
, Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-72, DTC 44 A COMBINATION OF AT CONTROL
ABNORMAL , Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-75, DTC 51 ABNORMAL VALVE RELAY , Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-79, DTC 52 ABNORMAL MOTOR AND/OR
MOTOR RELAY , Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-84, DTC 54 ABNORMAL STOP LIGHT SWITCH
, Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-86, DTC 56 ABNORMAL G SENSOR OUTPUT
VOLTAGE , Diagnostics Chart with Diagnosis Connector.>
ABS-25

ABS (DIAGNOSTICS)

DTC
No.
Display screen
Index No.
Communication for initializing impossible
<Ref. to ABS-92, COMMUNICATION FOR INITIALIZING IMPOSSIBLE, Diagnostics Chart with Subaru Select Monitor.>
No trouble code
21
Open or short circuit in

front right ABS sensor
circuit
Select monitor communication failure

Although no trouble
code appears on the
select monitor display,
the ABS warning light
remains on.
front right ABS sensor
circuit
22
Front right ABS sensor abnormal signal

abnormal signal

front left ABS sensor
circuit
abnormal signal
rear right ABS sensor
circuit
abnormal signal
rear left ABS sensor
circuit
abnormal signal
Abnormal ABS sensor
signal on any one of
four sensor
malfunction
malfunction
malfunction
malfunction
malfunction
malfunction
malfunction
malfunction

front left ABS sensor
circuit
abnormal signal
rear right ABS sensor
circuit
abnormal signal
rear left ABS sensor
circuit
abnormal signal
Abnormal ABS sensor
signal on any one of
four
malfunction
malfunction
malfunction
malfunction
malfunction
malfunction
malfunction
malfunction
ABS control module
and hydraulic control
unit malfunction
Power supply voltage
too low
too high
23
24
25
26
27
28
29
31
32
33
34
35
36
37
38
41
42
42
ABS control module

malfunction
too low
too high
<Ref. to ABS-96, NO TROUBLE CODE, Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-100, DTC 21 OPEN OR SHORT CIRCUIT IN
FRONT RIGHT ABS SENSOR CIRCUIT , Diagnostics Chart with
Subaru Select Monitor.>
<Ref. to ABS-107, DTC 22 FRONT RIGHT ABNORMAL ABS
SENSOR SIGNAL , Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-100, DTC 23 OPEN OR SHORT CIRCUIT IN
FRONT LEFT ABS SENSOR CIRCUIT , Diagnostics Chart with
Subaru Select Monitor.>
<Ref. to ABS-107, DTC 24 FRONT LEFT ABNORMAL ABS SENSOR SIGNAL , Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-100, DTC 25 OPEN OR SHORT CIRCUIT IN REAR
RIGHT ABS SENSOR CIRCUIT , Diagnostics Chart with Subaru
Select Monitor.>
<Ref. to ABS-107, DTC 26 REAR RIGHT ABNORMAL ABS SENSOR SIGNAL , Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-101, DTC 27 OPEN OR SHORT CIRCUIT IN REAR
LEFT ABS SENSOR CIRCUIT , Diagnostics Chart with Subaru
Select Monitor.>
<Ref. to ABS-108, DTC 28 REAR LEFT ABNORMAL ABS SENSOR SIGNAL , Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-114, DTC 29 ABNORMAL ABS SENSOR SIGNAL
ON ANY ONE OF FOUR SENSOR , Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-118, DTC 31 FRONT RIGHT INLET VALVE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-123, DTC 32 FRONT RIGHT OUTLET VALVE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-118, DTC 33 FRONT LEFT INLET VALVE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-123, DTC 34 FRONT LEFT OUTLET VALVE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-118, DTC 35 REAR RIGHT INLET VALVE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-123, DTC 36 REAR RIGHT OUTLET VALVE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-120, DTC 37 REAR LEFT INLET VALVE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-124, DTC 38 REAR LEFT OUTLET VALVE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-128, DTC 41 ABS CONTROL MODULE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-130, DTC 42 POWER SUPPLY VOLTAGE TOO
LOW , Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-132, DTC 42 POWER SUPPLY VOLTAGE TOO
HIGH , Diagnostics Chart with Subaru Select Monitor.>
ABS-26

ABS (DIAGNOSTICS)
DTC
No.
44
44
51
Display screen
ABS-AT control (Non
Controlled)
ABS-AT control (Controlled)
Valve relay malfunction
51
Valve relay ON failure
52
Open circuit in motor

relay circuit
52
Motor relay ON failure
52
Motor malfunction
54
Stop light switch signal circuit malfunction
56

G sensor circuit
56
56
56
Battery short in G sensor circuit

Abnormal G sensor
high output
Detection of G sensor
stick
Index No.
ABS-AT control (Non

Controlled)
ABS-AT control (Controlled)
<Ref. to ABS-136, DTC 44 ABS-AT CONTROL (NON CONTROLLED) , Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-138, DTC 44 ABS-AT CONTROL (CONTROLLED)
, Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-141, DTC 51 VALVE RELAY MALFUNCTION ,
Valve relay malfunction
<Ref. to ABS-145, DTC 51 VALVE RELAY ON FAILURE , DiagValve relay ON failure
nostics Chart with Subaru Select Monitor.>
Open circuit in motor
<Ref. to ABS-149, DTC 52 OPEN CIRCUIT IN MOTOR RELAY
relay circuit
CIRCUIT , Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-153, DTC 52 MOTOR RELAY ON FAILURE ,
Motor relay ON failure
<Ref. to ABS-157, DTC 52 MOTOR MALFUNCTION , DiagnosMotor malfunction
tics Chart with Subaru Select Monitor.>
<Ref. to ABS-160, DTC 54 STOP LIGHT SWITCH SIGNAL CIRStop light switch signal
CUIT MALFUNCTION , Diagnostics Chart with Subaru Select
circuit malfunction
Monitor.>
<Ref. to ABS-162, DTC 56 OPEN OR SHORT CIRCUIT IN G
SENSOR CIRCUIT , Diagnostics Chart with Subaru Select MoniG sensor circuit
tor.>
Battery short in G sen- <Ref. to ABS-166, DTC 56 BATTERY SHORT IN G SENSOR
sor circuit
CIRCUIT , Diagnostics Chart with Subaru Select Monitor.>
Abnormal G sensor
<Ref. to ABS-171, DTC 56 ABNORMAL G SENSOR HIGH
high output
OUTPUT , Diagnostics Chart with Subaru Select Monitor.>
Detection of G sensor
<Ref. to ABS-175, DTC 56 DETECTION OF G SENSOR STICK
stick
, Diagnostics Chart with Subaru Select Monitor.>
NOTE:
High means high friction coefficient against road surface.
ABS-27
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR

ABS (DIAGNOSTICS)
12.Diagnostics Chart with Diagnosis Connector

A: ABS AND BRAKE WARNING LIGHT DOES NOT COME ON.
DIAGNOSIS:
ABS warning light circuit is open or shorted.
Brake warning light circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), ABS and brake warning light does not come on.
WIRING DIAGRAM: LHD MODEL
BATTERY
SBF-1
SBF-4
SBF-3
E
IGNITION
SWITCH
F46
RELAY HOLDER
No.13
B108
10A
B36
23
: TURBO ENGINE MODEL
NA
: NON-TURBO ENGINE
A7
MODEL
ABS
WARNING
LIGHT
B225
BRAKE
WARNING
LIGHT
2
1
3
COMBINATION
METER
A:
i10
B:
i11
DIAGNOSIS
TERMINAL
B82
6
TB
NA
B3
B19
B81
B264
D2
ABS RELAY
TB
i1
No.18
No.8
16
B37
E3
B264
1
2
1 2
3 4
3
7
11
15
23
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B:
2
1
3 4 5 6
4
8
12
16
4
B36
B209
A1 K2 A3
B1 L2
C1 M2 C3
D1 N2
E1
F1
G1Q2
H1 R2
I1 S2
J1 T2
16
E3
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B225
i11
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B82
B22
2
6
10
14
i10
A:
B301
F60
22
NA
F46
F60
TB
ABS CONTROL MODULE AND HYDRAULIC CONTROL 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 31
1
5
9
13
21
24
B301
B209
F76
B22
i2
K4 A5
L4 B5
M4 C5
N4 D5
E5
F5
Q4 G5
H3 R4 H5
S4 I5
J3 T4 J5
ABS-28
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY HOLDER
BR0123

ABS (DIAGNOSTICS)
WIRING DIAGRAM: RHD MODEL

BATTERY
SBF-1
No.8
SBF-4
SBF-3
IGNITION
SWITCH
No.13
RELAY HOLDER
3
4
AT
No.18
MT
10A
B38
4
22
B36
i3
i1
AT
B225
BRAKE
WARNING
LIGHT
ABS
WARNING
LIGHT
A7
MT
ABS RELAY
A:
i10
B:
i11
DIAGNOSIS
TERMINAL
6
B3
B19
2
1
3
4
COMBINATION
METER
B82
B264
3
i2
B81
B37
E
19
20
B200
F49
B264
A:
i10
1 2 3 4 5 6 7 8 9 10
1 2
3 4
B:
i11
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
23
22
E
i1
i2
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B225
F49
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
21
24
F74
i3
F74
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
B82
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
2
1
3 4 5 6
BR0124
Step
Check
Yes
CHECK IF OTHER WARNING LIGHTS TURN Are other warning lights turned Go to step 2.
ON.
on?
Turn the ignition switch to ON (engine OFF).
ABS-29
No
Repair the combination meter.
<Ref. to IDI-15,
Combination
Meter Assembly.>

ABS (DIAGNOSTICS)
Step
CHECK ABS AND BRAKE WARNING LIGHT
BULB.
3)Remove the ABS and brake warning light
bulb from combination meter.
CHECK BATTERY SHORT OF ABS AND
BRAKE WARNING LIGHT HARNESS.
1)Disconnect the connector (i2) from connector (B37).
2)Measure the voltage between connector (i2)
and chassis ground.
LHD: (i2) No. 2 (+) and No. 4 (+) Chassis ground ():
RHD: (i2) No. 1 (+) and No. 3 (+) Chassis ground ():
and chassis ground.
CHECK WIRING HARNESS.
2)Install the ABS and brake warning light bulb
to combination meter.
3)Install the combination meter.
and chassis ground.
2)Measure the voltage between connector
(B37) and chassis ground.
LHD: (B37) No. 2 (+) and No.4 (+)
Chassis ground ():
RHD: (B37) No. 1 (+) and No. 3 (+)
Chassis ground ():
2)Measure the voltage between connector
LHD: (B37) No. 2 (+) and No.4 (+)
Chassis ground ():
RHD: (B37) No. 1 (+) and No. 3 (+)
Chassis ground ():
Check
Are the ABS and brake warning light bulb OK?
Yes
Go to step 3.
Go to step 4.
Go to step 5.
No
Replace the ABS
and brake warning light bulb.
<Ref. to IDI-15,
Combination
Meter Assembly.>
Repair the warning
light harness.
Repair the warning

light harness.

15 V?
Repair the wiring

harness.
Go to step 7.
Repair the wiring

harness.
Go to step 8.
Repair the wiring

harness.
ABS-30

ABS (DIAGNOSTICS)
10
Step
CHECK GROUND CIRCUIT OF ABSCM&H/U.
Measure the resistance between ABSCM&H/U
and chassis ground.
LHD: (B301) No. 23 Chassis ground:
RHD: (F49) No. 23 Chassis ground:
Measure the resistance between connector
LHD: (B37) No. 2 and No. 4 Chassis
ground:
RHD: (B37) No. 1 and No. 3 Chassis
ground:
Check
Yes
?
No
Repair the
ABSCM&H/U
ground harness.

?
Repair the harness/connector.
Is there poor contact in connectors between combination

meter and ABSCM&H/U?
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
ABS Control Module and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-31

ABS (DIAGNOSTICS)
B: ABS AND BRAKE WARNING LIGHT DOES NOT GO OFF.

DIAGNOSIS:
ABS warning light circuit is open or shorted.
Brake warning light circuit is open or shorted.
TROUBLE SYMPTOM:
When starting the engine and while ABS warning light is kept ON.
BATTERY
SBF-1
SBF-4
SBF-3
E
IGNITION
SWITCH
F46
RELAY HOLDER
No.13
B108
10A
B36
23
NA
: NON-TURBO ENGINE
A7
MODEL
ABS
WARNING
LIGHT
B225
BRAKE
WARNING
LIGHT
2
1
3
COMBINATION
METER
A:
i10
B:
i11
DIAGNOSIS
TERMINAL
B82
6
TB
NA
B3
B19
B81
B264
D2
ABS RELAY
TB
i1
No.18
No.8
16
B37
E3
1 2
3 4
3
7
11
15
2
1
3 4 5 6
4
8
12
16
23
1 2 3 4 5 6 7 8 9 10
B209
A1 K2 A3
B1 L2
C1 M2 C3
D1 N2
E1
F1
G1Q2
H1 R2
I1 S2
J1 T2
16
E3
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B225
i11
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B82
B22
2
6
10
14
B36
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:
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 25 26
27 28 29 30 31
F60
i10
A:
F60
TB
B264
1
2
22
NA
F46
1
5
9
13
21
24
B301
B209
F76
B22
i2
K4 A5
L4 B5
M4 C5
N4 D5
E5
F5
Q4 G5
H3 R4 H5
S4 I5
J3 T4 J5
ABS-32
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY HOLDER
BR0123

ABS (DIAGNOSTICS)

BATTERY
SBF-1
No.8
SBF-4
SBF-3
IGNITION
SWITCH
No.13
RELAY HOLDER
3
4
AT
No.18
MT
10A
B38
4
22
B36
i3
i1
AT
B225
BRAKE
WARNING
LIGHT
ABS
WARNING
LIGHT
A7
MT
ABS RELAY
A:
i10
B:
i11
DIAGNOSIS
TERMINAL
6
B3
B19
2
1
3
4
COMBINATION
METER
B82
B264
3
i2
B81
B37
E
19
20
B200
F49
B264
A:
B:
23
22
E
i10
1 2 3 4 5 6 7 8 9 10
1 2
3 4
21
24
F74
i1
i2
1 2 3
4 5 6
7 8 9 10 11 12 13 14
i11
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B225
F49
1 2 3 4 5 6 7 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
i3
F74
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
B82
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
2
1
3 4 5 6
BR0124
Step
CHECK INSTALLATION OF ABSCM&H/U
CONNECTOR.
Check
Yes
Is the ABSCM&H/U connector Go to step 2.
inserted into ABSCM until the
clamp locks onto it?
ABS-33
No
Insert the
ABSCM&H/U connector into
ABSCM&H/U until
the clamp locks
onto it.

ABS (DIAGNOSTICS)
Step
CHECK DIAGNOSIS TERMINAL.
Measure the resistance between diagnosis terminals (B81) and chassis ground.
Terminals
Diagnosis terminal (A) Chassis
ground:
Diagnosis terminal (B) Chassis
ground:
CHECK DIAGNOSIS LINE.
2)Connect the diagnosis terminal (B81) to
diagnosis connector (B82) No. 6.
3)Disconnect the connector from ABSCM&
H/U.
4)Measure the resistance between
ABSCM&H/U connector and chassis ground.
CHECK GENERATOR.
1)Start the engine.
2)Idle the engine.
3)Measure the voltage between generator and
chassis ground.
Terminal
ground ():
Check
Yes
?
No
Repair the diagnosis terminal harness.

?

between
ABSCM&H/U and
diagnosis connector.

15 V?

terminal?
15 V?
Go to step 6.
CHECK POWER SUPPLY OF ABSCM.

H/U.
2)Start the engine.
3)Idle the engine.
4)Measure the voltage between ABSCM&H/U
LHD: (B301) No. 1 (+) Chassis ground
():
RHD: (F49) No. 1 (+) Chassis ground
():
Does the ABS warning light
1)Disconnect the connector (i2) from connec- remain off?
tor (B37).
2)Turn ignition switch to ON.
Are the projection broken?
CHECK PROJECTION AT ABSCM&H/U.
2)Check for broken projection at the
ABSCM&H/U terminal.
CHECK ABSCM&H/U.
Measure the resistance between ABSCM&H/U M?
terminals.
Terminal
No. 22 No. 23:
ABS-34
Repair the
ABSCM&H/U
Go to step 8.
Repair the front or

body wiring harness.
Go to step 9.
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Go to step 10.

ABS (DIAGNOSTICS)
10
11
12
Step
LHD: (B37) No. 2 and No.4 Chassis
ground:
ground:
1)Connect the connector to ABSCM&H/U.
LHD: (B37) No. 2 and No.4 Chassis
ground:
ground:
CHECK POOR CONTACT IN ABSCM&H/U
CONNECTOR.
Check
Yes
?
No
Repair the harness.

M?
Go to step 12.
Repair the harness.
Is there poor contact in

ABSCM&H/U connector?
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
ABS-35

ABS (DIAGNOSTICS)
C: TROUBLE CODE DOES NOT APPEAR.

DIAGNOSIS:
Diagnosis circuit is open.
TROUBLE SYMPTOM:
The ABS warning light turns on or off normally but the start code cannot be read out in diagnostic mode.
BATTERY
SBF-1
SBF-4
SBF-3
E
IGNITION
SWITCH
F46
RELAY HOLDER
No.13
B108
10A
B36
23
NA
: NON-TURBO ENGINE
A7
MODEL
ABS
WARNING
LIGHT
B225
BRAKE
WARNING
LIGHT
2
1
3
COMBINATION
METER
A:
i10
B:
i11
DIAGNOSIS
TERMINAL
B82
6
TB
NA
B3
B19
B81
B264
D2
ABS RELAY
TB
i1
No.18
No.8
16
B37
E3
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
F60
B82
B22
2
1
3 4 5 6
3
7
11
15
4
8
12
16
23
4
B36
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B:
B301
2
6
10
14
i10
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
B209
F1
G1Q2
H1 R2
I1 S2
J1 T2
16
E3
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B225
i11
A1 K2 A3
B1 L2
C1 M2 C3
D1 N2
E1
F60
TB
B264
1
2
22
NA
F46
1
5
9
13
21
24
B301
B209
F76
B22
i2
K4 A5
L4 B5
M4 C5
N4 D5
E5
F5
Q4 G5
H3 R4 H5
S4 I5
J3 T4 J5
ABS-36
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY HOLDER
BR0123

ABS (DIAGNOSTICS)

BATTERY
SBF-1
No.8
SBF-4
SBF-3
IGNITION
SWITCH
No.13
RELAY HOLDER
3
4
AT
No.18
MT
10A
B38
4
22
B36
i3
i1
AT
B225
BRAKE
WARNING
LIGHT
ABS
WARNING
LIGHT
A7
MT
ABS RELAY
A:
i10
B:
i11
DIAGNOSIS
TERMINAL
6
B3
B19
2
1
3
4
COMBINATION
METER
B82
B264
3
i2
B81
B37
E
19
20
B200
F49
B264
A:
i10
1 2 3 4 5 6 7 8 9 10
1 2
3 4
B:
i11
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
23
22
E
i1
i2
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B225
F49
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
21
24
F74
i3
F74
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
B82
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
2
1
3 4 5 6
BR0124
ABS-37

ABS (DIAGNOSTICS)
Step
CHECK DIAGNOSIS TERMINAL.
2)Measure the resistance between diagnosis
terminals (B81) and chassis ground.
Terminals
Diagnosis terminal (A) Chassis
ground:
Diagnosis terminal (B) Chassis
ground:
CHECK DIAGNOSIS LINE.
2)Connect the diagnosis terminal (B81) to
diagnosis connector (B82) No. 6.
H/U.
CONNECTOR.
Check
Yes
?
No
Repair the diagnosis terminal harness.

?

between
ABSCM&H/U and
diagnosis connector.

Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
ABS-38

ABS (DIAGNOSTICS)
D: DTC 21
ABNORMAL ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO
HIGH) (FRONT RH)
NOTE:
For the diagnostic procedure, refer to DTC 27. <Ref. to ABS-40, DTC 27 ABNORMAL ABS SENSOR
(OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR LH) , Diagnostics Chart with Diagnosis Connector.>
E: DTC 23
HIGH) (FRONT LH)
NOTE:
F: DTC 25
HIGH) (REAR RH)
NOTE:
ABS-39

ABS (DIAGNOSTICS)
G: DTC 27
HIGH) (REAR LH)
DIAGNOSIS:
Faulty ABS sensor (Broken wire, input voltage too high)
TROUBLE SYMPTOM:
ABS does not operate.
7
8
14
15
23
11
12
9
10
B301
1
2
3
4
6
B303
SHIELD JOINT
CONNECTOR
23
9
10
16
4
5
20
24
B62
F45
R3
B15
R72
2
1
R73
2
1
1
2
F94
1
2
B99
E
FRONT
ABS
SENSOR LH
F94
R72
B15
R73
2 1
1 2
FRONT
ABS
SENSOR RH
REAR
ABS
SENSOR LH
B303
1 2 3 4
5 6 7 8
REAR
ABS
SENSOR RH
B99
B301
F45
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
BR0125
ABS-40

ABS (DIAGNOSTICS)
7
8
14
15
23
11
12
9
10
F49
1
2
3
4
7
F62
11
13
12
3
2
SHIELD JOINT
CONNECTOR
F74
22
20
21
10
8
9
B200
B99
R3
F95
R72
2
1
R73
2
1
1
2
1
2
F94
E
FRONT
ABS
SENSOR LH
F94
R72
F95
R73
2 1
1 2
FRONT
ABS
SENSOR RH
F62
1 2 3 4
5 6 7 8
REAR
ABS
SENSOR RH
REAR
ABS
SENSOR LH
F74
F49
B99
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 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
ABS-41
BR0038

ABS (DIAGNOSTICS)
Step
CHECK ABS SENSOR.
2)Disconnect the connector from ABS sensor.
3)Measure the resistance of ABS sensor connector terminals.
Terminal
Front RH No. 1 No. 2:
Front LH No. 1 No. 2:
Rear RH No. 1 No. 2:
Rear LH No. 1 No. 2:
CHECK BATTERY SHORT OF ABS SENSOR.
H/U.
2)Measure the voltage between ABS sensor
and chassis ground.
Terminal
Front RH No. 1 (+) Chassis ground ():
Front LH No. 1 (+) Chassis ground ():
Rear RH No. 2 (+) Chassis ground ():
Rear LH No. 2 (+) Chassis ground ():
and chassis ground.
Terminal
ABSCM&H/U AND ABS SENSOR.
2)Connect the connector to ABS sensor.
ABSCM&H/U connector terminals.
DTC 21 /
LHD: (B301) No. 11 No. 12:
RHD: (F49) No. 11 No. 12:
DTC 23 /
LHD: (B301) No. 9 No. 10:
RHD: (F49) No. 9 No. 10:
DTC 25 /
LHD: (B301) No. 14 No. 15:
RHD: (F49) No. 14 No. 15:
DTC 27 /
LHD: (B301) No. 7 No. 8:
RHD: (F49) No. 7 No. 8:
Check
and 1.5 k?
Yes
Go to step 2.
No
Replace the ABS
sensor. Front:
<Ref. to ABS-14,
Front ABS Sensor.> Rear: <Ref.
to ABS-17, Rear
ABS Sensor.>
Go to step 3.
Replace the ABS

sensor. Front:
<Ref. to ABS-14,
to ABS-17, Rear
ABS Sensor.>
Go to step 4.
Replace the ABS

sensor. Front:
<Ref. to ABS-14,
to ABS-17, Rear
ABS Sensor.>

and 1.5 k?
Go to step 5.
Repair the harness/connector

between
ABSCM&H/U and
ABS sensor.
ABS-42

ABS (DIAGNOSTICS)
Step
CHECK BATTERY SHORT OF HARNESS.
Measure the voltage between ABSCM&H/U
DTC 21 /
LHD: (B301) No. 11 (+) Chassis
ground ():
():
DTC 23 /
():
():
DTC 25 /
ground ():
():
DTC 27 /
():
():
DTC 21 /
ground ():
():
DTC 23 /
():
():
DTC 25 /
ground ():
():
DTC 27 /
():
():
CHECK INSTALLATION OF ABS SENSOR.
Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
Check
Yes
Go to step 6.
No
Repair the harness between
ABSCM&H/U and
ABS sensor.
Go to step 7.

ABSCM&H/U and
ABS sensor.
Are the ABS sensor installation Go to step 8.

bolts tightened securely?
Tighten the ABS

sensor installation
bolts securely.
ABS-43

ABS (DIAGNOSTICS)
Step
CHECK ABS SENSOR GAP.
Measure the tone wheel to ABS sensor piece
gap over entire perimeter of the wheel.
Front wheel
0.3 0.8 mm (0.012 0.031 in)
Rear wheel
0.7 1.2 mm (0.028 0.047 in)
Check
Yes
Is the gap within the specifica- Go to step 9.
tions?
CHECK TONE WHEEL RUNOUT.

Measure the tone wheel runout.
Is the runout less than 0.05

mm (0.0020 in)?
10
CHECK GROUND SHORT OF ABS SENSOR. Is the resistance more than 1

M?
2)Measure the resistance between ABS sensor and chassis ground.
Terminal
Front RH No. 1 Chassis ground:
Front LH No. 1 Chassis ground:
Rear RH No. 1 Chassis ground:
Rear LH No. 1 Chassis ground:
11
CHECK GROUND SHORT OF HARNESS.

M?
ABSCM&H/U connector terminal and chassis
ground.
DTC 21 / LHD: (B301) No. 11 Chassis
ground:
ground:
ground:
ground:
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in conRepair the connectors between ABSCM&H/U nector.
and ABS sensor?
12
ABS-44
Go to step 10.
Go to step 11.
No
Adjust the gap.
NOTE:
Adjust the gap using spacers (Part
No. 26755AA000).
If the spacers cannot correct gap, replace worn sensor
or
worn
tone
wheel.
Replace the tone
wheel. Front:
<Ref. to ABS-20,
Front Tone
Wheel.> Rear:
<Ref. to ABS-21,
Rear Tone
Wheel.>
Replace the ABS
sensor and
ABSCM&H/U.
Front: <Ref. to
ABS-14, Front
ABS Sensor.>
Rear: <Ref. to
ABS-17, Rear
ABS Sensor.> and
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
ABSCM&H/U and
ABS sensor.
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Go to step 13.

ABS (DIAGNOSTICS)
13
14
Step
CHECK ABSCM&H/U.
2)Erase the memory.
3)Perform the inspection mode.
4)Read out the DTC.
CHECK ANY OTHER DIAGNOSTIC TROUBLE CODES (DTCs) APPEARANCE.
Check
Yes
Is the same DTC as in current Replace the
diagnosis still being output?
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Are other DTCs being output? Proceed with the
DTC.
ABS-45
No
Go to step 14.
A temporary poor
contact.
NOTE:
Check the harness
and
connectors
between
ABSCM&H/U
and
ABS sensor.

ABS (DIAGNOSTICS)
H: DTC 22
ABNORMAL ABS SENSOR (ABNORMAL ABS SENSOR SIGNAL) (FRONT
RH)
NOTE:
For the diagnostic procedure, refer to DTC 28. <Ref. to ABS-47, DTC 28 ABNORMAL ABS SENSOR (ABNORMAL ABS SENSOR SIGNAL) (REAR LH) , Diagnostics Chart with Diagnosis Connector.>
I:
DTC 24
ABNORMAL ABS SENSOR (ABNORMAL ABS SENSOR SIGNAL) (FRONT
LH)
NOTE:
J: DTC 26
ABNORMAL ABS SENSOR (ABNORMAL ABS SENSOR SIGNAL) (REAR
RH)
NOTE:
ABS-46

ABS (DIAGNOSTICS)
K: DTC 28
ABNORMAL ABS SENSOR (ABNORMAL ABS SENSOR SIGNAL) (REAR
LH)
DIAGNOSIS:
Faulty ABS sensor signal (noise, irregular signal, etc.)
Faulty harness/connector
TROUBLE SYMPTOM:
7
8
14
15
23
11
12
9
10
B301
1
2
3
4
6
B303
SHIELD JOINT
CONNECTOR
23
9
10
16
4
5
20
24
B62
F45
R3
B15
R72
2
1
R73
2
1
1
2
F94
1
2
B99
E
FRONT
ABS
SENSOR LH
F94
R72
B15
R73
2 1
1 2
FRONT
ABS
SENSOR RH
REAR
ABS
SENSOR LH
B303
1 2 3 4
5 6 7 8
REAR
ABS
SENSOR RH
B99
B301
F45
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
BR0125
ABS-47

ABS (DIAGNOSTICS)
7
8
14
15
23
11
12
9
10
F49
1
2
3
4
7
F62
11
13
12
3
2
SHIELD JOINT
CONNECTOR
F74
22
20
21
10
8
9
B200
B99
R3
F95
R72
2
1
R73
2
1
1
2
1
2
F94
E
FRONT
ABS
SENSOR LH
F94
R72
F95
R73
2 1
1 2
FRONT
ABS
SENSOR RH
F62
1 2 3 4
5 6 7 8
Step
Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
REAR
ABS
SENSOR RH
REAR
ABS
SENSOR LH
F74
F49
B99
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 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
Check
Yes
ABS-48
BR0038
No
Tighten the ABS
sensor installation
bolts securely.

ABS (DIAGNOSTICS)
3
4
Step
Front wheel
0.3 0.8 mm (0.012 0.031 in)
Rear wheel
0.7 1.2 mm (0.028 0.047 in)
Check
Yes
tions?
Is an oscilloscope available?
Is the oscilloscope pattern
CHECK ABS SENSOR SIGNAL.
1)Raise all four wheels off ground.
smooth, as shown in figure?
3)Connect the oscilloscope to the connector.
5)Rotate the wheels and measure voltage at
specified frequency. <Ref. to ABS-17, WAVEFORM, Control Module I/O Signal.>
NOTE:
When this inspection is completed, the ABS
control module sometimes stores DTC 29.
DTC 22 /
LHD: (B15) No. 1 (+) No. 2 ():
RHD: (F95) No. 1 (+) No. 2 ():
DTC 24 /
LHD: (F45) No. 20 (+) No. 24 ():
RHD: (F94) No. 1 (+) No. 2 ():
DTC 26 /
LHD: (B99) No. 9 (+) No. 10 ():
RHD: (B99) No. 20 (+) No. 21 ():
DTC 28 /
LHD: (B99) No. 4 (+) No. 5 ():
RHD: (B99) No. 8 (+) No. 9 ():
CHECK CONTAMINATION OF ABS SENSOR
OR TONE WHEEL.
Remove the disc rotor or drum from hub in
accordance with DTC.
CHECK DAMAGE OF ABS SENSOR OR
TONE WHEEL.
Go to step 4.
Go to step 8.
No
Adjust the gap.
NOTE:
Adjust the gap using spacer (Part
No. 26755AA000).
If the spacer cannot correct gap, replace worn sensor
or
worn
tone
wheel.
Go to step 5.
Go to step 7.
Go to step 6.
Is the ABS sensor piece or the Thoroughly
tone wheel contaminated by
remove dirt or
dirt or other foreign matter?
other foreign matter.
Are there broken or damaged Replace the ABS Go to step 7.
in the ABS sensor piece or the sensor or tone
tone wheel?
wheel. Front:
<Ref. to ABS-14,
to ABS-17, Rear
ABS Sensor.> and
Front: <Ref. to
ABS-20, Front
Tone Wheel.>
Rear: <Ref. to
ABS-21, Rear
Tone Wheel.>
ABS-49

ABS (DIAGNOSTICS)
10
11
Step
Check
mm (0.0020 in)?
Yes
Go to step 8.
CHECK RESISTANCE OF ABS SENSOR.

3)Measure the resistance between ABS sensor connector terminals.
Terminal
CHECK GROUND SHORT OF ABS SENSOR.
Measure the resistance between ABS sensor
and chassis ground.
Terminal
H/U.
3)Measure the resistance at ABSCM&H/U
DTC 22 / LHD: (B301) No. 11 No. 12:
RHD: (F49) No. 11 No. 12:
DTC 24 / LHD: (B301) No. 9 No. 10:
RHD: (F49) No. 9 No. 10:
DTC 26 / LHD: (B301) No. 14 No. 15:
RHD: (F49) No. 14 No. 15:
DTC 28 / LHD: (B301) No. 7 No. 8:
RHD: (F49) No. 7 No. 8:
DTC 22 /
DTC 24 /
DTC 26 /
DTC 28 /

and 1.5 k?
Go to step 9.

M?
Go to step 10.
Replace the ABS

sensor. Front:
<Ref. to ABS-14,
to ABS-17, Rear
ABS Sensor.>

and 1.5 k?
Go to step 11.

between
ABSCM&H/U and
ABS sensor.

M?
Go to step 12.

between
ABSCM&H/U and
ABS sensor.
ABS-50
No
Replace the tone
wheel. Front:
<Ref. to ABS-20,
Front Tone
Wheel.> Rear:
<Ref. to ABS-21,
Rear Tone
Wheel.>
Replace the ABS
sensor. Front:
<Ref. to ABS-14,
to ABS-17, Rear
ABS Sensor.>

ABS (DIAGNOSTICS)
12
13
14
Step
Check
CHECK GROUND CIRCUIT OF ABSCM&H/U. Is the resistance less than 0.5
Measure the resistance between ABSCM&H/U ?
and chassis ground.
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in connectors between ABSCM&H/U
and ABS sensor?
CHECK SOURCES OF SIGNAL NOISE.
Is the car telephone or wireless
transmitter properly installed?
15
16
CHECK SHIELD CIRCUIT.

2)Measure the resistance between shield connector and chassis ground.
DTC 24 / LHD: (F45) No. 8 Chassis
ground:
ground:
DTC 26 / RHD: (B99) No. 22 Chassis
ground:
ground:
ground:
17
18
NOTE:
For the DTC 22 and 24: (RHD)
Go to step 17.
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
Are noise sources (such as an

antenna) installed near the
sensor harness?
Is the resistance less than 0.5
?
Yes
Go to step 13.
No
Repair the
ABSCM&H/U
ground harness.
Go to step 14.
Go to step 15.
Properly install the

car telephone or
wireless transmitter.
Go to step 16.
Install the noise

sources apart from
sensor harness.
Go to step 17.
Repair the shield
harness.
Is the same DTC as in the cur- Replace the

Go to step 18.
rent diagnosis still being outABSCM&H/U.
put?
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Are other DTCs being output? Proceed with the A temporary noise
diagnosis correinterference.
sponding to DTC.
ABS-51

ABS (DIAGNOSTICS)
L: DTC 29
ABNORMAL ABS SENSOR (ABNORMAL ABS SENSOR SIGNAL) (ANY
ONE OF FOUR)
DIAGNOSIS:
Faulty tone wheel
Wheels turning freely for a long time
TROUBLE SYMPTOM:
ABS-52

ABS (DIAGNOSTICS)
7
8
14
15
23
11
12
9
10
B301
1
2
3
4
6
B303
SHIELD JOINT
CONNECTOR
23
9
10
16
4
5
20
24
B62
F45
R3
B15
R72
2
1
R73
2
1
1
2
F94
1
2
B99
E
FRONT
ABS
SENSOR LH
F94
R72
B15
R73
2 1
1 2
FRONT
ABS
SENSOR RH
REAR
ABS
SENSOR LH
B303
1 2 3 4
5 6 7 8
REAR
ABS
SENSOR RH
B99
B301
F45
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
BR0125
ABS-53

ABS (DIAGNOSTICS)
7
8
14
15
23
11
12
9
10
F49
1
2
3
4
7
F62
11
13
12
3
2
SHIELD JOINT
CONNECTOR
F74
22
20
21
10
8
9
B200
B99
R3
F95
R72
2
1
R73
2
1
1
2
1
2
F94
E
FRONT
ABS
SENSOR LH
F94
R72
F95
R73
2 1
1 2
FRONT
ABS
SENSOR RH
F62
1 2 3 4
5 6 7 8
REAR
ABS
SENSOR RH
REAR
ABS
SENSOR LH
F74
F49
B99
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 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
ABS-54
BR0038

ABS (DIAGNOSTICS)
2
3
4
5
7
8
Step
CHECK IF THE WHEELS HAVE TURNED
FREELY FOR A LONG TIME.
Check
Check if the wheels have been
turned freely for more than 1
minute, such as when vehicle
is jacked-up, under full-lock
cornering or when tire is not in
contact with road surface.
Yes
The ABS is normal. Erase the
DTC.
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 DTC
may
sometimes
occur.
Go to step 3.
Replace the tire.
CHECK TIRE SPECIFICATIONS.

CHECK WEAR OF TIRE.
CHECK TIRE PRESSURE.
Are the tire specifications correct?

Is the tire worn excessively?
Is the tire pressure correct?

Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
Specifications
Front wheel
0.3 0.8 mm (0.012 0.031 in)
Rear wheel
0.7 1.2 mm (0.028 0.047 in)

Replace tire.
Go to step 5.

tions?
smooth, as shown in the figure?
NOTE:
When this inspection is completed, the ABSCM&H/U sometimes stores the DTC 29.
Front RH
LHD: (B15) No. 1 (+) No. 2 ():
RHD: (F95) No. 1 (+) No. 2 ():
Front LH
(F94) No. 1 (+) No. 2 ():
Rear RH
LHD: (B99) No. 9 (+) No. 10 ():
RHD: (B99) No. 20 (+) No. 21 ():
Rear LH
LHD: (B99) No. 4 (+) No. 5 ():
RHD: (B99) No. 8 (+) No. 9 ():
ABS-55
No
Go to step 2.
Go to step 8.
Go to step 12.
Go to step 4.
Adjust tire pressure.
Tighten the ABS
sensor installation
bolts securely.
Adjust the gap.
NOTE:
No. 26755AA000).
If the spacer cannot correct gap, replace worn sensor
or
worn
tone
wheel.
Go to step 9.
Go to step 9.

ABS (DIAGNOSTICS)
10
11
Step
Check
Yes
CHECK CONTAMINATION OF ABS SENSOR Is the ABS sensor piece or the Thoroughly
remove dirt or
OR TONE WHEEL.
Remove the disc rotor from hub.
Are there broken or damaged Replace the ABS
TONE WHEEL.
teeth in the ABS sensor piece sensor or tone
or the tone wheel?
wheel. Front:
<Ref. to ABS-14,
to ABS-17, Rear
ABS Sensor.> and
Front: <Ref. to
ABS-20, Front
Tone Wheel.>
Rear: <Ref. to
ABS-21, Rear
Tone Wheel.>
Go to step 12.
mm (0.0020 in)?
12
CHECK ABSCM&H/U.
3)Erase the memory.
5)Read out the DTC.
13
No
Go to step 10.
Go to step 11.
Replace the tone

wheel. Front:
<Ref. to ABS-20,
Front Tone
Wheel.> Rear:
<Ref. to ABS-21,
Rear Tone
Wheel.>
Go to step 13.

ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Are other DTCs being output? Proceed with the A temporary poor
diagnosis correcontact.
sponding to DTC.
ABS-56

ABS (DIAGNOSTICS)
M: DTC 31
ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U
(FRONT RH)
NOTE:
For the diagnostic procedure, refer to DTC 37. <Ref. to ABS-58, DTC 37 ABNORMAL INLET SOLENOID
VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH) , Diagnostics Chart with Diagnosis Connector.>
N: DTC 33
(FRONT LH)
NOTE:
O: DTC 35
(REAR RH)
NOTE:
ABS-57

ABS (DIAGNOSTICS)
P: DTC 37
(REAR LH)
DIAGNOSIS:
Faulty inlet solenoid valve in ABSCM&H/U
TROUBLE SYMPTOM:
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-4
GENERATOR
LHD
RHD
F46
2
IGNITION
SWITCH
LHD
B108
*1
RELAY
HOLDER
*1: LHD 5
RHD
*2
No.18
RHD 3
B225
ABS
RELAY
*2: LHD 6
RHD 4
*3: LHD
1
3
4
RHD
B301
F49
LHD
RHD
B264
E
9
B200
RHD
F74
LHD
1
23
*3
F46
B264
F74
1
2
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
*3
B225
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0126
ABS-58

ABS (DIAGNOSTICS)
1
2
Step
CHECK RELAY HOLDER.
CHECK INPUT VOLTAGE OF RELAY HOLDER.
2)Remove the relay holder fuse.
3)Measure the voltage between ABS relay
LHD model
RHD model
CHECK INPUT VOLTAGE OF ABS RELAY.
1)Install the fuse.
2)Remove the ABS relay.
Measure the voltage between ABS relay connector and chassis ground.
CHECK GROUND CIRCUIT OF ABS RELAY.
2)Measure the resistance between ABS relay
CHECK ABS RELAY.
1)Connect the battery to ABS relay terminal
No. 1 and 3.
terminals.
CHECK INPUT VOLTAGE OF ABSCM&H/U.
H/U.
():
():
Check
Yes
Is the fuse blown out?
Replace the fuse.
No
Go to step 2.
Repair the open
circuit in harness
between battery
and relay holder
connector.
Repair the open

circuit in harness
between battery
and relay holder
connector.

between battery,
ignition switch and
ABS relay.
Repair the open
circuit between
ABS relay and
chassis ground.

?
Go to step 6.

?
Go to step 7.
Replace the ABS

relay.

15 V?

between ABS
relay and
ABSCM&H/U.

?
Repair the
ABSCM&H/U
ground harness.
Is there poor contact in connectors between generator,

battery and ABSCM&H/U?
Go to step 10.
ABS-59

ABS (DIAGNOSTICS)
10
11
Step
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
Check
Yes
No
Go to step 11.
put?
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-60

ABS (DIAGNOSTICS)
Q: DTC 32
ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U
(FRONT RH)
NOTE:
For the diagnostic procedure, refer to DTC 38. <Ref. to ABS-62, DTC 38 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH) , Diagnostics Chart with Diagnosis Connector.>
R: DTC 34
(FRONT LH)
NOTE:
S: DTC 36
(REAR RH)
NOTE:
ABS-61

ABS (DIAGNOSTICS)
T: DTC 38
(REAR LH)
DIAGNOSIS:
Faulty outlet solenoid valve in ABSCM&H/U
TROUBLE SYMPTOM:
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-4
GENERATOR
LHD
RHD
F46
2
IGNITION
SWITCH
LHD
B108
*1
RELAY
HOLDER
*1: LHD 5
RHD
*2
No.18
RHD 3
B225
ABS
RELAY
*2: LHD 6
RHD 4
*3: LHD
1
3
4
RHD
B301
F49
LHD
RHD
B264
E
9
B200
RHD
F74
LHD
1
23
*3
F46
B264
F74
1
2
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
*3
B225
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0126
ABS-62

ABS (DIAGNOSTICS)
1
2
Step
CHECK RELAY HOLDER.
LHD:
RHD:
1)Install the fuse.
CHECK ABS RELAY.
No. 1 and 3.
terminals.
H/U.
():
():
Check
Yes
Replace the fuse.
No
Go to step 2.
Repair the open
circuit in harness
between battery
and relay holder
connector.
Repair the open

circuit in harness
between battery
and relay holder
connector.

between battery,
ignition switch and
ABS relay.
Repair the open
circuit between
ABS relay and
chassis ground.

?
Go to step 6.

?
Go to step 7.
Replace the ABS

relay.

15 V?

between battery,
ignition switch and
ABSCM&H/U.

?
Repair the
ABSCM&H/U
ground harness.

Go to step 10.
ABS-63

ABS (DIAGNOSTICS)
10
11
Step
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
Check
Yes
No
Go to step 11.
put?
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-64

ABS (DIAGNOSTICS)
ABS-65

ABS (DIAGNOSTICS)
U: DTC 41
ABNORMAL ABS CONTROL MODULE
DIAGNOSIS:
Faulty ABSCM&H/U.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
ABS CONTROL MODULE AND

HYDRAULIC CONTROL UNIT
23
*1
B301
*1: LHD
RHD
F49
*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
BR0127
Step
Check
Yes
CHECK GROUND CIRCUIT OF ABSCM&H/U. Is the resistance less than 0.5 Go to step 2.
?
H/U.
ABSCM&H/U and chassis ground.
ABS-66
No
Repair the
ABSCM&H/U
ground harness.

ABS (DIAGNOSTICS)
Step
Check
Yes
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in conRepair the connectors between battery, igni- nector.
tion switch and ABSCM&H/U?
Is the car telephone or the
Go to step 4.
wireless transmitter properly
installed?
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
No
Go to step 3.

car telephone or
Go to step 5.
Are noise sources (such as an Install the noise

sources apart from
sensor harness?
the sensor harness.
Go to step 6.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-67

ABS (DIAGNOSTICS)
V: DTC 42
SOURCE VOLTAGE IS ABNORMAL.
DIAGNOSIS:
Power source voltage of the ABSCM&H/U is low or high.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-4
GENERATOR
LHD
RHD
F46
2
IGNITION
SWITCH
LHD
B108
*1
RELAY
HOLDER
*1: LHD 5
RHD
*2
No.18
RHD 3
B225
ABS
RELAY
*2: LHD 6
RHD 4
*3: LHD
1
3
4
RHD
B301
F49
LHD
RHD
B264
E
9
B200
RHD
F74
LHD
1
23
*3
F46
B264
F74
1
2
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
*3
B225
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0126
ABS-68

ABS (DIAGNOSTICS)
3
4
Step
CHECK GENERATOR.
1)Start the engine.
Terminal
ground ():
Check
Yes
17 V?
Are the positive and negative Go to step 4.

clamped?
CHECK RELAY HOLDER.
Replace the fuse.
CHECK INPUT VOLTAGE OF RELAY HOLD- Is the voltage more than 10 V? Go to step 5.
ER.
LHD:
RHD:
CHECK INPUT VOLTAGE OF ABS RELAY. Is the voltage more than 10 V? Go to step 6.
1)Install the fuse.
CHECK GROUND CIRCUIT OF ABS RELAY. Is the resistance less than 5
Go to step 8.
?
Is the resistance less than 10 Go to step 9.
CHECK ABS RELAY.
?
No. 1 and 3.
terminals.
CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage between 10 and Go to step 10.
17 V?
H/U.
():
():
ABS-69
No
Tighten the clamp

of terminal.
Go to step 4.
Repair the open
circuit in harness
between battery
and relay holder
connector.
Repair the open

circuit in harness
between battery
and relay holder
connector.

between battery,
ignition switch and
ABS relay.
Repair the open
circuit between
ABS relay and
chassis ground.
Replace the ABS

relay.

between battery,
ignition switch and
ABSCM&H/U.

ABS (DIAGNOSTICS)
10
11
12
13
Step
Check
?
CHECK ABSCM&H/U.
Is the same DTC as in current
2)Erase the memory.
4)Read out the DTC.
Yes
Go to step 11.
No
Repair the
ABSCM&H/U
ground harness.
Go to step 12.
Replace the
Go to step 13.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-70

ABS (DIAGNOSTICS)
ABS-71

ABS (DIAGNOSTICS)
W: DTC 44
A COMBINATION OF AT CONTROL ABNORMAL
DIAGNOSIS:
Combination of AT control faults
TROUBLE SYMPTOM:
WIRING DIAGRAM:
31

*1
*1: LHD
RHD
B301
F49
LHD
RHD
21
F74
LHD
B200
21
RHD
B55
1 2 3 4
10 11 12 13
19 20 21
TCM
B55
*1
F74
5 6
14 15
1 2 3 4 5 6 7 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
7
16
22
8 9
17 18
23 24
BR0128
Step
CHECK SPECIFICATIONS OF THE ABSCM&H/U.
Check specifications of the mark to on
ABSCM&H/U.
CM: AT (Rear disc brake)
CN: MT (Rear disc brake)
CC: AT (Rear drum brake)
CD: MT (Rear drum brake)
Check
Is an ABSCM&H/U for AT
model installed on a MT
model?
ABS-72
Yes
No
Replace the
Go to step 2.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>

ABS (DIAGNOSTICS)
6
7
Step
2)Disconnect all connectors from TCM.
H/U.
():
():
():
():
CHECK TCM.
2)Connect all connectors to TCM.
4)Measure the voltage between TCM connector terminal and chassis ground.
CHECK AT.
():
ground ():
():
():
CHECK ABSCM&H/U.
3)Erase the memory.
5)Read out the DTC.
Check
M?
Yes
Go to step 3.
No
TCM and
ABSCM&H/U.
Go to step 4.

TCM and
ABSCM&H/U.
Go to step 5.

TCM and
ABSCM&H/U.

15 V?
Go to step 6.
Is the AT functioning normally? Replace the TCM. Repair the AT.

Repair the har15 V?
ness/connector
between TCM and
ABSCM&H/U.
Is there poor contact in connectors between TCM and

ABSCM&H/U?
Is the same DTC as in the current diagnosis still being output?
ABS-73
Go to step 9.
Replace the
Go to step 10.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>

ABS (DIAGNOSTICS)
10
Step
Check
Yes
diagnosis corresponding to DTC.
ABS-74
No
A temporary poor
contact.

ABS (DIAGNOSTICS)
X: DTC 51
ABNORMAL VALVE RELAY
DIAGNOSIS:
Faulty valve relay
TROUBLE SYMPTOM:
ABS-75

ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
SBF-1
No.8
SBF-4
SBF-3
LHD
RHD
E
IGNITION
SWITCH
F46
B108
LHD
RELAY
HOLDER
*1
*1: LHD 5
RHD 3
RHD
*2
No.18
*2: LHD 6
ABS RELAY B225
RHD 4
*3: LHD
RHD
B301
F49
1
3
4
LHD
RHD
B264
E
9
B200
RHD
F74
PUMP MOTOR
RR INLET
RR OUTLET
RL INLET
RL OUTLET
FR INLET
FR OUTLET
SOLENOID
VALVE
FL INLET

FL OUTLET
24
*3
23
LHD
E
VALVE RELAY
F46
B264
1
2
1 2
3 4
MOTOR RELAY
F74
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
B225
*3
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0129
ABS-76

ABS (DIAGNOSTICS)
1
2
Step
CHECK RELAY HOLDER.
LHD:
RHD:
1)Install the fuse.
CHECK ABS RELAY.
No. 1 and 3.
terminals.
H/U.
():
ground ():
():
():
Check
Yes
Replace the fuse.
No
Go to step 2.
Repair the open
circuit in harness
between battery
and relay holder
connector.
Repair the open

circuit in harness
between battery
and relay holder
connector.

between battery,
ignition switch and
ABS relay.
Repair the open
circuit between
ABS relay and
chassis ground.

?
Go to step 6.

?
Go to step 7.
Replace the ABS

relay.

15 V?

between battery,
ABS relay and
ABSCM&H/U.

?
Repair the
ABSCM&H/U
ground harness.
ABS-77

ABS (DIAGNOSTICS)
10
11
12
Step
Check
CHECK VALVE RELAY IN ABSCM&H/U.
and terminals.
Terminals
No. 23 No. 24:
Yes
Go to step 10.
CHECK ABSCM&H/U.
rent diagnosis still being out2)Erase the memory.
put?
4)Read out the DTC.
No
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Go to step 11.
Replace the
Go to step 12.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-78

ABS (DIAGNOSTICS)
Y: DTC 52
ABNORMAL MOTOR AND/OR MOTOR RELAY
DIAGNOSIS:
Faulty motor
Faulty motor relay
TROUBLE SYMPTOM:
ABS-79

ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
SBF HOLDER
SBF-4
SBF-1
SBF-1
LHD
RHD
E
IGNITION
SWITCH
F46
RHD
LHD
B108
LHD
RELAY
HOLDER
*1
B255
B61
RHD 3
*2
F96
*2: LHD 6
No.10
F44
*1: LHD 5
RHD
ABS RELAY B225
RHD 4
*3: LHD
RHD
1
3
4
B61
F44
B301
F49
LHD
LHD
RHD
B264
B200
9
RHD
RHD
F74
26
PUMP MOTOR
RR INLET
RR OUTLET
RL INLET
RL OUTLET
FR INLET
FR OUTLET
SOLENOID
VALVE
FL INLET

FL OUTLET
25
23
LHD
*3
E
VALVE RELAY
MOTOR RELAY
F46
B264
F44
F74
1
2
1 2
3 4
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
*3
B225
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0130
ABS-80

ABS (DIAGNOSTICS)
3
4
Step
H/U.
ground ():
():
CHECK GROUND CIRCUIT OF MOTOR.
CHECK RELAY HOLDER.
LHD:
RHD:
1)Install the fuse.
CHECK ABS RELAY.
No. 1 and 3.
terminals.
Check
Yes
15 V?
No
between battery
and ABSCM&H/U
and check fuse
SBF-holder.

?
Repair the
ABSCM&H/U
ground harness.

Replace the fuse.
Go to step 4.
Repair the open
circuit in harness
between battery
and relay holder
connector.
Repair the open

circuit in harness
between battery
and relay holder
connector.

between battery,
ignition switch and
ABS relay.
Repair the open
circuit between
ABS relay and
chassis ground.

?
Go to step 8.

?
Go to step 9.
ABS-81
Replace the ABS

relay.

ABS (DIAGNOSTICS)
10
11
Step
():
():
CHECK MOTOR OPERATION.
Operate the sequence control. <Ref. to ABS11, ABS Sequence Control.>
Check
Yes
15 V?
No
between battery,
ignition switch and
ABSCM&H/U.

?
Repair the
ABSCM&H/U
ground harness.
Can motor revolution noise

Go to step 12.
(buzz) be heard when carrying
out the sequence control?
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Go to step 13.
NOTE:
Use the diagnosis connector to operate the sequence control.
12
13
14
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in conTurn the ignition switch to OFF.
nector between generator, battery and ABSCM&H/U?
CHECK ABSCM&H/U.
put?
4)Read out the DTC.
Replace the
Go to step 14.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
contact.
ABS-82

ABS (DIAGNOSTICS)
ABS-83

ABS (DIAGNOSTICS)
Z: DTC 54
ABNORMAL STOP LIGHT SWITCH
DIAGNOSIS:
Faulty stop light switch
TROUBLE SYMPTOM:
WIRING DIAGRAM:
SBF-1
BATTERY
No.16
SBF-2
STOP LIGHT
SWITCH
STOP LIGHT
SWITCH
2
LHD
OC WC
1
2
2
3
RHD
1
B64
B64
: OC
B65
: WC
B61
RHD
F44
OC : WITHOUT CRUISE
CONTROL
LHD
2
WC : WITH CRUISE
CONTROL
*1: LHD
*1

RHD
B301
F49
B64
B65
*1
F44
1 2
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
1 2 3 4
5 6 7 8
BR0131
Step
CHECK STOP LIGHTS COME ON.
Depress the brake pedal.
Check
Do the stop lights come on?
ABS-84
Yes
Go to step 2.
No
Repair the stop
lights circuit.

ABS (DIAGNOSTICS)
Step
Check
Is the voltage between 10 and
CHECK OPEN CIRCUIT IN HARNESS.
15 V?
H/U.
3)Depress the brake pedal.
():
():
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in connector between stop light
switch and ABSCM&H/U?
CHECK ABSCM&H/U.
put?
4)Read out the DTC.
Yes
Go to step 3.
No
Repair the harness between stop
light switch and
ABSCM&H/U.
Go to step 4.
Replace the
Go to step 5.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-85

ABS (DIAGNOSTICS)
AA:DTC 56
ABNORMAL G SENSOR OUTPUT VOLTAGE
DIAGNOSIS:
Faulty G sensor output voltage
TROUBLE SYMPTOM:

23
30
6
28
B301
SHIELD JOINT
CONNECTOR
5
6
F62
1
2
3
B292
E
ABS
G SENSOR
B292
F62
1 2 3
1 2 3 4
5 6 7 8
B200
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
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 25 26
27 28 29 30 31
BR0132
ABS-86

ABS (DIAGNOSTICS)

23
30
6
28
F49
SHIELD JOINT
CONNECTOR
5
7
F62
14
5
4
15
F74
B200
1
2
3
B292
E
ABS
G SENSOR
B292
F62
F74
F49
1 2 3
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
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0045
Step
CHECK ALL FOUR WHEELS FOR FREE
TURNING.
Check
Have the wheels been turned
freely such as when the vehicle is lifted up, or operated on
a rolling road?
ABS-87
Yes
DTC.
No
Go to step 2.

ABS (DIAGNOSTICS)
Step
Check
CHECK SPECIFICATIONS OF ABSCM&H/U. Does the vehicle specification
Check the specifications of the mark to the
and ABSCM&H/U specificaABSCM&H/U.
tion match?
CHECK INPUT VOLTAGE OF G SENSOR.

(B292) No. 1 (+) No. 3 ():
CHECK OPEN CIRCUIT IN G SENSOR OUTPUT HARNESS AND GROUND HARNESS.
H/U.
LHD: (B301) No. 6 No. 28:
RHD: (F49) No. 6 No. 28:
CHECK GROUND SHORT IN G SENSOR
OUTPUT HARNESS.
1)Disconnect the connector from G sensor.
():
():
():
():
Is the voltage between 4.75

and 5.25 V?
Yes
No
Go to step 3.
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
CAUTION:
Be sure to turn
the ignition
switch to OFF
when removing
ABSCM&H/U.
Go to step 4.

between G sensor
and ABSCM&H/U.

and 5.6 k?
Go to step 5.

between G sensor
and ABSCM&H/U.

M?
Go to step 6.
Repair the harness between G

sensor and
ABSCM&H/U.
Go to step 7.

sensor and
ABSCM&H/U.
Go to step 8.

sensor and
ABSCM&H/U.
ABS-88

ABS (DIAGNOSTICS)
10
11
12
Step
Check
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ():
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ():
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ():
13
CHECK ABSCM&H/U.
2)Erase the memory.
3)Perform inspection mode.
4)Read out the DTC.
14
Yes
Go to step 9.

2.4 V when G sensor is horizontal?
No
sensor and
ABSCM&H/U.
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Replace the G
sensor. <Ref. to
ABS-22, G Sensor.>

4.1 V when G sensor is
Replace the G
sensor. <Ref. to
ABS-22, G Sensor.>

Replace the G
sensor. <Ref. to
ABS-22, G Sensor.>
Is there poor contact in connector between ABSCM&H/U

and G sensor?
Go to step 13.
Replace the
Go to step 14.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
contact.
ABS-89

ABS (DIAGNOSTICS)
AB:SELECT MONITOR
Applicable cartridge of select monitor: <Ref. to
ABS-10, SPECIAL TOOLS, PREPARATION
TOOL, General Description.>
NOTE:
For basic handling of the select monitor, refer to its
Operation Manual.
AC:DIAGNOSTIC TROUBLE CODES

(DTCs) ARE DISPLAYED.
A maximum of 3 DTCs are displayed in order of occurrence.
If a particular DTC is not properly stored in memory (due to a drop in ABSCM&H/U power supply,
etc.) when a problem occurs, the DTC, followed by
a question mark ?, appears on the select monitor
display. This shows it may be an unreliable reading.
AE:ANALOG DATA ARE DISPLAYED.

Display screen
FR wheel speed
FL wheel speed
RR wheel speed
RL wheel speed
Stop light switch
G sensor output
voltage
Wheel speed detected by Front Right
ABS sensor is displayed in km/h or mile/
h.
Wheel speed detected by Front Left ABS
sensor is displayed in km/h or mile/h.
Wheel speed detected by Rear Right
h.
Wheel speed detected by Rear Left ABS
Stop light switch monitor voltage is displayed.
Refers to vehicle acceleration detecting
by analog G sensor. It appears on the
select monitor display in volts.
AF:ON/OFF DATA ARE DISPLAYED.

Display screen
Stop light switch
Valve relay signal
Motor relay signal
ABS signal to TCM
S4M0076A
*a* refers to the troubles in order of occurrence

(Latest, Old, Older and Reference).
Display screen
Latest
Old
Older
Reference
The most recent DTC appears on select
monitor display.
The second most recent DTC appears
on select monitor display.
The third most recent DTC appears on
select monitor display.
A specified period of time proceeding
DTC appears on select monitor display.
ABS warning light

Valve relay monitor
Motor relay monitor
CCM signal
AG:ABS SEQUENCE CONTROL

Display
screen
Index No.
ABS
sequence
control
Perform ABS sequence

control by operating valve
and pump motor sequentially.
<Ref. to ABS11, ABS

Sequence Control.>
AD:CLEAR MEMORY
Display screen
Clear memory?
Valve relay signal
Motor relay signal
ABS warning light
Valve relay operation monitor signal
Motor relay operation monitor signal
Function of clearing DTC and freeze
frame data.
ABS-90

ABS (DIAGNOSTICS)
AH: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 maximum
to three.
If freeze frame data is not properly stored in
memory (due to a drop in ABSCM power supply,
etc.), a DTC, preceded by a question mark ?, appears on the select monitor display. This shows it
may be an unreliable reading.
Display screen
FR wheel speed
FL wheel speed
RR wheel speed
RL wheel speed
ABSCM power
voltage
G sensor output
voltage
Motor relay
monitor
Stop light switch
ABS signal to
TCM
ABS-AT control
ABS operation
signal
Wheel speed detected by Front Right
h.
Wheel speed detected by Front Left ABS
Wheel speed detected by Rear Right
h.
Wheel speed detected by Rear Left ABS
Power (in volts) supplied to ABSCM&
H/U appears on the select monitor display.
Refers to vehicle acceleration detected
by analog G sensor. It appears on the
select monitor display in volts.
Motor relay operation monitor signal
ABS operation signal from ABS control
module to TCM
ABS operation signal from ABS control
module to TCM
ABS operation signal
ABS-91
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR

ABS (DIAGNOSTICS)
13.Diagnostics Chart with Subaru Select Monitor

A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DIAGNOSIS:
TROUBLE SYMPTOM:
ABS warning light remains on.
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-4
GENERATOR
F74
RHD
LHD
LHD
*1
LHD
LHD
RHD
RHD
B108
RHD
RHD
IGNITION
SWITCH
RHD
F46
RELAY
HOLDER
B200
7
LHD
DATA LINK
CONNECTOR
4
5
LHD
*2
B40
No.18
B225
*1: LHD 5
RHD 3
ABS
RELAY
*2: LHD 6
1
3
4
*3: LHD
RHD 4
LHD
B301
F49
RHD
B264
RHD
E
9
B200
RHD
F74
LHD
23
5
*3
20
B40
*3
F74
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 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
9 10 11 12 13 14 15 16
F46
1
2
B225
B264
1 2
3 4
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
BR0133
ABS-92

ABS (DIAGNOSTICS)
Step
CHECK IGNITION SWITCH.
Check
Is the ignition switch turned to
ON?
CHECK BATTERY.
2)Measure the battery voltage.

MONITOR.
2)Using the select monitor, check whether
communication to other system can be executed normally.
MONITOR.
2)Disconnect the ABSCM&H/U connector.
3)Check whether communication to other systems can be executed normally.
MONITOR.
2)Connect the ABSCM&H/U connector.
3)Disconnect the cruise control module connector.
Yes
Go to step 2.

terminal?
tem displayed on select monitor?
No
Turn the ignition
switch to ON, and
select ABS mode
using select monitor.
Charge or replace
the battery.
Go to step 4.
Go to step 5.

tem displayed on select monitor?
Go to step 6.
Are the name and year of sys- Inspect the cruise

tem displayed on select moni- control module.
tor?
Go to step 7.
NOTE:
If the vehicle is not equipped with cruise control:
Go to step 8.
Are the name and year of sys- Inspect the immo- Go to step 8.
tem displayed on select moni- bilizer control
MONITOR.
tor?
module.
2)Connect the cruise control module connector.
3)Disconnect the immobilizer control module
connector.
NOTE:
If the vehicle is not quipped with immobilizer
control: Go to step 8.
EACH CONTROL MODULE AND DATA LINK M?
CONNECTOR.
2)Disconnect the ABSCM&H/U, cruise control
module and immobilizer control module connectors.
3)Measure the resistance between data link
ABS-93
Go to step 9.
Repair the harness and connector between each

control module

ABS (DIAGNOSTICS)
10
11
12
13
14
15
16
17
Step
CHECK OUTPUT SIGNAL FOR ABSCM&
H/U.
and chassis ground.
ABSCM&H/U AND DATA LINK CONNECTOR.
connector and data link connector.
LHD: (B301) No. 20 (B40) No. 5:
LHD: (B301) No. 5 (B40) No. 4:
RHD: (F49) No. 20 (B40) No. 5:
RHD: (F49) No. 5 (B40) No. 4:
CHECK INSTALLATION OF ABSCM&H/U
CONNECTOR.
LHD model
RHD model
CHECK RELAY HOLDER.
1)Install the fuse.
CHECK ABS RELAY.
No. 1 and 3.
terminals.
Check
Yes
No
ness and connector between each
control module
Is the resistance less than 0.5 Repair the harGo to step 11.
?
ness and connector between
ABSCM&H/U and
Is the ABSCM&H/U connector Go to step 12.

inserted into ABSCM&H/U until
the clamp locks onto it?
Insert the
ABSCM&H/U connector into
ABSCM&H/U.
Repair the open
circuit in harness
between battery
and relay holder
connector.

Replace the fuse.
Go to step 14.
Repair open circuit
in harness
between battery
and relay holder
connector.

between battery,
ignition switch and
ABS relay.
Repair the open
circuit between
ABS relay and
chassis ground.
Is the resistance less 5 ?
Go to step 17.

?
Go to step 18.
ABS-94
Replace the ABS

relay.

ABS (DIAGNOSTICS)
18
19
20
Step
CHECK POWER SUPPLY CIRCUIT.
2)Measure the ignition power supply voltage
between ABSCM&H/U connector and chassis
ground.
():
():
ABSCM&H/U AND CHASSIS GROUND.
2)Disconnect the connector from ABSCM&H/U
and transmission.
Check
Yes
No
Repair the open
circuit in harness
between
ABSCM&H/U and
battery.

?
Repair the open

circuit in harness
between
ABSCM&H/U and
inhibitor side connector, and poor
Go to step 20.
Is there poor contact in control Repair the conmodule power supply, ground nector.
line and data link connector?
ABS-95
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>

ABS (DIAGNOSTICS)
B: NO TROUBLE CODE
DIAGNOSIS:
ABS warning light circuit is shorted.
TROUBLE SYMPTOM:
ABS warning light remains on.
NO TROUBLE CODE displayed on the select monitor.
NOTE:
When the ABS warning light is OFF and NO TROUBLE CODE is displayed on select monitor, the system
is in normal condition.
ABS-96

ABS (DIAGNOSTICS)

BATTERY
SBF-1
SBF-4
SBF-3
E
IGNITION
SWITCH
F46
RELAY HOLDER
No.13
B108
10A
B36
23
NA
: NON-TURBO ENGINE
A7
MODEL
ABS
WARNING
LIGHT
B225
BRAKE
WARNING
LIGHT
2
1
3
COMBINATION
METER
A:
i10
B:
i11
DIAGNOSIS
TERMINAL
B82
6
TB
NA
B3
B19
B81
B264
D2
ABS RELAY
No.18
No.8
TB
i1
16
B37
E3
B264
1
2
1 2
3 4
B82
B22
2
1
3 4 5 6
4
8
12
16
23
4
B36
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B:
F60
3
7
11
15
i10
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
2
6
10
14
22
16
NA
F46
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B209
F1
G1Q2
H1 R2
I1 S2
J1 T2
E3
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B225
i11
A1 K2 A3
B1 L2
C1 M2 C3
D1 N2
E1
F60
TB
B301
1
5
9
13
21
24
B301
B209
F76
B22
i2
K4 A5
L4 B5
M4 C5
N4 D5
E5
F5
Q4 G5
H3 R4 H5
S4 I5
J3 T4 J5
ABS-97
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY HOLDER
BR0123

ABS (DIAGNOSTICS)

BATTERY
SBF-1
No.8
SBF-4
SBF-3
IGNITION
SWITCH
No.13
RELAY HOLDER
3
4
AT
No.18
MT
10A
B38
4
22
B36
i3
i1
AT
B225
BRAKE
WARNING
LIGHT
ABS
WARNING
LIGHT
A7
MT
ABS RELAY
A:
i10
B:
i11
DIAGNOSIS
TERMINAL
6
B3
B19
2
1
3
4
COMBINATION
METER
B82
B264
3
i2
B81
B37
E
19
20
B200
F49
B264
A:
i10
1 2 3 4 5 6 7 8 9 10
1 2
3 4
B:
23
22
21
24
F74
E
i1
i2
1 2 3
4 5 6
7 8 9 10 11 12 13 14
i11
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B225
F49
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
i3
F74
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
B82
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
2
1
3 4 5 6
BR0124
Step
2)Disconnect the connector (i2) from connector (B37).
3)Turn ignition switch to ON.
Check
Does the ABS warning light
remain off?
ABS-98
Yes
Go to step 2.
No
Repair the front
wiring harness.

ABS (DIAGNOSTICS)
Step
CHECK PROJECTION AT ABSCM&H/U.
H/U.
3)Check for broken projection at the
ABSCM&H/U terminal.
Check
Are the projection broken?

?
No
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Repair the harness.

M?
Go to step 6.
Repair the harness.

Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>

CHECK ABSCM&H/U.
terminals.
Terminals
No. 22 No. 23:

(B301 or F49) and chassis ground.
(B301 or F49) and chassis ground.
CONNECTOR.
ABS-99
Yes
Go to step 3.
Go to step 4.

ABS (DIAGNOSTICS)
C: DTC 21
OPEN OR SHORT CIRCUIT IN FRONT RIGHT ABS SENSOR CIRCUIT
NOTE:
For the diagnostic procedure, refer to DTC 27. <Ref. to ABS-101, DTC 27 OPEN OR SHORT CIRCUIT
IN REAR LEFT ABS SENSOR CIRCUIT , Diagnostics Chart with Subaru Select Monitor.>
D: DTC 23
OPEN OR SHORT CIRCUIT IN FRONT LEFT ABS SENSOR CIRCUIT
NOTE:
E: DTC 25
OPEN OR SHORT CIRCUIT IN REAR RIGHT ABS SENSOR CIRCUIT
NOTE:
ABS-100

ABS (DIAGNOSTICS)
F: DTC 27
OPEN OR SHORT CIRCUIT IN REAR LEFT ABS SENSOR CIRCUIT
DIAGNOSIS:
Faulty ABS sensor (Broken wire, input voltage too high)
TROUBLE SYMPTOM:
7
8
14
15
23
11
12
9
10
B301
1
2
3
4
6
B303
SHIELD JOINT
CONNECTOR
23
9
10
16
4
5
20
24
B62
F45
R3
B15
R72
2
1
R73
2
1
1
2
F94
1
2
B99
E
FRONT
ABS
SENSOR LH
F94
R72
B15
R73
2 1
1 2
FRONT
ABS
SENSOR RH
B303
1 2 3 4
5 6 7 8
REAR
ABS
SENSOR RH
REAR
ABS
SENSOR LH
B99
B301
F45
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
BR0125
ABS-101

ABS (DIAGNOSTICS)
7
8
14
15
23
11
12
9
10
F49
1
2
3
4
7
F62
11
13
12
3
2
SHIELD JOINT
CONNECTOR
F74
22
20
21
10
8
9
B200
B99
R3
F95
R72
2
1
R73
2
1
1
2
1
2
F94
E
FRONT
ABS
SENSOR LH
F94
R72
F95
R73
2 1
1 2
FRONT
ABS
SENSOR RH
F62
1 2 3 4
5 6 7 8
Step
CHECK OUTPUT OF ABS SENSOR USING
SELECT MONITOR.
1)Select Current data display & Save on the
select monitor.
2)Read the ABS sensor output corresponding
to faulty system in the select monitor data display mode.
REAR
ABS
SENSOR RH
REAR
ABS
SENSOR LH
F74
F49
B99
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 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
Check
Yes
Does the speed indicated on
Go to step 2.
display change in response to
speedometer reading during
acceleration/deceleration
when the steering wheel is in
straight-ahead position?
ABS-102
BR0038
No
Go to step 8.

ABS (DIAGNOSTICS)
Step
Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
Front wheel
0.3 0.8 mm (0.012 0.031 in)
Rear wheel
0.7 1.2 mm (0.028 0.047 in)
Check
Yes


mm (0.0020 in)?
nectors between ABSCM&H/U
and ABS sensor?
CHECK ABSCM&H/U.
put?
4)Read out the DTC.

tions?
Go to step 5.
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
CHECK ABS SENSOR.

and 1.5 k?
3)Measure the resistance of ABS sensor connector terminals.
Terminal
ABS-103
Go to step 9.
No
Tighten the ABS
sensor installation
bolts securely.
Adjust the gap.
NOTE:
No. 26755AA000).
or
worn
tone
wheel.
Replace the tone
wheel. Front:
<Ref. to ABS-20,
Front Tone
Wheel.> Rear:
<Ref. to ABS-21,
Rear Tone
Wheel.>
Go to step 6.
Go to step 7.
A temporary poor
contact.
NOTE:
Check the harness
and
connectors
between
ABSCM&H/U
and
ABS sensor.
Replace the ABS
sensor. Front:
<Ref. to ABS-14,
to ABS-17, Rear
ABS Sensor.>

ABS (DIAGNOSTICS)
10
11
12
Step
H/U.
and chassis ground.
Terminal
and chassis ground.
Terminal
DTC 21 / LHD: (B301) No. 11 No. 12:
RHD: (F49) No. 11 No. 12:
DTC 23 / LHD: (B301) No. 9 No. 10:
RHD: (F49) No. 9 No. 10:
DTC 25 / LHD: (B301) No. 14 No. 15:
RHD: (F49) No. 14 No. 15:
DTC 27 / LHD: (B301) No. 7 No. 8:
RHD: (F49) No. 7 No. 8:
DTC 21 / LHD: (B301) No. 11 (+) Chassis ground ():
():
():
():
():
Check
Yes
Go to step 10.
No
Replace the ABS
sensor. Front:
<Ref. to ABS-14,
to ABS-17, Rear
ABS Sensor.>
Go to step 11.
Replace the ABS

sensor. Front:
<Ref. to ABS-14,
to ABS-17, Rear
ABS Sensor.>

and 1.5 k?
Go to step 12.

between
ABSCM&H/U and
ABS sensor.
Go to step 13.

ABSCM&H/U and
ABS sensor.
ABS-104

ABS (DIAGNOSTICS)
Step
DTC 21 /
ground ():
():
DTC 23 /
():
():
DTC 25 /
ground ():
():
DTC 27 /
():
():
Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
Front wheel
0.3 0.8 mm (0.012 0.031 in)
Rear wheel
0.7 1.2 mm (0.028 0.047 in)
Check
16


mm (0.0020 in)?
17
CHECK GROUND SHORT OF ABS SENSOR. Is the resistance more than 1

M?
2)Measure the resistance between ABS sensor and chassis ground.
Terminal
13
14
15
Yes
Go to step 14.
No
ABSCM&H/U and
ABS sensor.

Tighten the ABS

sensor installation
bolts securely.
Adjust the gap.

tions?
ABS-105
Go to step 17.
Go to step 18.
NOTE:
No. 26755AA000).
or
worn
tone
wheel.
Replace the tone
wheel. Front:
<Ref. to ABS-20,
Front Tone
Wheel.> Rear:
<Ref. to ABS-21,
Rear Tone
Wheel.>
Replace the ABS
sensor and
ABSCM&H/U.
Front: <Ref. to
ABS-14, Front
ABS Sensor.>
Rear: <Ref. to
ABS-17, Rear
ABS Sensor.> and
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>

ABS (DIAGNOSTICS)
18
19
20
21
Step
Check
M?
ABSCM&H/U connector terminal and chassis
ground.
DTC 21 /
LHD: (B301)No. 11 Chassis ground:
DTC 23 /
DTC 25 /
DTC 27 /
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in connectors between ABSCM&H/U
and ABS sensor?
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
CHECK ANY OTHER DIAGNOSTIC TROU- Are other DTCs being output?
ABS-106
Yes
Go to step 19.
No
ABSCM&H/U and
ABS sensor.
And replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Go to step 20.
Replace the
ABSCM&H/U.
Go to step 21.
Proceed with the

A temporary poor
contact.
NOTE:
Check the harness
and
connectors
between
ABSCM&H/U
and
ABS sensor.

ABS (DIAGNOSTICS)
G: DTC 22
FRONT RIGHT ABNORMAL ABS SENSOR SIGNAL
NOTE:
For the diagnostic procedure, refer to DTC 28. <Ref. to ABS-108, DTC 28 REAR LEFT ABNORMAL ABS
H: DTC 24
FRONT LEFT ABNORMAL ABS SENSOR SIGNAL
NOTE:
I:
DTC 26
REAR RIGHT ABNORMAL ABS SENSOR SIGNAL
NOTE:
ABS-107

ABS (DIAGNOSTICS)
J: DTC 28
REAR LEFT ABNORMAL ABS SENSOR SIGNAL
DIAGNOSIS:
TROUBLE SYMPTOM:
7
8
14
15
23
11
12
9
10
B301
1
2
3
4
6
B303
SHIELD JOINT
CONNECTOR
23
9
10
16
4
5
20
24
B62
F45
R3
B15
R72
2
1
R73
2
1
1
2
F94
1
2
B99
E
FRONT
ABS
SENSOR LH
F94
R72
B15
R73
2 1
1 2
FRONT
ABS
SENSOR RH
B303
1 2 3 4
5 6 7 8
REAR
ABS
SENSOR RH
REAR
ABS
SENSOR LH
B99
B301
F45
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
BR0125
ABS-108

ABS (DIAGNOSTICS)
7
8
14
15
23
11
12
9
10
F49
1
2
3
4
7
F62
11
13
12
3
2
SHIELD JOINT
CONNECTOR
F74
22
20
21
10
8
9
B200
B99
R3
F95
R72
2
1
R73
2
1
1
2
1
2
F94
E
FRONT
ABS
SENSOR LH
F94
R72
F95
R73
2 1
1 2
FRONT
ABS
SENSOR RH
F62
1 2 3 4
5 6 7 8
Step
CHECK OUTPUT OF ABS SENSOR USING
SELECT MONITOR.
select monitor.
2)Read the ABS sensor output corresponding
to faulty system in the select monitor data display mode.
REAR
ABS
SENSOR RH
REAR
ABS
SENSOR LH
F74
F49
B99
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 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
Check
Yes
Does the speed indicated on
Go to step 2.
display change in response to
speedometer reading during
acceleration/deceleration
when the steering wheel is in
straight-ahead position?
ABS-109
BR0038
No
Go to step 8.

ABS (DIAGNOSTICS)
Step
Check
Yes
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in conRepair the conTurn the ignition switch to OFF.
nectors between ABSCM&H/U nector.
and ABS sensor?
Is the car telephone or wireless Go to step 4.

DTC 24 /
LHD: (F45) No. 8 Chassis ground:
DTC 26 /
DTC 26 /
RHD: (B99) No. 22 Chassis ground:
DTC 28 /
DTC 28 /
RHD: (B99) No. 10 Chassis ground:
NOTE:
Go to step 6.
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.

Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
gap over entire perimeter of wheel.
Front wheel
0.3 0.8 mm (0.012 0.031 in)
Rear wheel
0.7 1.2 mm (0.028 0.047 in)
10

sensor harness?
Is the resistance less than 0.5
?
No
Go to step 3.

car telephone or
Go to step 5.
Install the noise

sources apart from
sensor harness.
Go to step 6.
Repair the shield
harness.

put?
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Go to step 7.
A temporary noise
interference.
Is the gap within specifications?
Go to step 10.
Tighten the ABS

sensor installation
bolts securely.
Adjust the gap.
Go to step 11.
NOTE:
No. 26755AA000).
or
worn
tone
wheel.
Go to step 12.
ABS-110

ABS (DIAGNOSTICS)
11
12
13
Step
Check
smooth, as shown in the fig1)Raise all four wheels off ground.
ure?
NOTE:
When this inspection is completed, the
ABSCM&H/U sometimes stores DTC 29.
DTC 22 /
LHD: (B15) No. 1 (+) No. 2 ():
RHD: (F95) No. 1 (+) No. 2 ():
DTC 24 /
(F94) No. 1 (+) No. 2 ():
DTC 26 /
LHD: (B99) No. 9 (+) No. 10 ():
RHD: (B99) No. 20 (+) No. 21 ():
DTC 28 /
LHD: (B99) No. 4 (+) No. 5 ():
RHD: (B99) No. 8 (+) No. 9 ():
CHECK CONTAMINATION OF ABS SENSOR
OR TONE WHEEL.
Remove the disc rotor or drum from hub in
accordance with DTC.
TONE WHEEL.
Is the ABS sensor piece or

Are there broken or damaged
in the ABS sensor piece or
tone wheel?

mm (0.0020 in)?
14

15

CHECK RESISTANCE OF ABS SENSOR.
and 1.5 k?
3)Measure the resistance between ABS sensor connector terminals.
Terminal
ABS-111
Yes
Go to step 15.
No
Go to step 12.
Go to step 13.
Thoroughly
remove dirt or
Replace the ABS Go to step 14.
sensor or tone
wheel. Front:
<Ref. to ABS-14,
to ABS-17, Rear
ABS Sensor.> and
Front: <Ref. to
ABS-20, Front
Tone Wheel.>
Rear: <Ref. to
ABS-21, Rear
Tone Wheel.>
Go to step 15.
Replace the tone
wheel. Front:
<Ref. to ABS-20,
Front Tone
Wheel.> Rear:
<Ref. to ABS-21,
Rear Tone
Wheel.>
Go to step 16.
Replace the ABS
sensor. Front:
<Ref. to ABS-14,
to ABS-17, Rear
ABS Sensor.>

ABS (DIAGNOSTICS)
20
Step
CHECK GROUND SHORT OF ABS SENSOR.
Measure the resistance between ABS sensor
and chassis ground.
Terminal
H/U.
3)Measure the resistance at ABSCM&H/U
DTC 22 /
LHD: (B301)No. 11 No. 12:
RHD: (F49) No. 11 No. 12:
DTC 24 /
LHD: (B301) No. 9 No. 10:
RHD: (F49) No. 9 No. 10:
DTC 26 /
LHD: (B301) No. 14 No. 15:
RHD: (F49) No. 14 No. 15:
DTC 28 /
LHD: (B301) No. 7 No. 8:
RHD: (F49) No. 7 No. 8:
DTC 22 /
DTC 24 /
DTC 26 /
DTC 28 /
and chassis ground.
21
22
16
17
18
19
Check
M?
Yes
Go to step 17.
No
Replace the ABS
sensor. Front:
<Ref. to ABS-14,
to ABS-17, Rear
ABS Sensor.>

and 1.5 k?
Go to step 18.

between
ABSCM&H/U and
ABS sensor.

M?
Go to step 19.

between
ABSCM&H/U and
ABS sensor.

?
Repair the
ABSCM&H/U
ground harness.
Repair the conIs there poor contact in connectors between ABSCM&H/U nector.
and ABS sensor?
Is the car telephone or the
Go to step 22.
wireless transmitter properly
installed?
Go to step 21.
Are noise sources (such as an Install the noise

sources apart from
sensor harness?
sensor harness.
ABS-112

car telephone or
Go to step 23.

ABS (DIAGNOSTICS)
23
24
25
Step
Check
Yes
?
DTC 24 / LHD: (F45) No. 8 Chassis
ground:
ground:
ground:
ground:
ground:
NOTE:
Go to step 24.
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
No
Repair the shield
harness.

Go to step 25.
put?
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Are other DTCs being output? Proceed with the A temporary noise
diagnosis correinterference.
sponding to DTC.
ABS-113

ABS (DIAGNOSTICS)
K: DTC 29
ABNORMAL ABS SENSOR SIGNAL ON ANY ONE OF FOUR SENSOR
DIAGNOSIS:
Faulty tone wheel
Wheels turning freely for a long time
TROUBLE SYMPTOM:
7
8
14
15
23
11
12
9
10
B301
1
2
3
4
6
B303
SHIELD JOINT
CONNECTOR
23
9
10
16
4
5
20
24
B62
F45
R3
B15
R72
2
1
R73
2
1
1
2
F94
1
2
B99
E
FRONT
ABS
SENSOR LH
F94
R72
B15
R73
2 1
1 2
FRONT
ABS
SENSOR RH
B303
1 2 3 4
5 6 7 8
REAR
ABS
SENSOR RH
REAR
ABS
SENSOR LH
B99
B301
F45
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
BR0125
ABS-114

ABS (DIAGNOSTICS)
7
8
14
15
23
11
12
9
10
F49
1
2
3
4
7
F62
11
13
12
3
2
SHIELD JOINT
CONNECTOR
F74
22
20
21
10
8
9
B200
B99
R3
F95
R72
2
1
R73
2
1
1
2
1
2
F94
E
FRONT
ABS
SENSOR LH
F94
R72
F95
R73
2 1
1 2
FRONT
ABS
SENSOR RH
F62
1 2 3 4
5 6 7 8
REAR
ABS
SENSOR RH
REAR
ABS
SENSOR LH
F74
F49
B99
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 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
ABS-115
BR0038

ABS (DIAGNOSTICS)
2
3
4
5
7
8
Step
CHECK IF THE WHEELS HAVE TURNED
FREELY FOR A LONG TIME.
Check
Check if the wheels have been
turned freely for more than one
minute, such as when vehicle
is jacked-up, under full-lock
cornering or when tire is not in
contact with road surface.
Yes
DTC.
NOTE:
When the wheels
turn freely for a
long time, such as
when vehicle is
towed or jackedup, or when steering wheel is continuously turned all
way, this trouble
code may sometimes occur.
Go to step 3.
Replace the tire.
CHECK TIRE SPECIFICATIONS.

CHECK WEAR OF TIRE.
CHECK TIRE PRESSURE.
Are the tire specifications correct?

Is the tire worn excessively?
Is the tire pressure correct?

Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
Front wheel
0.3 0.8 mm (0.012 0.031 in)
Rear wheel
0.7 1.2 mm (0.028 0.047 in)

3)Connect the oscilloscope to connector (B15),
(B99), (F95) or (F94) in accordance with DTC.
No
Go to step 2.
Is the gap within specifications?
Go to step 7.
Go to step 4.
Adjust the tire
pressure.
Tighten the ABS
sensor installation
bolts securely.
Adjust the gap.
smooth, as shown in the figure?
Go to step 8.
Go to step 12.
NOTE:
No. 26755AA000).
or
worn
tone
wheel.
Go to step 9.
Go to step 9.
NOTE:
When this inspection is completed, ABSCM&
H/U sometimes stores the DTC 29.
Front RH
LHD: (B15) No. 1 (+) No. 2 ():
RHD: (F95) No. 1 (+) No. 2 ():
Front LH
(F94) No. 1 (+) No. 2 ():
Rear RH
LHD: (B99) No. 9 (+) No. 10 ():
RHD: (B99) No. 20 (+) No. 21 ():
Rear LH
LHD: (B99) No. 4 (+) No. 5 ():
RHD: (B99) No. 8 (+) No. 9 ():
ABS-116
Replace the tire.

Go to step 5.

ABS (DIAGNOSTICS)
Step
Check
CHECK CONTAMINATION OF ABS SENSOR Is the ABS sensor piece or
OR TONE WHEEL.
Remove the disc rotor from hub.
10

TONE WHEEL.
11

12
CHECK ABSCM&H/U.
3)Erase the memory.
5)Read out the DTC.
13
Yes
No
Thoroughly
Go to step 10.
remove dirt or
Are there broken or damaged Replace the ABS Go to step 11.
teeth in the ABS sensor piece sensor or tone
or tone wheel?
wheel. Front:
<Ref. to ABS-14,
to ABS-17, Rear
ABS Sensor.> and
Front: <Ref. to
ABS-20, Front
Tone Wheel.>
Rear: <Ref. to
ABS-21, Rear
Tone Wheel.>
Go to step 12.
Replace the tone
mm (0.0020 in)?
wheel. Front:
<Ref. to ABS-20,
Front Tone
Wheel.> Rear:
<Ref. to ABS-21,
Rear Tone
Wheel.>
Go to step 13.
put?
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-117

ABS (DIAGNOSTICS)
L: DTC 31
FRONT RIGHT INLET VALVE MALFUNCTION
NOTE:
For the diagnostic procedure, refer to DTC 37. <Ref. to ABS-120, DTC 37 REAR LEFT INLET VALVE
MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.>
M: DTC 33
FRONT LEFT INLET VALVE MALFUNCTION
NOTE:
N: DTC 35
REAR RIGHT INLET VALVE MALFUNCTION
NOTE:
ABS-118

ABS (DIAGNOSTICS)
ABS-119

ABS (DIAGNOSTICS)
O: DTC 37
REAR LEFT INLET VALVE MALFUNCTION
DIAGNOSIS:
Faulty inlet solenoid valve
TROUBLE SYMPTOM:
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-4
GENERATOR
LHD
RHD
F46
2
IGNITION
SWITCH
LHD
B108
*1
RELAY
HOLDER
*1: LHD 5
RHD
*2
No.18
RHD 3
B225
ABS
RELAY
*2: LHD 6
RHD 4
*3: LHD
1
3
4
RHD
B301
F49
LHD
RHD
B264
E
9
B200
RHD
F74
LHD
1
23
*3
F46
B264
F74
1
2
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
*3
B225
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0126
ABS-120

ABS (DIAGNOSTICS)
1
2
Step
CHECK RELAY HOLDER.
LHD:
RHD:
1)Install the fuse.
CHECK ABS RELAY.
No. 1 and 3.
terminals.
H/U.
():
():
Check
Yes
Replace the fuse.
No
Go to step 2.
Repair the open
circuit in harness
between battery
and relay holder
connector.
Repair the open

circuit in harness
between battery
and relay holder
connector.

between battery,
ignition switch and
ABS relay.
Repair the open
circuit between
ABS relay and
chassis ground.

?
Go to step 6.

?
Go to step 7.
Replace the ABS

relay.

15 V?

between battery,
ignition switch and
ABSCM&H/U.

?
Repair the
ABSCM&H/U
ground harness.

Go to step 10.
ABS-121

ABS (DIAGNOSTICS)
10
11
Step
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
Check
Yes
No
Go to step 11.
put?
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-122

ABS (DIAGNOSTICS)
P: DTC 32
FRONT RIGHT OUTLET VALVE MALFUNCTION
NOTE:
For the diagnostic procedure, refer to DTC 38. <Ref. to ABS-124, DTC 38 REAR LEFT OUTLET VALVE
Q: DTC 34
FRONT LEFT OUTLET VALVE MALFUNCTION
NOTE:
R: DTC 36
REAR RIGHT OUTLET VALVE MALFUNCTION
NOTE:
ABS-123

ABS (DIAGNOSTICS)
S: DTC 38
REAR LEFT OUTLET VALVE MALFUNCTION
DIAGNOSIS:
Faulty outlet solenoid valve
TROUBLE SYMPTOM:
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-4
GENERATOR
LHD
RHD
F46
2
IGNITION
SWITCH
LHD
B108
*1
RELAY
HOLDER
*1: LHD 5
RHD
*2
No.18
RHD 3
B225
ABS
RELAY
*2: LHD 6
RHD 4
*3: LHD
1
3
4
RHD
B301
F49
LHD
RHD
B264
E
9
B200
RHD
F74
LHD
1
23
*3
F46
B264
F74
1
2
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
*3
B225
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0126
ABS-124

ABS (DIAGNOSTICS)
1
2
Step
CHECK RELAY HOLDER.
LHD:
RHD:
1)Install the fuse.
CHECK ABS RELAY.
No. 1 and 3.
terminals.
H/U.
():
():
Check
Yes
Replace the fuse.
No
Go to step 2.
Repair the open
circuit in harness
between battery
and relay holder
connector.
Repair the open

circuit in harness
between battery
and relay holder
connector.

between battery,
ignition switch and
ABS relay.
Repair the open
circuit between
ABS relay and
chassis ground.

?
Go to step 6.

?
Go to step 7.
Replace the ABS

relay.

15 V?

between battery,
ignition switch and
ABSCM&H/U.

?
Repair the
ABSCM&H/U
ground harness.

Go to step 10.
ABS-125

ABS (DIAGNOSTICS)
10
11
Step
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
Check
Yes
No
Go to step 11.
put?
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-126

ABS (DIAGNOSTICS)
ABS-127

ABS (DIAGNOSTICS)
T: DTC 41
ABS CONTROL MODULE MALFUNCTION
DIAGNOSIS:
Faulty ABSCM&H/U
TROUBLE SYMPTOM:
WIRING DIAGRAM:

23
*1
B301
*1: LHD
RHD
F49
*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
BR0127
Step
Check
Yes
?
H/U.
ABS-128
No
Repair the
ABSCM&H/U
ground harness.

ABS (DIAGNOSTICS)
Step
Check
Yes
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in conRepair the connectors between battery, igni- nector.
tion switch and ABSCM&H/U?
Is the car telephone or wireless Go to step 4.
CHECK ABSCM&H/U.
3)Erase the memory.
5)Read out the DTC.

sensor harness?
No
Go to step 3.

car telephone or
Go to step 5.
Install the noise

sources apart from
sensor harness.
Replace the
Go to step 6.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-129

ABS (DIAGNOSTICS)
U: DTC 42
POWER SUPPLY VOLTAGE TOO LOW
DIAGNOSIS:
Power source voltage of the ABSCM&H/U is low.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-4
GENERATOR
LHD
RHD
F46
2
IGNITION
SWITCH
LHD
B108
*1
RELAY
HOLDER
*1: LHD 5
RHD
*2
No.18
RHD 3
B225
ABS
RELAY
*2: LHD 6
RHD 4
*3: LHD
1
3
4
RHD
B301
F49
LHD
RHD
B264
E
9
B200
RHD
F74
LHD
1
23
*3
F46
B264
F74
1
2
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
*3
B225
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0126
ABS-130

ABS (DIAGNOSTICS)
Step
CHECK GENERATOR.
1)Start the engine.
Terminal
Generator B terminal Chassis ground:
Check
Yes
15 V?

clamped?
15 V?
H/U.
():
():
?
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in conRepair the connectors between generator,
nector.
CHECK ABSCM&H/U.
2)Erase the memory.
put?
<Ref. to ABS-7,
ABS Control Mod4)Read out the DTC.
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
CHECK ANY OTHER DIAGNOSTIC TROU- Are other DTCs being output? Proceed with the
ABS-131
No
Tighten the clamp

of terminal.
between battery,
ignition switch and
ABSCM&H/U.
Repair the
ABSCM&H/U
ground harness.
Go to step 6.
Go to step 7.
A temporary poor
contact.

ABS (DIAGNOSTICS)
V: DTC 42
POWER SUPPLY VOLTAGE TOO HIGH
DIAGNOSIS:
Power source voltage of the ABSCM&H/U is high.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-4
GENERATOR
LHD
RHD
F46
2
IGNITION
SWITCH
LHD
B108
*1
RELAY
HOLDER
*1: LHD 5
RHD
*2
No.18
RHD 3
B225
ABS
RELAY
*2: LHD 6
RHD 4
*3: LHD
1
3
4
RHD
B301
F49
LHD
RHD
B264
E
9
B200
RHD
F74
LHD
1
23
*3
F46
B264
F74
1
2
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
*3
B225
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0126
ABS-132

ABS (DIAGNOSTICS)
3
4
Step
CHECK GENERATOR.
1)Start the engine.
Terminal
Generator B terminal Chassis ground:
Check
Yes
17 V?

clamped?
CHECK RELAY HOLDER.
Replace the fuse.
CHECK INPUT VOLTAGE OF RELAY HOLD- Is the voltage more than 10 V? Go to step 5.
ER.
2)Remove the fuse.
LHD:
RHD:
1)Install the fuse.
Go to step 8.
CHECK GROUND CIRCUIT OF ABS RELAY. Is the resistance less than 5
?
CHECK ABS RELAY.
Is the resistance less than 10 Go to step 9.
?
No. 1 and 3.
terminals.
17 V?
H/U.
():
():
ABS-133
No
Tighten the clamp

of terminal.
Go to step 4.
Repair the open
circuit in harness
between battery
and relay holder
connector.
Repair the open

circuit in harness
between battery
and relay holder
connector.

between battery,
ignition switch and
ABS relay.
Repair the open
circuit between
ABS relay and
chassis ground.
Replace the ABS

relay.

between battery,
ignition switch and
ABSCM&H/U.

ABS (DIAGNOSTICS)
10
11
12
13
Step
Check
?
CHECK ABSCM&H/U.
put?
4)Read out the DTC.
Yes
Go to step 11.
No
Repair the
ABSCM&H/U
ground harness.
Go to step 12.
Replace the
Go to step 13.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-134

ABS (DIAGNOSTICS)
ABS-135

ABS (DIAGNOSTICS)
W: DTC 44
ABS-AT CONTROL (NON CONTROLLED)
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
31

*1
*1: LHD
RHD
B301
F49
LHD
RHD
21
F74
LHD
B200
21
RHD
B55
1 2 3 4
10 11 12 13
19 20 21
TCM
B55
*1
F74
5 6
14 15
1 2 3 4 5 6 7 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
7
16
22
8 9
17 18
23 24
BR0128
Step
CHECK SPECIFICATIONS OF THE ABSCM&H/U.
Check specifications of the mark on the
ABSCM&H/U.
Check
Is an ABSCM&H/U for AT
model installed on a MT
model?
ABS-136
Yes
No
Replace the
Go to step 2.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>

ABS (DIAGNOSTICS)
4
5
Step
2)Disconnect the two connectors from TCM.
H/U.
CHECK TCM.
3)Measure the voltage between TCM connector terminal and chassis ground.
CHECK AT.
():
ground ():
():
():
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
Check
M?
Yes
Go to step 3.

15 V?
No
TCM and
ABSCM&H/U.
Go to step 4.
Is the AT functioning normally? Replace the TCM. Repair the AT.

between TCM and
ABSCM&H/U.

ABSCM&H/U?
Go to step 7.
Replace the
Go to step 8.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-137

ABS (DIAGNOSTICS)
X: DTC 44
ABS-AT CONTROL (CONTROLLED)
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
31

*1
*1: LHD
RHD
B301
F49
LHD
RHD
21
F74
LHD
B200
21
RHD
B55
1 2 3 4
10 11 12 13
19 20 21
TCM
B55
*1
F74
5 6
14 15
1 2 3 4 5 6 7 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
7
16
22
8 9
17 18
23 24
BR0128
ABS-138

ABS (DIAGNOSTICS)
Step
2)Disconnect all connectors from TCM.
H/U.
():
():
():
():
():
ground ():
():
():
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
Check
Yes
Go to step 2.
No
TCM and
ABSCM&H/U.
Go to step 3.

TCM and
ABSCM&H/U.

13 V?

between TCM and
ABSCM&H/U.

ABSCM&H/U?
Go to step 5.
Replace the
Go to step 6.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-139

ABS (DIAGNOSTICS)
ABS-140

ABS (DIAGNOSTICS)
Y: DTC 51
VALVE RELAY MALFUNCTION
DIAGNOSIS:
Faulty valve relay
TROUBLE SYMPTOM:
ABS-141

ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
SBF-1
No.8
SBF-4
SBF-3
LHD
RHD
E
IGNITION
SWITCH
F46
B108
LHD
RELAY
HOLDER
*1
*1: LHD 5
RHD 3
RHD
*2
No.18
*2: LHD 6
ABS RELAY B225
RHD 4
*3: LHD
RHD
B301
F49
1
3
4
LHD
RHD
B264
E
9
B200
RHD
F74
PUMP MOTOR
RR INLET
RR OUTLET
RL INLET
RL OUTLET
FR INLET
FR OUTLET
SOLENOID
VALVE
FL INLET

FL OUTLET
24
*3
23
LHD
E
VALVE RELAY
F46
B264
1
2
1 2
3 4
MOTOR RELAY
F74
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
B225
*3
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0129
ABS-142

ABS (DIAGNOSTICS)
1
2
Step
CHECK RELAY HOLDER.
LHD:
RHD:
1)Install the fuse.
CHECK ABS RELAY.
No. 1 and 3.
terminals.
H/U.
():
ground ():
():
():
Check
Yes
Replace the fuse.
No
Go to step 2.
Repair the open
circuit in harness
between battery
and relay holder
connector.
Repair the open

circuit in harness
between battery
and relay holder
connector.

between battery,
ignition switch and
ABS relay.
Repair the open
circuit between
ABS relay and
chassis ground.

?
Go to step 6.

?
Go to step 7.
Replace the ABS

relay.

15 V?

between battery
and ABSCM&H/U.

?
Repair the
ABSCM&H/U
ground harness.
ABS-143

ABS (DIAGNOSTICS)
10
11
Step
Check
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
Yes
No
Go to step 10.
Replace the
Go to step 11.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-144

ABS (DIAGNOSTICS)
Z: DTC 51
VALVE RELAY ON FAILURE
DIAGNOSIS:
Faulty valve relay
TROUBLE SYMPTOM:
ABS-145

ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
SBF-1
No.8
SBF-4
SBF-3
LHD
RHD
E
IGNITION
SWITCH
F46
B108
LHD
RELAY
HOLDER
*1
*1: LHD 5
RHD 3
RHD
*2
No.18
*2: LHD 6
ABS RELAY B225
RHD 4
*3: LHD
RHD
B301
F49
1
3
4
LHD
RHD
B264
E
9
B200
RHD
F74
PUMP MOTOR
RR INLET
RR OUTLET
RL INLET
RL OUTLET
FR INLET
FR OUTLET
SOLENOID
VALVE
FL INLET

FL OUTLET
24
*3
23
LHD
E
VALVE RELAY
F46
B264
1
2
1 2
3 4
MOTOR RELAY
F74
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
B225
*3
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0129
ABS-146

ABS (DIAGNOSTICS)
Step
Check
CHECK VALVE RELAY IN ABSCM&H/U.
M?
H/U.
ABSCM&H/U terminals.
Terminals
No. 23 No. 24:
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
Yes
Go to step 2.
No
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Go to step 3.
Replace the
Go to step 4.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-147

ABS (DIAGNOSTICS)
ABS-148

ABS (DIAGNOSTICS)
AA:DTC 52
OPEN CIRCUIT IN MOTOR RELAY CIRCUIT
DIAGNOSIS:
Faulty motor
Faulty motor relay
TROUBLE SYMPTOM:
ABS-149

ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
SBF HOLDER
SBF-4
SBF-1
SBF-1
LHD
RHD
E
IGNITION
SWITCH
F46
RHD
LHD
B108
LHD
RELAY
HOLDER
*1
B255
B61
RHD 3
*2
F96
*2: LHD 6
No.10
F44
*1: LHD 5
RHD
ABS RELAY B225
RHD 4
*3: LHD
RHD
1
3
4
B61
F44
B301
F49
LHD
LHD
RHD
B264
B200
9
RHD
RHD
F74
26
PUMP MOTOR
RR INLET
RR OUTLET
RL INLET
RL OUTLET
FR INLET
FR OUTLET
SOLENOID
VALVE
FL INLET

FL OUTLET
25
23
LHD
*3
E
VALVE RELAY
MOTOR RELAY
F46
B264
F44
F74
1
2
1 2
3 4
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
*3
B225
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0130
ABS-150

ABS (DIAGNOSTICS)
Step
H/U.
ground ():
():
Check
Yes
13 V?
No
between battery
and ABSCM&H/U
and check fuse
SBF6.

?
Repair the
ABSCM&H/U
ground harness.

Go to step 4.
out the check sequence?
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Go to step 5.
NOTE:
Use the diagnosis connector to operate sequence control.
4
nector between hydraulic unit,
relay box and ABSCM&H/U?
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
Replace the
Go to step 6.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
contact.
ABS-151

ABS (DIAGNOSTICS)
ABS-152

ABS (DIAGNOSTICS)
AB:DTC 52
MOTOR RELAY ON FAILURE
DIAGNOSIS:
Faulty motor
Faulty motor relay
TROUBLE SYMPTOM:
ABS-153

ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
SBF HOLDER
SBF-4
SBF-1
SBF-1
LHD
RHD
E
IGNITION
SWITCH
F46
RHD
LHD
B108
LHD
RELAY
HOLDER
*1
B255
B61
RHD 3
*2
F96
*2: LHD 6
No.10
F44
*1: LHD 5
RHD
ABS RELAY B225
RHD 4
*3: LHD
RHD
1
3
4
B61
F44
B301
F49
LHD
LHD
RHD
B264
B200
9
RHD
RHD
F74
26
PUMP MOTOR
RR INLET
RR OUTLET
RL INLET
RL OUTLET
FR INLET
FR OUTLET
SOLENOID
VALVE
FL INLET

FL OUTLET
25
23
LHD
*3
E
VALVE RELAY
MOTOR RELAY
F46
B264
F44
F74
1
2
1 2
3 4
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
*3
B225
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0130
ABS-154

ABS (DIAGNOSTICS)
Step
CHECK MOTOR RELAY IN ABSCM&H/U.
H/U.
ABSCM&H/U terminals.
Terminals
No. 25 No. 26:
Check
M?
Yes
Go to step 2.

Go to step 3.
NOTE:
3
nector between hydraulic unit,
relay box and ABSCM&H/U?
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
No
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Go to step 4.
Replace the
Go to step 5.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-155

ABS (DIAGNOSTICS)
ABS-156

ABS (DIAGNOSTICS)
AC:DTC 52
MOTOR MALFUNCTION
DIAGNOSIS:
Faulty motor
Faulty motor relay
TROUBLE SYMPTOM:
ABS-157

ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
SBF HOLDER
SBF-4
SBF-1
SBF-1
LHD
RHD
E
IGNITION
SWITCH
F46
RHD
LHD
B108
LHD
RELAY
HOLDER
*1
B255
B61
RHD 3
*2
F96
*2: LHD 6
No.10
F44
*1: LHD 5
RHD
ABS RELAY B225
RHD 4
*3: LHD
RHD
1
3
4
B61
F44
B301
F49
LHD
LHD
RHD
B264
B200
9
RHD
RHD
F74
26
PUMP MOTOR
RR INLET
RR OUTLET
RL INLET
RL OUTLET
FR INLET
FR OUTLET
SOLENOID
VALVE
FL INLET

FL OUTLET
25
23
LHD
*3
E
VALVE RELAY
MOTOR RELAY
F46
B264
F44
F74
1
2
1 2
3 4
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
*3
B225
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0130
ABS-158

ABS (DIAGNOSTICS)
Step
H/U.
ground ():
():
():
():
Check
Yes
13 V?
No
between battery
and ABSCM&H/U
and check fuse
SBF6.

?
Repair the
ABSCM&H/U
ground harness.

15 V?

between battery,
ignition switch and
ABSCM&H/U.

?
Repair the
ABSCM&H/U
ground harness.

Go to step 6.
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Go to step 7.
NOTE:
6
nector between generator, battery and ABSCM&H/U?
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
Replace the
Go to step 8.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-159

ABS (DIAGNOSTICS)
AD:DTC 54
STOP LIGHT SWITCH SIGNAL CIRCUIT MALFUNCTION
DIAGNOSIS:
Faulty stop light switch
TROUBLE SYMPTOM:
WIRING DIAGRAM:
SBF-1
BATTERY
No.16
SBF-2
STOP LIGHT
SWITCH
STOP LIGHT
SWITCH
2
LHD
OC WC
1
2
2
3
RHD
1
B64
B64
: OC
B65
: WC
B61
RHD
F44
OC : WITHOUT CRUISE
CONTROL
LHD
2
WC : WITH CRUISE
CONTROL
*1: LHD
*1

RHD
B301
F49
B64
B65
*1
F44
1 2
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
1 2 3 4
5 6 7 8
BR0131
Step
CHECK OUTPUT OF STOP LIGHT SWITCH
USING SELECT MONITOR.
select monitor.
2)Release the brake pedal.
3)Read the stop light switch output in select
monitor data display.
Check
Is the reading indicated on
monitor display less than 1.5
V?
ABS-160
Yes
Go to step 2.
No
Go to step 3.

ABS (DIAGNOSTICS)
3
4
Step
CHECK OUTPUT OF STOP LIGHT SWITCH
USING SELECT MONITOR.
2)Read the stop light switch output in select
monitor data display.
CHECK IF STOP LIGHTS COME ON.
Depress the brake pedal.
CHECK OPEN CIRCUIT IN HARNESS.
H/U.
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
Check
Is the reading indicated on
monitor display between 10
and 15 V?
Yes
Go to step 5.
No
Go to step 3.
Do the stop lights turn on?
Go to step 4.
Repair the stop

lights circuit.
Repair the harness between stop
light switch and
ABSCM&H/U connector.

15 V?
Is there poor contact in connector between stop light

switch and ABSCM&H/U?
Go to step 6.
Replace the
Go to step 7.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-161

ABS (DIAGNOSTICS)
AE:DTC 56
OPEN OR SHORT CIRCUIT IN G SENSOR CIRCUIT
DIAGNOSIS:
TROUBLE SYMPTOM:

23
30
6
28
B301
SHIELD JOINT
CONNECTOR
5
6
F62
1
2
3
B292
E
ABS
G SENSOR
B292
F62
1 2 3
1 2 3 4
5 6 7 8
B200
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
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 25 26
27 28 29 30 31
BR0132
ABS-162

ABS (DIAGNOSTICS)

23
30
6
28
F49
SHIELD JOINT
CONNECTOR
5
7
F62
14
5
4
15
F74
B200
1
2
3
B292
E
ABS
G SENSOR
B292
F62
F74
F49
1 2 3
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
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0045
Step
CHECK OUTPUT OF G SENSOR USING SELECT MONITOR.
select monitor.
2)Read the G sensor output in select monitor
data display.
Check
Yes
Is the G sensor output on mon- Go to step 2.
itor display between 2.1 and
2.5 V when G sensor is in horizontal position?
ABS-163
No
Go to step 5.

ABS (DIAGNOSTICS)
Step
Check
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in connector between ABSCM&H/U
and G sensor?
Is the same DTC as in the curCHECK ABSCM&H/U.
put?
4)Read out the DTC.

disconnect connector.)
(B292) No. 1 (+) No. 3 ():
H/U.
LHD: (B301) No. 6 No. 28:
RHD: (F49) No. 6 No. 28:
CHECK GROUND SHORT IN G SENSOR
OUTPUT HARNESS.
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ():
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ():
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ():
10
Yes
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Go to step 6.
and 5.25 V?
No
Go to step 3.
Go to step 4.
A temporary poor
contact.
between G sensor
and ABSCM&H/U.

and 5.6 k?
Go to step 7.

between G sensor
and ABSCM&H/U.

M?
Go to step 8.

sensor and
ABSCM&H/U.

Replace the G
sensor. <Ref. to
ABS-22, G Sensor.>

Replace the G
sensor. <Ref. to
ABS-22, G Sensor.>

Replace the G
sensor. <Ref. to
ABS-22, G Sensor.>
ABS-164

ABS (DIAGNOSTICS)
11
12
13
Step
Check
nector between ABSCM&H/U
and G sensor?
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
Yes
No
Go to step 12.
Replace the
Go to step 13.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-165

ABS (DIAGNOSTICS)
AF:DTC 56
BATTERY SHORT IN G SENSOR CIRCUIT
DIAGNOSIS:
TROUBLE SYMPTOM:

23
30
6
28
B301
SHIELD JOINT
CONNECTOR
5
6
F62
1
2
3
B292
E
ABS
G SENSOR
B292
F62
1 2 3
1 2 3 4
5 6 7 8
B200
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
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 25 26
27 28 29 30 31
BR0132
ABS-166

ABS (DIAGNOSTICS)

23
30
6
28
F49
SHIELD JOINT
CONNECTOR
5
7
F62
14
5
4
15
F74
B200
1
2
3
B292
E
ABS
G SENSOR
B292
F62
F74
F49
1 2 3
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
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0045
Step
select monitor.
2)Read the G sensor output in select monitor
data display.
Check
Yes
2.5 V when G sensor is in horizontal position?
ABS-167
No
Go to step 5.

ABS (DIAGNOSTICS)
Step
Check
and G sensor?
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
CHECK FREEZE FRAME DATA.

1)Select Freeze frame data on the select
monitor.
2)Read front right wheel speed on the select
monitor display.
Read front left wheel speed on the select monitor display.
Read rear right wheel speed on the select
monitor display.
Read rear left wheel speed on the select monitor display.
Read G sensor output on the select monitor
display.
H/U.
LHD: (B301) No. 6 No. 28:
RHD: (F49) No. 6 No. 28:
H/U.
():
():
10
11
Yes
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Is the front right wheel speed Go to step 6.
on monitor display 0 km?
No
Go to step 3.
Go to step 4.
A temporary poor
contact.
Go to step 16.
Is the front left wheel speed on Go to step 7.

monitor display 0 km?
Go to step 16.
Is the rear right wheel speed

on monitor display 0 km?
Go to step 8.
Go to step 16.
Is the rear left wheel speed on Go to step 9.

monitor display 0 km?
Go to step 16.

itor display more than 3.65 V?
Go to step 16.

and 4.9 k?
Go to step 11.

between G sensor
and ABSCM&H/U.
Go to step 12.

sensor and
ABSCM&H/U.
ABS-168

ABS (DIAGNOSTICS)
12
13
14
Step
Check
():
():
and G sensor?
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
15
16

disconnect connector.)
(B292) No. 1 (+) No. 3 ():
H/U.
LHD: (B301) No. 6 No. 28:
RHD: (F49) No. 6 No. 28:
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ():
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ():
17
18
19
Yes
Go to step 13.
No
sensor and
ABSCM&H/U.
Go to step 14.
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Go to step 17.
and 5.25 V?

and 5.6 k?
Go to step 18.
Go to step 15.
A temporary poor
contact.
between G sensor
and ABSCM&H/U.

between G sensor
and ABSCM&H/U.

Replace the G
sensor. <Ref. to
ABS-22, G Sensor.>

Replace the G
sensor. <Ref. to
ABS-22, G Sensor.>
ABS-169

ABS (DIAGNOSTICS)
20
21
Step
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ():
22
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
23
Check
Yes
No
Replace the G
sensor. <Ref. to
ABS-22, G Sensor.>
Is there poor contact in connector between ABSCM&H/U

and G sensor?
Go to step 22.
Replace the
Go to step 23.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-170

ABS (DIAGNOSTICS)
AG:DTC 56
ABNORMAL G SENSOR HIGH OUTPUT
DIAGNOSIS:
TROUBLE SYMPTOM:

23
30
6
28
B301
SHIELD JOINT
CONNECTOR
5
6
F62
1
2
3
B292
E
ABS
G SENSOR
B292
F62
1 2 3
1 2 3 4
5 6 7 8
B200
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
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 25 26
27 28 29 30 31
BR0132
ABS-171

ABS (DIAGNOSTICS)

23
30
6
28
F49
SHIELD JOINT
CONNECTOR
5
7
F62
14
5
4
15
F74
B200
1
2
3
B292
E
ABS
G SENSOR
B292
F62
F74
F49
1 2 3
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
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0045
Step
select monitor.
2)Read G sensor output on the select monitor
display.
Check
Yes
itor display 2.30.2 V when G
sensor is in horizontal position?
ABS-172
No
Go to step 6.

ABS (DIAGNOSTICS)
Step
Check
and G sensor?
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
Yes
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
diagnosis correBLE CODES (DTCs) APPEARANCE.
sponding to DTC.
CHECK OPEN CIRCUIT IN G SENSOR OUT- Is the resistance between 5.0 Go to step 6.
PUT HARNESS AND GROUND HARNESS. and 5.6 k?
H/U.
LHD: (B301) No. 6 No. 28:
RHD: (F49) No. 6 No. 28:
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ():
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ():
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ():

No
Go to step 3.
Go to step 4.
A temporary poor
contact.
between G sensor
and ABSCM&H/U.

sensor and
ABSCM&H/U.
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
Replace the G
sensor. <Ref. to
ABS-22, G Sensor.>

Replace the G
sensor. <Ref. to
ABS-22, G Sensor.>

Replace the G
sensor. <Ref. to
ABS-22, G Sensor.>
ABS-173

ABS (DIAGNOSTICS)
10
11
Step
CHECK ABSCM&H/U.
3)Erase the memory.
5)Read out the DTC.
Check
Yes
No
Go to step 11.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-174

ABS (DIAGNOSTICS)
AH:DTC 56
DETECTION OF G SENSOR STICK
DIAGNOSIS:
TROUBLE SYMPTOM:

23
30
6
28
B301
SHIELD JOINT
CONNECTOR
5
6
F62
1
2
3
B292
E
ABS
G SENSOR
B292
F62
1 2 3
1 2 3 4
5 6 7 8
B200
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
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 25 26
27 28 29 30 31
BR0132
ABS-175

ABS (DIAGNOSTICS)

23
30
6
28
F49
SHIELD JOINT
CONNECTOR
5
7
F62
14
5
4
15
F74
B200
1
2
3
B292
E
ABS
G SENSOR
B292
F62
F74
F49
1 2 3
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
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
BR0045
Step
CHECK ALL FOUR WHEELS FOR FREE
TURNING.
Check
Yes
Have the wheels been turned The ABS is norfreely such as when vehicle is mal. Erase the
lifted up, or operated on a roll- DTC.
ing road?
ABS-176
No
Go to step 2.

ABS (DIAGNOSTICS)
10
Step
select monitor.
select monitor.
Read the select monitor display.
Check
Yes
2.5 V when the vehicle is in
horizontal position?
No
Go to step 8.

Replace the G
sensor. <Ref. to
ABS-22, G Sensor.>
Is the G sensor output on the

monitor display between 0.5
and 0.9 V when G sensor is
and G sensor?
CHECK ABSCM&H/U.
2)Erase the memory.
4)Read out the DTC.
Go to step 5.
Replace the
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
CHECK OPEN CIRCUIT IN G SENSOR OUT- Is the resistance between 5.0 Go to step 9.
PUT HARNESS AND GROUND HARNESS. and 5.6 k?
H/U.
LHD: (B301) No. 6 No. 28:
RHD: (F49) No. 6 No. 28:
CHECK G SENSOR.
2.5 V when G sensor is hori1)Remove the console box.
zontal?
(B292) No. 2 (+) No. 3 ():
CHECK G SENSOR.
Measure the voltage between G sensor con- 4.1 V when G sensor is
nector terminals.
(B292) No. 2 (+) No. 3 ():
ABS-177
Replace the G
sensor. <Ref. to
ABS-22, G Sensor.>
Go to step 6.
Go to step 7.
A temporary poor
contact.
between G sensor
and ABSCM&H/U.
Replace the G
sensor. <Ref. to
ABS-22, G Sensor.>
Replace the G
sensor. <Ref. to
ABS-22, G Sensor.>

ABS (DIAGNOSTICS)
11
12
13
Step
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ():
CHECK ABSCM&H/U.
3)Erase the memory.
5)Read out the DTC.
Check
Yes
No
Replace the G
sensor. <Ref. to
ABS-22, G Sensor.>

Go to step 13.
ABSCM&H/U.
<Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to DTC.
ABS-178

ABS (DIAGNOSTICS)
14.General Diagnostics Table

A: INSPECTION
Symptom
Vehicle pulls to either side.

Vehicle instability during braking
Vehicle spins.
Long braking/stopping distance
Wheel locks.
Brake dragging
Poor braking
Long brake pedal stroke

Vehicle pitching
Unstable or uneven braking
Excessive pedal vibration

Noise from ABSCM&H/U
Vibration and/or noise

(while driving on slippery roads)
Noise from front of vehicle
Noise from rear of vehicle
ABS-179
Probable faulty units/parts

ABSCM&H/U (solenoid valve)
ABS sensor
Brake (caliper & piston, pads)
Wheel alignment
Tire specifications, tire wear and air pressures
Incorrect wiring or piping connections
Road surface (uneven, camber)
ABS sensor
Brake (pads)
Brake (pads)
Air in brake line
ABSCM&H/U (solenoid valve, motor)
ABS sensor
ABS sensor
Master cylinder
Brake (caliper & piston)
Parking brake
Axle & wheels
Brake pedal play
Air in brake line
Brake pedal play
Suspension play or fatigue (reduced damping)
Road surface (uneven)
ABS sensor
Brake (caliper & piston, pads)
ABSCM&H/U (mount bushing)
ABS sensor
Brake piping
ABSCM&H/U (mount bushing)
ABS sensor
Master cylinder
Brake (caliper & piston, pads, rotor)
Brake piping
Brake booster & check valve
Suspension play or fatigue
ABS sensor
Brake (caliper & piston, pads, rotor)
Parking brake
Brake piping
Suspension play or fatigue

ABS (DIAGNOSTICS)
ABS-180
BRAKE
BR
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Page
Front Brake Pad ........................................................................................22
Front Disc Rotor ........................................................................................25
Front Disc Brake Assembly.......................................................................27
Rear Brake Pad.........................................................................................33
Rear Disc Rotor.........................................................................................35
Rear Disc Brake Assembly .......................................................................37
Rear Drum Brake Shoe.............................................................................41
Rear Drum Brake Drum ............................................................................43
Rear Drum Brake Assembly......................................................................44
Master Cylinder .........................................................................................47
Brake Booster ...........................................................................................49
Proportioning Valve...................................................................................54
Brake Fluid ................................................................................................55
Air Bleeding...............................................................................................57
Brake Hose ...............................................................................................59
Brake Pipe.................................................................................................61
Hill Holder..................................................................................................62
Brake Pedal...............................................................................................65
Stop Light Switch ......................................................................................69
General Diagnostics..................................................................................71
GENERAL DESCRIPTION
BRAKE
A: SPECIFICATIONS
Front
disc
brake
Rear
disc
brake
Size
Type
Effective disc diameter
Disc thickness Outer diameter
Effective cylinder diameter
Pad dimensions
(length width thickness)
Clearance adjustment
Type
Effective disc diameter
Disc thickness Outer diameter
Pad dimensions
Type
Rear
drum
brake
Effective drum diameter

Lining dimensions
Type
Master
cylinder
Effective diameter
Reservoir type
14 inch type
15 inch type
16 inch type
Disc (Floating type, ventilated)
210 mm (8.27 in)
228 mm (8.98 in)
255 mm (10.04 in)
24 260 mm
24 277 mm
24 294 mm
(0.94 10.24 in)
(0.94 10.91 in)
(0.94 11.57 in)
57.2 mm (2.252 in)
42.8 mm (1.685 in) 2
40.4 mm (1.591 in) 4
112.4 44.3 11.0 mm
112.3 50.0 11.0 mm
116.0 48.3 10.0 mm
(4.425 1.744 0.433 in) (4.421 1.969 0.433 in) (4.567 1.902 0.394 in)
Automatic adjustment
Disc (Floating type)
230 mm (9.06 in)

261 mm (10.28 in)
10 266 mm
18 290 mm
(0.39 10.47 in)

(0.71 11.42 in)
38.1 mm (1.500 in)

82.4 33.7 9.0 mm
71.8 35.0 11.5 mm
(3.244 1.327 0.354 in) (2.827 1.378 0.453 in)
Drum
(Leading-Trailing type)
228.6 mm (9 in)
17.5 mm (0.689 in)
218.8 35.0 4.1 mm
(8.61 1.378 0.161 in)

Tandem
23.81 mm (0.9374 in)
26.99 mm (1-1/16 in)
[25.4 mm (1 in)]
Sealed type
205 cm3 (12.51 cu in)
Vacuum suspended
Brake fluid reservoir capacity

Type
Brake
booster
Proportioning
valve
Effective diameter
230 mm (9.06 in)

[180 + 205 mm
(7.09 + 8.07 in)]
1,961 kPa
(20 kg/cm2, 285 psi)
Split point
Reducing ratio
Brake line
Brake fluid
CAUTION:
Avoid mixing brake fluid of different
brands to prevent the fluid performance from degrading.
When brake fluid is supplemented,
be careful not to allow any dust into
the reservoir.
Use fresh DOT3 or 4 brake fluid
when replacing or refilling the fluid.
205 + 230 mm
(8.07 + 9.06 in)
0.4
0.3
Dual circuit system
FMVSS No. 116, DOT3 or DOT4
[ ] : ABS equipped vehicle.
NOTE:
Refer to PB section for parking brake SPECIFICATIONS. <Ref. to PB-2, SPECIFICATIONS, General Description.>
BR-2
GENERAL DESCRIPTION
BRAKE
ITEM
Pad thickness
(including back metal)
Front brake
Disc thickness
Disc runout
Pad thickness
(including back metal)
Rear brake (Disc type)
Rear brake (Drum type)

Rear brake (Disc type
parking)
Parking brake
Disc thickness
14
15
14
15
Disc runout
Inside diameter
Lining thickness
Inside diameter
Lining thickness
Lever stroke
Brake pedal
force
Brake fluid pressure

without engine running
Brake
booster
Brake fluid pressure
with engine running
and vacuum at 66.7
kPa (500 mmHg, 19.69
inHg)
Brake pedal
14,15
16
Free play
147 N
(15 kgf, 33 lb)
294 N
(30 kgf, 66 lb)
147 N
(15 kgf, 33 lb)
294 N
(30 kgf, 66 lb)
STANDARD
SERVICE LIMIT
17 mm (0.67 in)
7.5 mm (0.295 in)
14.5 mm (0.571 in)
6.0 mm (0.236 in)
24 mm (0.94 in)
22 mm (0.87 in)
0.075 mm (0.0030 in)

14 mm (0.55 in)
6.5 mm (0.256 in)
16 mm (0.63 in)
6.0 mm (0.236 in)
10 mm (0.39 in)
8.5 mm (0.335 in)
18 mm (0.71 in)
16.0 mm (0.63 in)
0.07 mm (0.0028 in)

228.6 mm (9 in)
230.6 mm (9.08 in)
4.1 mm (0.161 in)
1.5 mm (0.059 in)
170 mm (6.69 in)
171 mm (6.73 in)
3.2 mm (0.126 in)
1.5 mm (0.059 in)
7 to 8 notches/196 N (20 kgf, 44 lb)
Fluid pressure
14 inch type
15 inch type
16 inch type
Without ABS
With ABS
686 kPa
686 kPa
588 kPa
(7 kg/cm2,
(7 kg/cm2,
(6 kg/cm2, 85 psi)
100 psi)
100 psi)
1,961 kPa
1,961 kPa
1,471 kPa
(20 kg/cm2,
(20 kg/cm2,
(15 kg/cm2, 213 psi)
284 psi)
284 psi)
5,982 kPa
5,296 kPa
4,707 kPa
5,982 kPa
2
2
2
,
(61
kg/cm
,
(54
kg/cm
,
(48
kg/cm2,
(61 kg/cm
868 psi)
868 psi)
768 psi)
683 psi)
8,434 kPa
7,649 kPa
9,120 kPa
(86 kg/cm2,
(78 kg/cm2,
(93 kg/cm2, 1,323 psi)
1,109 psi)
1,223 psi)
1 3 mm (0.04 0.12 in)

[Depress brake pedal pad with a force of less than 10 N (1 kgf, 2 lb).]
BR-3
GENERAL DESCRIPTION
BRAKE
B: COMPONENT
1. 14 INCH TYPE
(1)
(2)
T1
T3
(3)
(4)
(5)
(6)
(7)
(8)
T4
(17)
(9)
(4)
(1 6 )
T2
(15)
(11)
(12)
(10)
(12)
(11)
(14)
(13)
BR0112
(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-4
(17)
Bushing

T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
T3: 37 (3.8, 27.5)
T4: 80 (8.2, 59)
GENERAL DESCRIPTION
BRAKE
2. 15 INCH TYPE
(2)
(1)
T1
(3)
T3
(4)
(5)
(6)
(7)
(8)
T4
(9)
(18)
(4)
(1 7 )
(10)
T2
(16)
(12)
(13)
(11)
(13)
(12)
(15)
(14)
BR0113
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Caliper body
Air bleeder screw
Guide pin (Green)
Pin boot
Piston seal
Piston
Piston boot
Boot ring (Except Australia model)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Lock pin (Yellow)

Support
Pad clip
Outer shim
Inner shim
Pad (Outside)
Pad (Inside)
Disc rotor
BR-5
(17)
(18)
Disc cover
Bushing

T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
T3: 37 (3.8, 27.5)
T4: 80 (8.2, 59)
GENERAL DESCRIPTION
BRAKE
3. 16 INCH TYPE
BR0003
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Housing
Air bleeder screw
Caliper body
M clip
Cross spring
Pad pin
Piston seal
Piston
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Piston boot
Boot ring
Shim A
Shim B
Pad (Outside)
Pad (Inside)
Disc rotor
Disc cover
BR-6

T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
T3: 80 (8.2, 59)
GENERAL DESCRIPTION
BRAKE
4. REAR DISC BRAKE (14 INCH TYPE)

T1
(2)
(3)
T2
(4)
(1)
(5)
(10)
(6)
(7)
(8)
(14)
(12)
(9)
(33)
(4)
(11)
(14)
T3
(1 7)
(1 5 )
(1 6 )
(11)
(13)
(18)
(19)
(20)
(23)
(21)
(24)
(25)
(26)
T3
(27)
(22)
(28)
(3 2 )
(31)
(30)
(29)
BR0114
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Caliper body
Air bleeder screw
Guide pin (Green)
Pin boot
Piston seal
Piston
Piston boot
Boot ring
Lock pin (Yellow)
Support
Pad clip
Inner pad
Outer pad
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
Shim
Shoe hold-down pin
Cover
Back plate
Retainer
Spring washer
Parking brake lever
Parking brake shoe (Secondary)
Parking brake shoe (Primary)
Strut
Strut shoe spring
Shoe guide plate
Secondary shoe return spring
BR-7
(27)
(28)
(29)
(30)
(31)
(32)
(33)
Primary shoe return spring

Adjusting spring
Adjuster
Shoe hold-down cup
Shoe hold-down spring
Disc rotor
Bushing

T1: 8 (0.8, 5.8)
T2: 37 (3.8, 27.5)
T3: 52 (5.3, 38.3)
GENERAL DESCRIPTION
BRAKE
5. REAR DISC BRAKE (15 INCH TYPE)
BR0135
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Caliper body
Air bleeder screw
Pad pin
Piston seal
Piston
Piston boot
Boot ring
Pad clip
Inner pad
Outer pad
Inner shim
Outer shim
M clip
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
Washer
Cross spring
Shoe hold-down pin
Cover
Back plate
Retainer
Spring washer
Parking brake lever
Strut
Strut shoe spring
Shoe guide plate
BR-8
(27)
(28)
(29)
(30)
(31)
(32)
(33)
Secondary shoe return spring

Primary shoe return spring
Adjusting spring
Adjuster
Shoe hold-down cup
Disc rotor

T1: 8 (0.8, 5.8)
T2: 52 (5.3, 38.3)
GENERAL DESCRIPTION
BRAKE
6. REAR DRUM BRAKE
(1)
(8)
T2
(2)
(3)
T1
(4)
(5)
(6)
(9)
(12)
(13)
(7)
(5)
(14)
(8)
(4)
(3)
(15)
(17)
(18)
(24)
(10)
(19)
(11)
(22)
(16)
(20)
T3
(21)
(23)
B4M1120A
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Air bleeder cap

Air bleeder screw
Boot
Piston
Cup
Spring
Wheel cylinder body
Pin
Plug
Back plate
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Upper shoe return spring

Retainer
Washer
Parking brake lever
Brake shoe (Trailing)
Brake shoe (Leading)
Cup
Adjusting lever
Adjuster
BR-9
(21)
(22)
(23)
(24)

Adjusting spring
Drum
Plug

T1: 8 (0.8, 5.8)
T2: 10 (1.0, 7.2)
T3: 52 (5.3, 38.3)
GENERAL DESCRIPTION
BRAKE
7. MASTER CYLINDER
LHD MODEL
(1)
(2)
(3)
(11)
(4)
(10)
T1
(9)
(5)
(6)
(7)
(8)
S4M0186A
(1)
(2)
(3)
(4)
(5)
(6)
Cap
Filter
Reservoir tank
Bracket
Piston retainer
Primary piston
(7)
(8)
(9)
(10)
(11)
Secondary piston
Cylinder body
Cylinder pin (with ABS)
Seal
Pin
BR-10

T1: 14 (1.4, 10.1)
GENERAL DESCRIPTION
BRAKE
RHD MODEL
(1)
(2)
(3)
(11)
(4)
(10)
T1
(9)
(5)
(6)
(7)
(8)
B4M1155C
(1)
(2)
(3)
(4)
(5)
Cap
Filter
Reservoir tank
Bracket
Piston retainer
(6)
(7)
(8)
(9)
(10)
Primary piston
Secondary piston
Cylinder body
Cylinder pin (with ABS)
Seal
BR-11
(11)
Pin

T1: 14 (1.4, 10.1)
GENERAL DESCRIPTION
BRAKE
8. FRONT BRAKE PIPES AND HOSE FOR LHD MODEL

A
BR0116
(A)
AT model
MT model without hill holder (1.6 L)
(C)
(D)
(B)
AT model
MT model without hill holder (Except 1.6 L)
(1)
(2)
(3)
(4)
(5)
(6)
Front brake pipe assembly

Proportioning valve
Front brake hose RH
Front brake hose LH
Clamp
Gasket
MT model without hill holder

Without ABS
(7)
ABS control module and hydraulic

control unit
(8)
(9)
(10)
(11)
Bracket
Master cylinder
Hill holder
Two-way connector
BR-12

T1: 15 (1.5, 10.8)
T2: 18 (1.8, 13.0)
T3: 32 (3.3, 23.6)
GENERAL DESCRIPTION
BRAKE
9. FRONT BRAKE PIPES AND HOSE FOR RHD MODEL

A
BR0117
(A)
AT model
MT model without hill holder (1.6 L)
(C)
(D)
(B)
AT model
MT model without hill holder (Except 1.6 L)
(1)
(2)
(3)
(4)
(5)
(6)
Front brake pipe assembly

Proportioning valve
Front brake hose RH
Front brake hose LH
Clamp
Gasket
MT model without hill holder

Without ABS
(7)
ABS control module and hydraulic

control unit
(12)
(8)
(9)
(10)
(11)
Bracket
Master cylinder
Hill holder
Adapter pipe

T1: 15 (1.5, 10.8)
T2: 18 (1.8, 13.0)
T3: 32 (3.3, 23.6)
BR-13
Two-way connector
GENERAL DESCRIPTION
BRAKE
10.CENTER AND REAR BRAKE PIPES AND HOSE
BR0118
(1)
(2)
(3)
(4)
(5)
Center brake pipe assembly

Two-way connector
Rear brake pipe assembly
Rear brake hose RH (Disc brake
model)
Rear brake hose (Drum brake
model)
(6)
Rear brake hose LH (Disc brake

model)
(7)
Rear brake hose LH (Drum brake

model)
(8)
(9)
Clamp
Gasket
BR-14

T1: 15 (1.5, 10.8)
T2: 18 (1.8, 13.0)
T3: 32 (3.3, 23.6)
GENERAL DESCRIPTION
BRAKE
11.BRAKE BOOSTER
MODEL with ABS
B4M1974A
(1)
(2)
(3)
(4)
Push rod
Return spring
Reaction disc
Key
(5)
(6)
(7)
(8)
Filter
Silencer
Operating rod
Poppet valve
(9)
(10)
(11)
(12)
Valve body
Plunger valve
Diaphragm plate
Valve return spring
MODEL without ABS
(3)
(5)
(7)
(8)
(9)
(1)
(4)
( 12 )
(6)
( 11 )
( 10 )
(2)
BR0136
(1)
(2)
(3)
(4)
Push rod
Return spring
Diaphragm plate
Reaction disc
(5)
(6)
(7)
(8)
Plunger valve
Key
Poppet valve
Valve return spring
BR-15
(9)
(10)
(11)
(12)
Operating rod
Silencer
Filter
Valve body
GENERAL DESCRIPTION
BRAKE
12.HILL HOLDER
S4M0240B
(1)
(2)
(3)
(4)
Clamp
PHV cable
PHV (Pressure hold valve)
Adjusting nut
(5)
(6)
Lock nut
To clutch pedal
BR-16

T1: 3.5 (0.35, 2.5)
T2: 18 (1.8, 13.0)
GENERAL DESCRIPTION
BRAKE
13.BRAKE PEDAL
1.6 L MODEL
RHD
LHD
BR0137
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Stopper
Bushing
Pedal bracket
Snap pin
Brake pedal pad
Brake pedal
Clevis pin
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Spring
Clutch pedal pad
Clutch pedal
Clutch cable
Clutch cable clamp
Clip
Spring assist
BR-17
(15)
Stop light switch

T1: 5.9 (0.6, 4.3)
T2: 8 (0.8, 5.8)
T3: 18 (1.8, 13.0)
T4: 30 (3.1, 22.4)
GENERAL DESCRIPTION
BRAKE
2.0 L MODEL
LHD
RHD
BR0138
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Stopper
Bushing
Spring pin
Snap pin
Brake pedal pad
Brake pedal
Clevis pin
Brake pedal spring
Clutch pedal pad
Clutch pedal
Bushing C
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Clutch clevis pin

Assist rod A
Clip
Assist spring
Assist bushing
Assist rod B
Spring S
Rod S
Bushing S
O-ring
Clip
BR-18
(23)
(24)
(25)
(26)
Stop light switch

Pedal bracket
Clutch master cylinder bracket
Lever

T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
T3: 30 (3.1, 22.4)
GENERAL DESCRIPTION
BRAKE
14.BRAKE PEDAL FOR AT MODEL
BR0139
(1)
(2)
(3)
(4)
(5)
Stopper
Bushing
Pedal bracket
Stop light switch
Snap pin
(6)
(7)
(8)
(9)
Brake pedal pad

Brake pedal
Clevis pin
Brake pedal spring
BR-19

T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
T3: 29 (3.0, 21.7)
GENERAL DESCRIPTION
BRAKE
C: CAUTION
points.
Do not put fluid on body. If the body is tainted,
wash away with water.
BR-20
GENERAL DESCRIPTION
BRAKE
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
925460000
DESCRIPTION
WHEEL CYLINDER
11/16 ADAPTER
REMARKS
Used for installing cup onto wheel cylinder piston
(Size 11/16 in).
B4M2406

TOOL NAME
SNAP RING PLIERS
REMARKS
BR-21
FRONT BRAKE PAD

BRAKE
2. Front Brake Pad
(4) Attach a rod of less than 12 mm (0.47 in) dia.

to the shaded area of brake pad, and strike the
rod with a hammer to drive brake pad out of
place.
A: REMOVAL
1. 14 INCH AND 15 INCH TYPE
3) Jack-up the vehicle, and then remove the front
wheel.
4) Remove the lower caliper bolt.
5) Raise the caliper body upward and support it.
NOTE:
Do not disconnect the brake hose from caliper
body.
6) Remove the pad.
B4M2231
2. 16 INCH TYPE
wheel.
4) Remove the M clip.
B4M1167
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 a support in a vise between wooden
blocks.
H4M1367A
5) Remove the pad pins, then remove the cross

spring.
(2)
B4M2230B
(1)
BR0115
(1) Support
(2) Wooden blocks
(1) Pad pin

(2) Cross spring
BR-22
FRONT BRAKE PAD

BRAKE
6) Use a wrench to expand the pads, then push the

piston back.
2. 16 INCH TYPE
1) Apply thin coat of Molykote AS880N (Part
No.26298AC000) to the frictional portion between
pad and pad inner shim.
H4M1370
7) Remove the pad.

BR0008
2) Install the pads on caliper body.

3) Install the pad pins on caliper body.
4) Install the M clip.
5) Install the cross spring.
C: INSPECTION
Check the pad thickness A.
H4M1371
B: INSTALLATION
1) Apply thin coat of Molykote AS880N (Part No.
26298AC000) to the frictional portion between pad
and pad clip.
and pad inner shim.
B4M1168A
Pad thickness
(including back
metal)
Standard value
Wear limit
17 mm (0.67 in)
7.5 mm (0.295 in)
CAUTION:
Always replace the pads for both right and
left wheels at the same time. Also replace the
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.
Replace the pad if there is oil or grease on it.
B4M1169A
3) Install the pads on support.

4) Install the caliper body on support.
Tightening torque:
37 Nm (3.8 kgf-m, 27.5 ft-lb)
NOTE:
If it is difficult to push the piston during pad replacement, loosen the air bleeder to facilitate work.
BR-23
FRONT BRAKE PAD

BRAKE
2. 16 INCH TYPE
A
BR0009
Pad thickness
(including back
metal)
Standard value
14.5 mm (0.571 in)
Wear limit
6.0 mm (0.236 in)
CAUTION:
pad.
BR-24
FRONT DISC ROTOR

BRAKE
3. Front Disc Rotor
4) Remove the caliper body from housing and suspend from strut using a wire.
A: REMOVAL
wheel.
4) Remove the caliper body from housing, and suspend it from struct using a wire.
BR0010

NOTE:
If the disc rotor seizes up within the hub, drive the
disc rotor out by installing an 8-mm bolt in holes B
on the rotor.
BR0076
5) Remove the disc rotor.

NOTE:
If the disc rotor seizes up within the hub, drive the
disc rotor out by installing an 8-mm bolt in holes B
on rotor.
G4M0365
6) Clean mud and foreign particles from the caliper

body assembly and support.
B: INSTALLATION
1) Install the disc rotor.
2) Install the caliper body on housing.
Tightening torque:
80 Nm (8.2 kgf-m, 59 ft-lb)
G4M0365

2. 16 INCH TYPE
2) Loosen the wheel nut.
wheel.
CAUTION:
pad.
3) Install the wheel.
BR-25
FRONT DISC ROTOR

BRAKE
C: INSPECTION
1) Secure the disc rotor by tightening five wheel
nuts.
2) Set a dial gauge on the disc rotor. Turn the disc
rotor to check runout.
CAUTION:
Securely fix the disc rotor to hub.
B4M2353
NOTE:
Make sure that the dial gauge is set 5 mm (0.20
in) inward of rotor outer perimeter.
If the disc rotor runout is above standard value,
inspect the play of hub bearing axial direction and
runout of axle hub. <Ref. to DS-23, INSPECTION,
Front Axle.> If the bearing and hub are normal, replace the disc rotor.
0.075 mm (0.0030 in)
3) Measure the disc rotor thickness.
If the thickness of disc rotor is outside the standard
value, replace the disc rotor.
G4M0365
NOTE:
Make sure that a micrometer is set 5 mm (0.20 in)
inward of the rotor outer perimeter.
14
Disc rotor
thickness A
15
16
Standard
value
24 mm
(0.94 in)
24 mm
(0.94 in)
24 mm
(0.94 in)
Service
limit
22 mm
(0.87 in)
22 mm
(0.87 in)
22 mm
(0.87 in)
Disc outer
dia.
260 mm
(10.24 in)
277 mm
(10.91 in)
294 mm
(11.57 in)
BR-26
FRONT DISC BRAKE ASSEMBLY

BRAKE
4. Front Disc Brake Assembly
2. 16 INCH TYPE
A: REMOVAL

wheel.
4) Remove the union bolt and, then disconnect the
brake hose from caliper body assembly.
5) Remove the caliper body from housing.

wheel.
4) Remove the union bolt, and then disconnect the
brake hose from caliper body assembly.
BR0011

B4M1844
5) Remove the bolt securing lock pin to caliper

body.
B4M1845
6) Raise the caliper body and move it toward vehicle center to separate it from support.
7) Remove the support from housing.
NOTE:
Remove the support only when replacing it or the
rotor. It need not be removed when servicing the
caliper body assembly.
B4M1192

BR-27

BRAKE
B: INSTALLATION
2. 16 INCH TYPE
1) Install the support on housing.
Tightening torque:
80 Nm (8.2 kgf-m, 59 ft-lb)
Tightening torque:
80 Nm (8.2 kgf-m, 59 ft-lb)
CAUTION:
pad.
When replacing the pads, replace pads of the
right and left wheels at the same time.
and pad clip.
and inner shim.
CAUTION:
pad.
and pad inner shim.
BR0008

4) Install the pad pins and cross spring on caliper
body.
6) Connect the brake hose.
B4M1169A
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)

CAUTION:
Replace the brake hose gaskets with new ones.
Tightening torque:
37 Nm (3.8 kgf-m, 27.5 ft-lb)
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
CAUTION:
Replace the brake hose gaskets with new ones.
BR-28

BRAKE
C: DISASSEMBLY
2) Using a standard screwdriver, remove the boot

ring from piston. (Except Australia model)
1. 14 INCH TYPE
CAUTION:
Be careful not to allow foreign particles to enter
inlet (at the brake hose connector).
2) Gradually supply compressed air via inlet of
brake hose to force piston out.
CAUTION:
Place a wooden block as shown in the figure
to prevent damage to piston.
Do not apply excessively high-pressure.
B4M1164C
(1) Boot ring
3) Remove the boot from piston end.

4) Gradually supply compressed air via inlet of the
CAUTION:
Place a wooden block as shown in the figure to
prevent damage to piston.
B4M1174C
(1) Place a 30 mm (1.18 in) wide wooden block

here.
3) Remove the piston boot.

4) Remove the piston seal from caliper body cylinder.
B4M1165C

here.
B4M1173
5) Remove the guide pin and boot from caliper

body.
2. 15 INCH TYPE
CAUTION:
inlet (at brake hose connector).
B4M1172B
(1) Piston pin
6) Remove the lock pin boot and guide pin boot.
BR-29

BRAKE
3. 16 INCH TYPE
body assembly.

(1)
CAUTION:
2) Using a standard screwdriver, remove the boot
ring from piston.
BR0142
(1) Piston seal
D: ASSEMBLY
1. 14 INCH TYPE
(1)
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 groove on ends of cylinder and install piston
boot onto cylinder.
BR0140
(1) Boot ring
3) Remove the boot from piston end.
Grease:
NIGLUBE RX-2 (Part No. 003606000)
5) Insert the piston into cylinder.
CAUTION:
Do not force the piston into cylinder.
BR0013

CAUTION:
Place a wooden block as shown in the figure to
prevent damage to the piston.
B4M1175B
(1) Piston
(2) Piston boot
(1)
BR0141
(1) Place a 30 mm (1.18 in) wide wood block

here.
BR-30

BRAKE
6) Position the boot in grooves on cylinder and piston.
2. 15 INCH TYPE
CAUTION:
B4M0072B
(1)
(2)
(3)
(4)
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:
8) Install the lock and guide pin boot on support.
B4M0771

fit in groove on ends of cylinder and piston.
Grease:
To facilitate installation, fit the boot starting with piston end.
B4M1176B
(1) Pin boot

(2) Lock pin or guide pin
(3) Apply grease.
S4M0448A
(1)
(2)
(3)
(4)
Piston boot
Boot ring
Piston seal
Caliper body

7) Install the boot ring. Be careful not scratch the
boot.
BR-31

BRAKE
8) Apply a coat of specified grease to the lock pin

and guide pin, outer surface, cylinder inner surface,
and boot grooves.
Grease:

Grease:
To facilitate installation, fit the boot starting with piston end.
Piston
Piston boot
B4M1176B
Piston seal
(1) Pin boot

(3) Apply grease.
9) Install the lock pin boot and guide pin boot on

support.
3. 16 INCH TYPE
Boot ring BR0017

7) Install the boot ring. Be careful not scratch the
boot.
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.
CAUTION:
BR0016
BR-32
REAR BRAKE PAD

BRAKE
5. Rear Brake Pad
2. 15 INCH TYPE
A: REMOVAL

wheel.
4) Remove the M clip.
1. 14 INCH TYPE
3) Jack-up the vehicle, and then remove the rear
wheel.
4) Remove the lower caliper bolt.
BR0018
(1) M clip
(2) Caliper
S4M0115
5) Raise the caliper body upward and support it.

NOTE:
Do not disconnect the brake hose from caliper
body.
6) Remove the pad.
5) Remove the two pad pins.

6) Remove the cross spring.
NOTE:
If the brake pad is difficult to remove, use the same
procedure as for front disc brake pad.
<Ref. to BR-22, REMOVAL, Front Brake Pad.>
BR0019
(1) Cross spring

(2) Pad pin
7) Expand the pads and push piston back.

8) Remove the pad and shim.
B4M1770
BR0020
(1) Brake pad
BR-33
REAR BRAKE PAD

BRAKE
B: INSTALLATION
2. 15 INCH TYPE
1. 14 INCH TYPE
1) Apply a thin coat of Molykote AS880N (Part No.

and pad clip.
2) Install the pad on support.
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
NOTE:
If it is difficult to push the piston during pad replacement, loosen air bleeder to facilitate work.
2. 15 INCH TYPE
1) Apply a thin coat of Molykote AS880N (Part No.
26298AC000) to frictional portion between pad and
pad inner shim.
3) Install the cross spring.
4) Install the pad pins on caliper body.
C: INSPECTION
1. 14 INCH TYPE
Check pad thickness A.
A
BR0021
Pad thickness
(including back
metal)
Standard value
14.0 mm (0.551 in)
Wear limit
6.5 mm (0.256 in)
16.0 mm (0.63 in)
Wear limit
6.0 mm (0.236 in)
CAUTION:
pad.
S4M0187A
Pad thickness
(including back
metal)
Standard value
CAUTION:
pad.
BR-34
REAR DISC ROTOR

BRAKE
6. Rear Disc Rotor
(2) If the disc rotor seizes up within hub, drive

the disc rotor out by installing an 8-mm bolt in
holes B on rotor.
A: REMOVAL
1) Lift-up the vehicle, and then remove the wheels.
2) Remove the two mounting bolts, and then remove the disc brake assembly.
G4M0383
B: INSTALLATION
2) Adjust the parking brake. <Ref. to PB-11, ADJUSTMENT, Parking Brake Assembly (Rear Disc
Brake).>
S4M0459A
(1) Disk brake
3) Suspend the disc brake assembly so that hose is

not stretched.
4) Pull down and release the parking brake.
NOTE:
If the disc rotor is difficult to remove try following
two methods in order.
(1) Turn the adjusting screw using a slot-type
screwdriver until brake shoe gets away enough
from the disc rotor.
C: INSPECTION
1) Secure the disc rotor by tightening five wheel
nuts.
2) Set a dial gauge on the disc rotor. Turn the disc
rotor to check runout.
CAUTION:
Securely fix the disc rotor to hub.
B4M1771
S4M0463A
(1)
(2)
(3)
(4)
Adjusting screw
Cover
Slot-type screwdriver
Back plate
NOTE:
Make sure that a dial gauge is set 5 mm (0.20 in) inward of rotor outer perimeter.
0.070mm (0.0027 in)
BR-35
REAR DISC ROTOR

BRAKE
3) Measure the disc rotor thickness.
G4M0383
NOTE:
Make sure that a micrometer is set 5 mm (0.20 in)
inward of the rotor outer perimeter.
Disc rotor thickness: A (14 inch type)
Standard value
10 mm (0.39 in)
Service limit
8.5 mm (0.335 in)
Disc rotor thickness: A (15 inch type)
Standard value
18 mm (0.71 in)
Service limit
16 mm (0.63 in)
BR-36
REAR DISC BRAKE ASSEMBLY

BRAKE
7. Rear Disc Brake Assembly
6) Remove the caliper body from housing.
A: REMOVAL
1. 14 INCH TYPE
CAUTION:
Do not allow brake fluid to come in contact with
vehicle body; wipe off completely if spilled.
4) Disconnect the brake hose from caliper body assembly.
5) Remove the bolt securing lock pin to caliper
body.
BR0063

body assembly.
CAUTION:
B: INSTALLATION
1. 14 INCH TYPE
2) Install the support on housing.
Tightening torque:
52 Nm (5.3 kgf-m, 38.3 ft-lb)
S4M0119
6) Raise the caliper body and move it toward vehicle center to separate it from support.
7) Remove the support from housing.
NOTE:
Remove the support only when replacing it or the
rotor. It need not be removed when servicing the
caliper body assembly.
CAUTION:
2. 15 INCH TYPE
CAUTION:
Do not allow brake fluid to come in contact with
vehicle body; wipe off completely if spilled.
4) Remove the pads from caliper body. <Ref. to
BR-33, REMOVAL, Rear Brake Pad.>
5) Disconnect the brake hose from caliper body assembly.
CAUTION:
pad.
Replace the pads if there is oil or grease on
them.
and pad clip.
Tightening torque:
37 Nm (3.8 kgf-m, 27.5 ft-lb)
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
CAUTION:
The brake hose must be connected without
any twist.
Replace the brake hose gaskets with new
ones.
BR-37

BRAKE
2. 15 INCH TYPE

Tightening torque:
52 Nm (5.3 kgf-m, 38.3 ft-lb)
CAUTION:
pad.
Replace the pads if there is oil or grease on
them.
and pad clip.
S4M0121

CAUTION:
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
CAUTION:
The brake hose must be connected without
any twist.
Replace the brake hose gaskets with new
ones.
C: DISASSEMBLY
B4M1174C

here.
1. 14 INCH TYPE
1) Remove the boot ring.
S4M0122
S4M0120B
(1) Boot ring
5) Remove the lock pin sleeve and boot from caliper body.
6) Remove the guide pin boot.
BR-38

BRAKE
2. 15 INCH TYPE
1) Remove the boot ring.
BR0065
BR0023
D: ASSEMBLY
(1) Boot ring
1. 14 INCH TYPE

CAUTION:
Do not force piston into cylinder.
BR0064

CAUTION:
Grease:
6) Install the piston boot to caliper body, and attach
boot ring.
S4M0448A
(1)
(2)
(3)
(4)
BR0025

here.
BR-39
Piston boot
Boot ring
Piston seal
Caliper body

BRAKE
7) Apply a coat of specified grease to the guide pin,

outer surface, sleeve outer surface, cylinder inner
surface, and boot grooves.
6) Install the piston boot to the caliper body, and attach boot ring.
Grease:
BR0027
(1)
(2)
(3)
(4)
B4M1176B
(1) Pin boot

(3) Apply grease.
Piston
Piston boot
Piston seal
Boot ring
E: INSPECTION
8) Install the guide pin boot on support.

9) Install the lock pin boot on support and insert
lock pin sleeve into place.
2. 15 INCH TYPE
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.

CAUTION:
Do not force piston into cylinder.
Grease:
BR-40
REAR DRUM BRAKE SHOE

BRAKE
8. Rear Drum Brake Shoe
4) Hold the hold-down pin by securing rear of back

plate with your hand.
A: REMOVAL
1) Loosen the wheel nuts, jack-up the vehicle, support it with rigid racks, and remove the wheel.
3) Remove the brake drum from brake assembly.
NOTE:
If it is difficult to remove the brake drum, remove
turn adjuster assembly pawls using a slot-type
screwdriver until brake shoe separates from the
drum.
S4M0451A
(1) Hold-down cup

(2) Hold-down pin
5) Disconnect the hold-down cup from hold-down

pin by rotating hold-down cup.
6) Disconnect the lower shoe return spring from
shoes.
S4M0369A
(1)
(2)
(3)
(4)
(5)
(6)
Back plate
Wheel cylinder
Adjuster ASSY pawls
Adjusting lever
Push.
S4M0452

by installing an 8-mm bolt into bolt hole in brake
drum.
7) Remove the shoes one by one from back plate

with adjuster.
CAUTION:
Be careful not to bend the parking brake cable
excessively when removing brake shoes.
B4M0243
S4M0453A
(1)
(2)
(3)
(4)
(5)
(6)
BR-41
Wheel cylinder
Adjuster
Back plate
Parking lever
Trailing shoe
REAR DRUM BRAKE SHOE

BRAKE
8) Disconnect the parking brake cable from parking

lever.
6) While positioning the shoes (one at a time) in

groove on wheel cylinder, secure the shoes.
B: INSTALLATION
1) Clean the back plate and wheel cylinder.
2) Apply grease to portions indicated by arrows in
the figure.
Brake grease:
Dow Corning Molykote No. 7439 (Part No.
725191460)
S4M0458A
(1) Wheel cylinder

(2) Shoe (Trailing)
G4M0407
3) Apply grease to the adjusting screw and both

ends of adjuster.
Brake grease:
725191460)
7) Fix the shoes by connecting hold-down cup to

hold-down pin.
8) Connect the lower shoe return spring.
9) Set the outside diameter of brake shoes less
than 0.5 to 0.8 mm (0.020 to 0.031 in) in comparison with inside diameter of brake drum.
C: INSPECTION
1) Measure the lining thickness.
Lining thickness:
Service limit 1.5 mm (0.059 in)
etc. are notable, replace them.
3) When the shoe return spring tension is excessively weakened, replace it, taking care to identify
the upper and lower springs.
S4M0457B
4) Connect the upper shoe return spring to shoes.

5) Connect the parking brake cable to parking lever.
BR-42
REAR DRUM BRAKE DRUM

BRAKE
9. Rear Drum Brake Drum
B: INSTALLATION
A: REMOVAL
Set the outside diameter of brake shoes less than

0.5 to 0.8 mm (0.020 to 0.031 in) in comparison
with inside diameter of brake drum.
1) Loosen the wheel nuts, jack-up the vehicle, support it with rigid racks, and remove wheel.
NOTE:
If it is difficult to remove the brake drum, remove
turn the adjuster assembly pawls using a slot-type
screwdriver until brake shoe separates from drum.
C: INSPECTION
1) If the inside surface of brake drum is streaked,
correct the surface. And, if it is unevenly worn, taperingly streaked, or the outside surface of brake
drum is damaged, correct or replace it.
2) Measure the drum inner diameter.
Drum inner diameter: L
Standard 228 mm (9 in)
Service limit 230.6 mm (9.08 in)
S4M0369A
(1)
(2)
(3)
(4)
(5)
(6)
Back plate
Wheel cylinder
Adjuster ASSY pawls
Adjusting lever
Push.
G4M0403

by installing an 8-mm bolt into bolt hole in the brake
drum.
B4M0243
BR-43
REAR DRUM BRAKE ASSEMBLY

BRAKE
10.Rear Drum Brake Assembly
B: INSTALLATION
A: REMOVAL
1) Clean the back plate and wheel cylinder.

2) Install the wheel cylinder on back plate, and
tighten bolts.
1) Loosen the wheel nuts, jack-up the vehicle, support it with rigid racks, and remove the wheel.
<Ref. to BR-43, REMOVAL, Rear Drum Brake
Drum.>
4) Remove the brake shoe. <Ref. to BR-41, REMOVAL, Rear Drum Brake Shoe.>
5) Unscrew the brake hose flare nut and disconnect brake hose.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
S4M0454
3) Apply grease to the portions indicated by arrows

in the figure.
Brake grease:
725191460)
BR0104
6) Remove the hub.

<Ref. to DS-24, REMOVAL, Rear Axle.>
7) Disconnect the ABS sensor from back plate.
(only vehicle equipped ABS)
8) Remove the brake assembly.
G4M0407
G4M0400
9) Remove the bolts installing wheel cylinder on

back plate, and remove it.
S4M0454
BR-44

BRAKE
4) Install the brake assembly on housing, and tighten the bolts to install back plate.
Tightening torque:
53 Nm (5.4 kgf-m, 39.1 ft-lb)
C: DISASSEMBLY
1) Remove the right and left dust boots from wheel
cylinder.
B4M1126B
G4M0400
(1)
(2)
(3)
(4)
(5)
(6)
(7)
5) Install the hub. <Ref. to DS-27, INSTALLATION,

Rear Axle.>
6) Connect the brake hose, and tighten the brake
hose flange nut.
Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
7) Connect the ABS sensor to back plate. (only vehicle equipped with ABS)
Bleeder cap
Bleeder screw
Spring
Cylinder
Cup
Piston
Boot
2) Remove the piston, cup, spring and air bleeder

screw and cap.
Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
8) Apply grease to the adjusting screw and both
ends of adjuster.
Brake grease:
725191460)
S4M0457B
9) Install the brake shoe. <Ref. to BR-42, INSTALLATION, Rear Drum Brake Shoe.>
10) Install the brake drum. <Ref. to BR-43, INSTALLATION, Rear Drum Brake Drum.>
11) After installing the brake assembly, bleed air
from the brake line. <Ref. to BR-57, Air Bleeding.>
BR-45

BRAKE
D: ASSEMBLY
1) Clean all parts in brake fluid. Check and replace
the faulty parts.
Cup and boot for damage or fatigue
Cylinder, piston and spring or damage or rust formation
(1) When installing the cup, use ST, apply
brake fluid to the frictional surface for smooth installation and pay attention to cup direction.
(2) STs are available in different sizes.
3) Apply rubber grease to the boot inside as shown

in the figure.
CAUTION:
Never use brake grease.
Grease:
CAUTION:
When replacing the repair kit, make sure that
the sizes of cylinder and cup are same as those
which were replaced.
Use only the tool of correct size.
S4M0456B
ST: ADAPTER
Applicable size
17.5 mm (11/16 in)
E: INSPECTION
Part No.
925460000
CAUTION:
While assembling, be careful to prevent any
metal chip, dust or dirt from entering the wheel
cylinder.

etc. are notable, replace them.
S4M0455A
(1) Cup
(2) Piston
BR-46
MASTER CYLINDER
BRAKE
11.Master Cylinder
C: DISASSEMBLY
A: REMOVAL
1. PRECAUTIONS FOR DISASSEMBLING
1) Thoroughly drain brake fluid from reservoir tank.

2) Disconnect the fluid level indicator harness connector.
3) Remove the brake pipes from master cylinder.
4) Remove the master cylinder mounting nuts, and
take out master cylinder from brake booster.
1) Remove mud and dirt from the surface of brake

master cylinder.
2) Prepare tools necessary for disassembly operation, and arrange them neatly on the work bench.
3) Clean the work bench.
CAUTION:
Be extremely careful not to spill the brake fluid.
Brake fluid spilt on the vehicle body will harm
the painted surface; wipe it off quickly if spilt.
B: INSTALLATION
2. DISASSEMBLING PROCEDURE
1) Remove the pin with drift pin which secures reserve tank to master cylinder.
2) Remove the cylinder pin with magnetic pick-up
tool while pushing in primary piston. (with ABS)
1) To install the master cylinder to body, reverse

the sequence of removal procedure.
Tightening torque:
Master cylinder mounting nut
14 Nm (1.4 kgf-m, 10.1 ft-lb)
Piping flare nut
15 Nm (1.5 kgf-m, 10.8 ft-lb)
CAUTION:
Be sure to use recommended brake fluid.
2) Bleed air from the brake system. <Ref. to BR-57,
PROCEDURE, Air Bleeding.>
S4M0123B
(1) Cylinder pin
3) Pry up the pawl and remove piston retainer.

NOTE:
The piston may jump out from master cylinder.
S4M0124
4) Extract the primary piston assembly and secondary piston assembly.

CAUTION:
Do not disassemble the piston assembly;
otherwise, the spring set value may be
changed.
Use brake fluid or methanol to wash the inside wall of cylinder, pistons and piston cups.
Be careful not to damage the parts when washing. If methanol is used for washing, do not dip
rubber parts, such as piston cups, in it for more
than 30 seconds; otherwise, they may become
swelled.
BR-47
MASTER CYLINDER
BRAKE
D: ASSEMBLY
E: INSPECTION
1. PRECAUTIONS FOR ASSEMBLING

1) When assembling, be sure to use the recommended brake fluid.
2) Ensure that the inside wall of cylinder, pistons,
and piston cups are free from dirt when assembling.
3) Be extremely careful not to damage, scratch, or
dent the cylinder inside wall, pistons, and piston
cups.
4) Do not drop the parts. Never attempt to use any
part that has been dropped accidentally.
2. ASSEMBLING PROCEDURE
If any damage, deformation, wear, swelling, rust,

and other faults are found on the primary piston assembly, secondary piston assembly, supply the
valve stopper, or gasket, replace the faulty part.
CAUTION:
The primary and secondary pistons must be
replaced as complete assemblies.
The service limit of clearance between each
piston and the master cylinder inner dia. is 0.11
mm (0.0043 in).
When handling parts, be extremely careful
not to damage or scratch the parts, or let any
foreign matter get on them.
1) Assembling the piston assembly:

Apply recommended brake fluid to the inside wall of
cylinder, and to outer surface of the piston assembly, and install the piston assemblies carefully into
cylinder.
2) Assembling the cylinder pin:
Press the pawl and install the piston retainer into
master cylinder.
S4M0124
3) Install the seal to reservoir tank.
B4M1450C
(1) Seal
4) Install the pin with drift pins which secure reservoir tank to master cylinder.
BR-48
BRAKE BOOSTER
BRAKE
12.Brake Booster
A: REMOVAL
1) Remove or disconnect the following parts at engine compartment.
(1) Disconnect the connector for brake fluid level indicator.
(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
3) Remove the brake booster while shunning brake
pipes.
CAUTION:
If external force is applied from above when the
brake booster is placed in this position, the resin portion as indicated by P, may be damaged.
NOTE:
Be careful not to drop the brake booster. The
brake booster should be discarded if it has been
dropped.
Use special care when handling the operating
rod.
If excessive force is applied to the operating rod,
sufficient to cause a change in the angle in excess
of 3, it may result in damage to the power piston
cylinder.
Use care when placing the brake booster on
floor.
Do not change the push rod length. If it has been
changed, reset the projected length L to standard
length.
Standard:
L = 10.4 mm (0.41 in)
G4M0424
BR-49
S4M0464A
(1) Force
BRAKE BOOSTER
BRAKE
B: INSTALLATION
7) Adjust the operating rod of brake booster.
1) Mount the brake booster in position.

2) Connect the operating rod to brake pedal with
clevis pin and snap pin.
Standard: L
LHD model:
144.6 mm (5.69 in)
RHD model:
173.2 mm (6.82 in)
If it is not within specified value, adjust it by adjusting the brake booster operating rod.
B4M0616A
8) Measure the clearance between 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.
CAUTION:
Be careful not to rotate the stop light switch.
B4M0117C
(1)
(2)
(3)
(4)
Stop light switch clearance: A

0.3 mm (0.012 in)
Nuts
Clevis pin
Snap pin
Operating rod
3) Connect the vacuum hose to brake booster.
B4M0617H
9) Apply grease to operating rod connecting pin to

prevent it from wearing.
S4M0125
4) Mount the master cylinder onto brake booster.

5) Connect the brake pipes to master cylinder.
6) Connect the electric connector for brake fluid
level indicator.
Tightening torque (Air bleeder screw):

8 Nm (0.8 kgf-m, 5.8 ft-lb)
11) Conduct road tests to ensure brakes do not
drag.
BR-50
BRAKE BOOSTER
BRAKE
C: INSPECTION
Operation check
1. OPERATION CHECK (WITHOUT GAUGES)
1) With the engine off, depress the brake pedal

several times applying same pedal force and make
sure that pedal height does not vary with each depression of pedal.
CAUTION:
When checking operation, be sure to securely
apply the hand brake.
Checking without gauges
This method cannot determine the exact portion
which has failed, but it can provide a rough understanding of the nature of failure if checking is conducted in accordance with the following
procedures.
Air tightness check
Start the engine, and run it for 1 to 2 minutes, then
turn it off. Depress the brake pedal several times
applying same pedal force as that used in ordinary
braking operations. The pedal stroke should be
greatest on 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.
S4M0466A
(1) When engine is stopped

(2) When engine is started
2) With the brake pedal depressed, start the engine.

3) As the engine starts, the brake pedal should
move slightly 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 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.
S4M0465A
(1)
(2)
(3)
(4)
(5)
NOTE:
If faulty, check precisely with gauges.
OK
NOT OK
1st
2nd
3rd
NOTE:
In the event of defective operation, inspect the
condition of check valve and vacuum hose.
Replace them if faulty and conduct the test
again.
If no improvement is observed, check precisely
with gauges.
BR-51
BRAKE BOOSTER
BRAKE
2. OPERATION CHECK (WITH GAUGES)

CAUTION:
When checking operation, be sure to securely
apply the hand brake.
Checking with gauges
Connect gauges as shown in the figure. After
bleeding air from pressure gauges, proceed to
each check.
1) Start the engine and depress 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.
S4M0467A
(1)
(2)
(3)
(4)
(5)
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 engine,
the brake booster is functioning properly.
If defective, the cause may be one of those listed
below.
Check valve malfunction
Leak from vacuum hose
Leak from the shell jointed portion or stud bolt
welded portion
Damaged diaphragm
Leak from valve body seal and bearing portion
Leak from plate and seal assembly portion
Leak from poppet valve assembly portion
Loaded air tightness check
Pressure gauge
Vacuum gauge
Adapter hose
Vacuum hose
Pedal force gauge
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.
S4M0469A
(1)
(2)
(3)
(4)
S4M0468A
(1) Pressure gauge

(2) Vacuum gauge
BR-52
Pressure gauge
Vacuum gauge
Pedal force gauge
Depress
BRAKE BOOSTER
BRAKE
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
engine, the brake booster is functioning properly.
If defective, refer to AIR TIGHTNESS CHECK.
<Ref. to BR-51, INSPECTION, Brake Booster.>
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.
Brake pedal
force
Fluid
pressure
14
15
16
147 N
(15 kgf, 33 lb)
686 kPa
(7 kg/cm2, 100 psi)
[ 588 kPa
(6 kg/cm2, 85 psi) ]
588 kPa
(6 kg/cm2, 85 psi)
294 N
(30 kgf, 66 lb)
1,961 kPa
(20 kg/cm2, 284 psi)
[ 1,667 kPa
(17 kg/cm2, 242 psi) ]
1,471 kPa
(15 kg/cm2, 213 psi)
[ ]: ABS equipped vehicle.
Boosting action check

Set the vacuum gauge reading at 66.7 kPa (500
mmHg, 19.69 inHg) by running engine. Then,
check the fluid pressure when brake pedal is depressed. The pressure must be greater than the
standard value listed.
Brake pedal
force
14
Fluid
pressure
15
16
147 N
(15 kgf, 33 lb)
294 N
(30 kgf, 66 lb)
7,649 kPa
5,982 kPa
(78 kg/cm2, 1,109 psi)
[8,434 kPa (86 kg/
(61 kg/cm2, 868 psi)
cm2, 1,223 psi)
5,296 kPa
(54 kg/cm2,
9,120 kPa
768 psi)
(93 kg/cm2, 1,323 psi)
4,707 kPa
(48 kg/cm2, 683psi)
[ ]: ABS equipped vehicle.
BR-53
PROPORTIONING VALVE
BRAKE
C: INSPECTION
A: REMOVAL
1) Install the oil pressure gauges to measure the

master cylinder fluid pressure (front wheel brake
fluid pressure) and rear wheel cylinder fluid pressure.
2) Bleed air from the oil pressure gauges.
3) Check the master cylinder fluid pressure and
rear wheel cylinder fluid pressure.
The standard values are shown in the figure.
Rear wheel cylinder
fluid pressure: P 3
13.Proportioning Valve
BR0066
1) Remove the brake pipe from proportioning valve

at four places.
2) Remove the proportioning valve from its bracket.
CAUTION:
Do not disassemble or adjust the proportioning
valve. (The proportioning valve must be replaced as an assembly.)
B: INSTALLATION
1) Install the proportioning valve to bracket.
2) Connect the brake pipes correctly to proportioning valve.
3) Bleed air, then check each joint of the brake pipe
for oil leaks.
When both circuits

are normal
Master cylinder fluid pressure: P 2
BR0067
4) For the oil pressure in case of split point, refer to

SPECIFICATIONS.
<Ref. to BR-2, SPECIFICATIONS, General Description.>
Tightening torque:
Proportioning valve to brake pipe flare nut:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
Proportioning valve to bracket
18 Nm (1.8 kgf-m, 13.0 ft-lb)
BR-54
BRAKE FLUID
BRAKE
14.Brake Fluid
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.
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 the 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.
fluid must be used.
Cover the bleeder with waste cloth, when
loosening it, to prevent brake fluid from being
to prevent degrading the quality of fluid.
the reservoir tank.
NOTE:
During bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate entry of
air.
The brake pedal operating must be very slow.
For convenience and safety, two people should
do the work.
m2 (16.9 US fl oz, 17.6 Imp fl oz) for total brake
system.
stand under it, or left up vehicle.
2) Remove both front and rear wheels.
3) Draw out the brake fluid from master cylinder
with syringe.
brake fluid.
S4M0246
S4M0477A
(1) Air bleeder screw
CAUTION:
Brake fluid replacement sequence; (A) Front
right (B) Rear left (C) Front left (D) Rear
right
S4M0475A

(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 screw approx. 1/4 turn until a
small amount of brake fluid drains into container,
and then quickly tighten the screw.
BR-55
BRAKE FLUID
BRAKE
8) Repeat steps 6) and 7) until there are no air bubbles in the drained brake fluid and new fluid flows
through vinyl tube.
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
brake pedal depressed and tighten screw and install bleeder cap.
Tightening torque (Bleeder screw):
8 Nm (0.8 kgf-m, 5.8 ft-lb)
10) Bleed air from each wheel cylinder using the
same procedures as described in steps 6) through
7) above.
11) Depress 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
shows any unusual movement.
Visually inspect the bleeder screws and brake pipe
joints to make sure that 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
make sure that brakes are operating properly.
BR-56
AIR BLEEDING
BRAKE
15.Air Bleeding
5) Close the outlet plug with your finger, and release the brake pedal.
A: PROCEDURE
CAUTION:
fluid must be used.
Cover the bleeder with waste cloth when
loosening it to prevent brake fluid from being
to prevent degrading the quality of the fluid.
the reservoir tank.
NOTE:
Start with the brakes (wheels) connected to the
secondary chamber of master cylinder.
The time interval between two brake pedal operations (from the time when pedal is released to the
time when it is depressed another time) shall be approx. 3 seconds.
The air bleeder on each brake shall be released
for 1 to 2 seconds.
S4M0541
6) Repeat step4) and 5) until the brake fluid is completey bled 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-57,
BRAKE LINE, PROCEDURE, Air Bleeding.>
2. BRAKE LINE
1. MASTER CYLINDER
NOTE:
If the master cylinder is disassembled or reservoir tank is empty, bleed the master cylinder.
During the bleeding operation, keep the brake
reservoir tank filled with brake fluid to eliminate entry of air.
do the work.
1) Loosen the wheel nuts, jack-up the vehicle, support it with safety stands, and remove the wheel.
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.
NOTE:
During the bleeding operation, keep the brake
reservoir tank filled with brake fluid to eliminate entry of air.
do the work.
1) Make sure that there is no leak from the joints
and connections of brake system.
S4M0540
BR-57
AIR BLEEDING
BRAKE
2) Fit one end of vinyl tube into the air bleeder and
put the other end into a brake fluid container.
S4M0246
CAUTION:
Brake fluid replacement sequence; (A) Front
right (B) Rear left (C) Front left (D) Rear
right
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 approx.
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, depress the brake pedal
with a 490 N (50 kgf, 110 lb) load and measure the
distance between brake pedal and steering wheel.
With the brake pedal released, measure the distance between pedal and steering wheel again.
The difference between the two measurements
must be more than specified.
S4M0476A
(1) Steering wheel

(2) Toe board
S4M0475A
(1) Master cylinder

(2) Hydraulic unit
(3) Proportioning valve
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 waste cloth, when loosening it, to prevent brake fluid from being
NOTE:
4) Tighten the air bleeder securely when no air
bubbles are visible.
Air bleeder tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
Specified pedal stroke:

Without ABS
90 mm (3.54 in)
With ABS
95 mm (3.74 in)
When depressing brake pedal with a 490 N
(50 kg, 110 lb) load.
7) If the distance is more than the specifications,
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. (With ABS)
9) Recheck the brake stroke.
10) If the distance is more than specifications,
there is a possibility air is in the inside of hydraulic
unit. Repeat above steps 2) to 9) above until pedal
stroke meets the specification.
11) Add brake fluid to the required level (MAX. level) of reservoir tank.
12) As a final step, test run the vehicle at low speed
and apply brakes relatively hard 2 to 3 times to ensure that brakes provide normal braking action on
all four wheels without dragging and uneven braking.
BR-58
BRAKE HOSE
BRAKE
16.Brake Hose
B: INSTALLATION
A: REMOVAL
1. FRONT BRAKE HOSE
1. FRONT BRAKE HOSE
1) Route the end of brake hose (on caliper side)

through hole in brake hose bracket at strut location.
2) Tighten the end of brake hose at caliper using a
union bolt.
1) Separate the brake pipe from brake hose.

(Always use flare nut wrench and be careful not to
deform the flare nut.)
2) Pull out the clamp to remove brake hose.
3) Remove the bolt at strut and union bolt.
Tightening torque (Union bolt):

18 Nm (1.8 kgf-m, 13.0 ft-lb)
B4M1844
B4M1843B
3) Secure the middle fitting of brake hose to bracket at strut location using a bolt.
4) Position the disc in straight-forward direction and
route brake hose through hole in bracket on wheel
apron side.
(1) Brake hose

(2) Brake pipe
2. REAR BRAKE HOSE

1) Separate the brake pipe from brake hose.
NOTE:
Always use flare nut wrench and be careful not to
deform the flare nut.
2) Pull out the clamp to remove brake hose.
CAUTION:
Be sure brake hose is not twisted.
5) Temporarily tighten the flare nut to connect
brake pipe and hose.
6) Fix the brake hose with clamp at wheel apron
bracket.
7) While holding the hexagonal part of brake hose
fitting with a wrench, tighten the flare nut to the
specified torque.
Tightening torque (Brake pipe flare nut):
15 Nm (1.5 kgf-m, 10.8 ft-lb)
BR0068
(1) Brake hose clamp

(2) Brake hose
(3) Brake pipe
BR-59
BRAKE HOSE
BRAKE
2. REAR BRAKE HOSE

1) Pass the brake hose through hole of bracket,
and lightly tighten the flare nut to connect brake
pipe.
2) Insert the clamp upward to fix brake hose.
3) While holding the hexagonal part of brake hose
fitting with a wrench, tighten the flare nut to the
specified torque.
Tightening torque (Brake pipe flare nut):
15 Nm (1.5 kgf-m, 10.8 ft-lb)
BR0068
(1) Brake hose clamp

(2) Brake hose
(2) Brake pipe
C: INSPECTION
Ensure there are no cracks, breakage, or damage
on the hoses. Check the joints for fluid leakage. If
any cracks, breakage, damage or leakage is found,
repair or replace the hose.
BR-60
BRAKE PIPE
BRAKE
17.Brake Pipe
A: REMOVAL
NOTE:
center brake pipe.
CAUTION:
All airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits.
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 the air.
After installing the brake hose, make sure
that it does not touch the tire or suspension assembly, etc.
Brake pipe tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
C: INSPECTION
Ensure there are no cracks, breakage, or damage
on pipes. Check the joints for fluid leakage. If any
cracks, breakage, damage or leakage is found, repair or replace the pipe.
NOTE:
Use a mirror when inspecting low-visible part or
back side.
BR-61
HILL HOLDER
BRAKE
18.Hill Holder
5) Detach the PHV along with support from side

frame.
A: REMOVAL
1. PHV (PRESSURE HOLD VALVE)
1) Drain the brake fluid from reservoir of master cylinder.
2) Remove the adjusting nut and lock nut.
CAUTION:
Exercise utmost care to prevent foreign matter
from entering into the PHV when removing it.
S4M0243B
(1) PHV
S4M0241C
2. PHV CABLE
(1) Adjusting nut

(2) Lock nut
(3) PHV
1) Remove the adjusting nut and lock nut.
3) Remove the cable clamp, and disconnect the

PHV cable from PHV.
CAUTION:
Carefully protect the boots and inner cable
from damage when disconnecting PHV cable.
S4M0241C
(1) Adjusting nut

(2) Lock nut
(3) PHV
2) Remove the cable clamp, and disconnect PHV

cable from PHV.
S4M0242C
CAUTION:
damage when disconnecting PHV cable.
(1) PHV cable

(2) Clamp
4) Disconnect the brake pipes from PHV.

CAUTION:
Pay attention not to drop the brake fluid onto
body painting since it may dissolve paint.
Pay attention not to damage hexagonal head
of the flare nut by using pipe wrench without
fail.
S4M0242C
(1) PHV cable

(2) Clamp
BR-62
HILL HOLDER
BRAKE
3) Remove the cable clamp from clutch pedal

bracket.
LHD MODEL
C: INSTALLATION
1. PHV (PRESSURE HOLD VALVE)
1) Install the PHV onto side frame.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
2) Connect the brake pipes to PHV.
Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
CAUTION:
Confirm that the brake pipes are not deformed
and/or damaged. Replace them with new ones if
necessary.
3) Install the PHV cable to PHV.
S4M0244B
(1) Clamp
(2) PHV cable
(3) Clutch pedal
CAUTION:
If the cable clamp (and clips) is damaged, replace it with a new one.
Avoid sharp bending of PHV cable as it may
cause breakage.
4) Connect the PHV cable with clips.
5) Apply grease to the following points.
Hook portion of return spring
Cable end portion of lever
RHD MODEL
Grease:
SUNLIGHT 2 (Part No. 003602010)
6) Be sure to bleed air from the brake system.
7) Adjust the PHV cable. <Ref. to BR-63, PHV CABLE, INSTALLATION, Hill Holder.>
S4M0245B
CAUTION:
After replacing the PHV cable with new one, operate the clutch pedal about 30 times as a running-in operation prior to adjustment.
(1) Clamp
(2) PHV cable
(3) Clutch pedal
4) Remove the PHV cable.
2. PHV CABLE
B: INSPECTION
Check up removed parts as follows, and replace
defective ones.
1) Check if the boots of PHV cable are damaged or
degraded, the inner cable is damaged or corroded.
2) Check if the return spring is worn out, damaged
or corroded.
3) Confirm that rolling sound of the ball is heard
with PHV inclined and lever rotates smoothly.
CAUTION:
Never disassemble the PHV. Replace entire
PHV assembly if necessary.
1) Install the PHV cable in the reverse order of removal.

CAUTION:
a new one.
Avoid sharp bending of PHV cable as it may
cause breakage.
2) Apply grease to the following points.
Hook portion of return spring
Cable end portion of lever
Grease:
SUNLIGHT 2 (Part No. 003602010)
BR-63
HILL HOLDER
BRAKE
3) Adjust the PHV cable. <Ref. to BR-64, ADJUSTMENT, Hill Holder.>

CAUTION:
After replacing the PHV cable with new one, operate the clutch pedal about 30 times as a running-in operation prior to adjustment.
D: ADJUSTMENT
Confirm stopping and starting performances by activating the hill holder on an uphill road of 3 or higher inclination.
1) If the vehicle does not stop;
Tighten the adjusting nut of PHV cable.
2) If the vehicle does not start properly;
Case A When the hill holder is released later
than engagement of clutch pedal (Engine tends to
stall.):
Loosen adjusting nut gradually until smooth starting is enabled.
Case B When the hill holder is released earlier
than engagement of clutch pedal (Vehicle slips
down slightly.):
Tighten the adjusting nut so that hill holder is released later than engagement of clutch pedal (status in Case A). Then make adjustment the same as
in Case A.
CAUTION:
Whenever turning the adjusting nut, prevent
the PHV cable from revolving.
S4M0241C
(1) Adjusting nut

(2) Lock nut
(3) PHV
3) Tighten the lock nut.

Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
BR-64
BRAKE PEDAL
BRAKE
19.Brake Pedal
2. LHD 2.0 L MT MODEL
A: REMOVAL
1) Remove the steering bolts.

2) Raise the vehicle on hoist and remove the two
bolts which secure steering unit to underside of
body.
3) Lower the vehicle to floor.
instrument panel.
5) Disconnect the following parts from pedal bracket.
Operating rod of brake booster
Electrical connectors (for stop light switch, etc.)
6) Remove the clevis pin which secures lever to
push rod.
7) Remove the nut which secures clutch master
cylinder.
8) Remove the steering assembly.
9) Remove the accelerator pedal.
10) Remove the bolts and nuts which secure pedal
bracket.

instrument panel.
4) Disconnect the following parts from pedal bracket.
Operating rod of brake booster
Electrical connectors (for stop light switch, etc.)
5) Remove the clevis pin which secures pedal to
push rod.
and clutch pedals, and remove the pedal bracket
and clutch cable as a unit.
CAUTION:
Before removing the clutch cable from toe
board, remove the grommet. Slowly remove the
clutch cable, being careful not to scratch it.
BR0075
3. AT MODEL AND RHD MT MODEL
(A)

instrument panel.
3) Remove the clevis pin which secures brake pedal to brake booster operating rod. Also disconnect
the stop light switch connector.
4) Remove the two bolts and four nuts which secure the brake pedal to pedal.
(B)
TR0494
(A) Clutch pedal

(B) Brake pedal
7) Depress the clutch pedal, disconnect the clutch

cable from clutch pedal.
G4M0324
BR-65
BRAKE PEDAL
BRAKE
B: INSTALLATION
1) Remove the brake switch.

<Ref. to BR-69, REMOVAL, Stop Light Switch.>
2) Remove the clutch pedal.
<Ref. to CL-43, DISASSEMBLY, Clutch Pedal.>
3) Remove the clutch master cylinder bracket.
CAUTION:
a new one.
boot.
2) Adjust the clutch pedal <Ref. to CL-46, ADJUSTMENT, Clutch Pedal.>
3) Inspect the brake pedal after installation <Ref. to
BR-68, INSPECTION, Brake Pedal.>
C: DISASSEMBLY
B4M2349
1) Remove the stop light switch.

<Ref. to BR-69, REMOVAL, Stop Light Switch.>
2) Remove the nut and pull out the bolt until brake
pedal is able to remove, then remove brake pedal.
4) Remove the bushing, spring and stopper.
B4M2350A
(1)
(2)
(3)
(4)
BR0069
3) Remove the bushing, spring and stopper.
Stopper
Bushing
Brake pedal
Brake pedal spring
5) Remove the brake pedal pad.
BR0070
(1)
(2)
(3)
(4)
Stopper
Bushing
Brake pedal
Brake pedal spring
4) Remove the brake pad.
BR-66
BRAKE PEDAL
BRAKE
3. AT MODEL AND RHD MT MODEL
D: ASSEMBLY
1) Remove the brake switch.

2) Unbolt, and then remove the brake pedal.
1) Attach the stop light switch, etc. to pedal bracket

temporarily.
2) Clean the inside of bores of clutch pedal and
brake pedal, apply grease, and set the bushings
into bores.
3) Align bores of the pedal bracket, clutch pedal
and brake pedal, attach the brake pedal return
spring and clutch pedal effort reducing spring (vehicle with hill holder), and then install the pedal bolt.
NOTE:
Clean up the inside of bushings and apply grease
before installing spacer.
B4M2347
3) Remove the bushing, spacer and spring.
Tightening torque:
T: 29 Nm (3.0 kgf-m, 21.7 ft-lb)
BR0028
(1)
(2)
(3)
(4)
Plug
Stopper
Brake pedal
Brake pedal spring
4) Remove the brake pedal pad.
B4M1753C
4) Set the brake pedal position by adjusting position of stop light switch.
Pedal position: L
125.9 mm (4.96 in)
Tightening torque:
T: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
B4M1754B
BR-67
BRAKE PEDAL
BRAKE
E: INSPECTION
2) Check the position of pedal pad.
1) Move the brake and clutch 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.
Pedal height: L
148 mm (5.83 in)
CAUTION:
bushings with new ones.
Brake pedal free play: A

1 3 mm (0.04 0.12 in) [Depress brake
pedal pad with a force of less than 10 N (1 kgf,
2 lb).]
Deflection of brake and clutch pedal:

Service limit
B4M0366B
(1)
(2)
(3)
(4)
S4M0135B
(1) Clutch pedal

(2) Brake pedal
Stop light switch

Mat
Toe board
Brake booster operating rod
3) If it is not within specified value, adjust it by adjusting the brake booster operating rod length.
G4M0326
BR-68
STOP LIGHT SWITCH

BRAKE
20.Stop Light Switch
C: INSPECTION
A: REMOVAL
1) If the stop light switch does not operate properly

(or if it does not stop at the specified position), replace with a new one.

2) Disconnect the stop light switch connector.
3) Loosen nuts, and unscrew stop light switch to remove.
Specified position: L
2 mm (0.079 in)
G4M0327
B4M1753D
2) Measure the clearance between threaded end of

stop light switch and stopper.
(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-70, ADJUSTMENT, Stop Light
Switch.>
CAUTION:
Be careful not to rotate stop light switch.
Stop light switch clearance: A
0.3 mm (0.012 in)
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
B4M0617E
(1) Stop light switch

(2) Stopper
(3) Brake pedal
B4M1753E
3) If it is not within specified value, adjust it by adjusting position of stop light switch.
CAUTION:
Be careful not to rotate the stop light switch.
BR-69
STOP LIGHT SWITCH

BRAKE
D: ADJUSTMENT
Loosen the lock nut, and adjust the stop light switch
position until the clearance between threaded end
of stop light switch and stopper becomes 0.3 mm
(0.012 in). Then, tighten the lock nut.
B4M0617E
BR-70
GENERAL DIAGNOSTICS
BRAKE
21.General Diagnostics
A: INSPECTION
1. Insufficient braking
2. Unstable or uneven
braking
3. Excessive pedal
stroke
4. Brake dragging or
improper brake return
5. Brake noise (1)

(creak sound)
6. Brake noise (2)

(hissing sound)

(1) Fluid leakage from the hydraulic mechanism
(2) Entry of air into the hydraulic mechanism
(3) Excessively wide shoe clearance
(4) Wear, deteriorated surface material, adhering
water or fluid on the lining
(5) Improper operation of master cylinder, disc caliper, brake booster or check valve
(1) Fluid on the lining, drum or rotor
(2) Drum or rotor eccentricity
(3) Worn brake drum, or damage to the drum
caused by sand
(4) Improper lining contact, deteriorated surface
material, improper inferior material, or wear
(5) Deformed back plate
(6) Improper tire inflation
(7) Disordered wheel alignment
(8) Loosened back plate or the support installing
bolts
(9) Loosened wheel bearing
(10) Trouble in the hydraulic system
(11) Uneven effect of the parking brake
Corrective action
Repair or replace (cup, piston seal, piston boot,
master cylinder piston kit, pipe or hose).
Bleed the air.
Adjust the clearance.
Replace, grind or clean.
Correct or replace.
Eliminate cause of fluid leakage, clean, or replace.
Correct or replace the drum or rotor.
Correct by grinding, or replace.
Correct by grinding, or replace.
Correct or replace.
Inflate to correct pressure.
Adjust alignment.
Retighten.
Retighten to normal tightening torque or replace.

Replace the cylinder, brake pipe or hose.
Check, adjust, or replace the rear brake and cable
system.
(1) Entry of air into the hydraulic mechanism
Bleed the air.
(2) Excessive play in the master cylinder push rod Adjust.
(3) Fluid leakage from the hydraulic mechanism
Repair or replace (cup, piston seal, piston boot,
master cylinder piston kit, pipe or hose).
(4) Improperly adjusted shoe clearance
Adjust.
(5) Improper lining contact or worn lining
Correct or replace.
(1) Insufficient pedal play
Adjust play.
(2) Improper master cylinder return
Clean or replace the cylinder.
(3) Clogged hydraulic system
Replace.
(4) Improper return or adjustment of parking brake Correct or adjust.
(5) Weakened spring tension or breakage of shoe Replace the spring.
return spring
(6) Excessively narrow shoe clearance
Adjust the clearance.
(7) Improper disc caliper operation
Correct or replace.
(8) Improper adjusted wheel bearing
Adjust or replace.
(1) Hardened or deteriorated lining
Replace the shoe assembly or pad.
(2) Worn lining
(3) Loosened back plate or the support installing
Retighten.
bolts
(4) Loose wheel bearing
Retighten to normal tightening torque.
(5) Dirty drum or rotor
Clean the drum or rotor, or clean and replace the
brake assembly.
(1) Worn lining
(2) Improper installed shoe or pad
Correct or replace the shoe assembly or pad.
(3) Loose or bent drum or rotor
Retighten or replace.
BR-71
GENERAL DIAGNOSTICS
BRAKE
7. Brake noise (3)

(click sound)

In the case of the disc brake:
(1) Excessively worn pad or the support
In the case of the drum brake:
(1) Excessively worn shoe ridge
(2) Lack of oil on the shoe ridge surface and
anchor
BR-72
Corrective action
Replace the pad or the support.
Replace the back plate.
Add more grease.
PARKING BRAKE
PB
1.
2.
3.
4.
5.
Page
Parking Brake Lever....................................................................................6
Parking Brake Cable ...................................................................................7
Parking Brake Assembly (Rear Disc Brake) ...............................................9
GENERAL DESCRIPTION
PARKING BRAKE
A: SPECIFICATIONS
Model
Type
Effective drum diameter
Lining dimensions
Lever stroke
mm (in)
mm (in)
notches/N (kgf, lb)
Rear drum brake

Rear disc brake
Mechanical on rear brakes, drum in disc
228.6 (9)
170 (6.69)
218.8 35.0 4.1
162.6 30.0 3.2
(8.61 1.378 0.161)
(6.40 1.181 0.126)
Manual adjustment
7 to 8/196 (20, 44)
PB-2
GENERAL DESCRIPTION
PARKING BRAKE
B: COMPONENT
B4M1127A
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Back plate
Retainer
Spring washer
Lever
Strut spring
Strut
Shoe guide plate
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Primary return spring

Secondary return spring
Adjusting spring
Adjuster
Shoe hold-down cup
Shoe hold down spring
Shoe hold down pin
Adjusting hole cover
PB-3

T: 53 (5.4, 39.1)
GENERAL DESCRIPTION
PARKING BRAKE
2. PARKING BRAKE CABLE
B4M0705B
(1)
(2)
(3)
(4)
(5)
(6)
Parking brake lever

Parking brake switch
Lock nut
Adjusting nut
Equalizer
Bracket
(7)
(8)
(9)
(10)
Clamp
Parking brake cable RH
Cable guide
Clamp (Rear disc brake model
only)
(11)
Parking brake cable LH
PB-4

T1: 5.9 (0.6, 4.3)
T2: 18 (1.8, 13.0)
T3: 32 (3.3, 23.6)
GENERAL DESCRIPTION
PARKING BRAKE
C: CAUTION
points.
Keep grease etc. away from parking brake
shoes.
PB-5
PARKING BRAKE LEVER

PARKING BRAKE
2. Parking Brake Lever
C: INSPECTION
A: REMOVAL
While pulling the parking brake lever upward, count

the notches.

2) Remove the rear tire and wheel.
3) Remove the rear cushion.
4) Remove the console box.
5) Loosen the parking cable adjusting nut and console bracket.
6) Disconnect the connector parking brake switch.
7) Remove the parking brake lever.
Lever stroke:
7 to 8 notches when pulled with a force of 196
N (20 kgf, 44 lb)
If incorrect, adjust the parking brake. <Ref. to PB11, ADJUSTMENT, Parking Brake Assembly (Rear
Disc Brake).>
D: ADJUSTMENT
2) Forcibly pull the parking brake lever 3 to 5 times.
3) Adjust the parking brake lever by turning adjuster until parking brake lever stroke is set at 7 to 8
notches with operating force of 196 N (20 kgf, 44
lb).
Lever stroke:
N (20 kgf, 44 lb)
BR0029
8) Unbend the parking brake lever pawls and remove cable.

5.9 Nm (0.6 kgf-m, 4.3 ft-lb)
S4M0471A
BR0054

(2) Cable

(2) Lock nut
(3) Adjusting nut
B: INSTALLATION
5) Install the console cover.

Tightening torque:
Parking brake lever;
18 Nm (1.8 kgf-m, 13.0 ft-lb)
Adjusting nut;
5.9 Nm (0.6 kgf-m, 4.3 ft-lb)
NOTE:
Be sure to pass the cable through guide inside
the tunnel.
Be sure to adjust the lever stroke. <Ref. to PB-6,
ADJUSTMENT, Parking Brake Lever.>
PB-6
PARKING BRAKE CABLE

PARKING BRAKE
3. Parking Brake Cable

A: REMOVAL
2) Remove the rear tires and wheels.
4) Remove the console box from front floor.
5) Loosen the parking cable adjusting nut and console bracket.
6) Remove the parking brake lever.
10) Pull out the parking brake cable from rear

brake.
Disc brake
<Ref. to PB-9, REMOVAL, Parking Brake Assembly (Rear Disc Brake).>
Drum brake
<Ref. to BR-44, Rear Drum Brake Assembly.>
11) Pull out the clamp from rear brake.
12) Remove the bolt and bracket from trailing link
bracket.
13) Remove the bolt and clamp from rear floor.
BR0029
S4M0474
7) Roll up the floor mat and remove clamps.
14) Detach the grommet from rear floor.

15) Remove the cable assembly from cabin by
forcibly pulling it backward.
16) Detach the parking brake cable from cable
guide at rear trailing link.
BR0030
8) Remove the equalizer cover.

9) Remove the inner cable end from equalizer.
S4M0473A
(1) Equalizer
(2) Inner cable end
PB-7
PARKING BRAKE CABLE

PARKING BRAKE
B: INSTALLATION
C: INSPECTION
Install the (new) parking brake assembly in the reverse order of removal.

cracks.
NOTE:
Be sure to pass the cable through cable guide inside the tunnel.
Be sure to adjust the lever stroke. <Ref. to PB-6,
ADJUSTMENT, Parking Brake Lever.>
PB-8
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

the disc rotor out by installing an 8-mm bolt in
holes B on rotor.
A: REMOVAL
1) Remove the two mounting bolts and remove the
disc brake assembly.
G4M0383
5) Remove the shoe return spring from parking

brake assembly.
6) Remove the front shoe hold down spring and pin
with pliers.
S4M0459A
(1) Disc brake assembly
2) Suspend the disc brake assembly so that the

hose is not stretched.
3) Pull down and release the parking brake.
NOTE:
If the disc rotor is difficult to remove, try the following two methods in order.
(1) Turn the adjusting screw using a slot-type
screwdriver until brake shoe gets away enough
from the disc rotor.
BR0055
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 cable from parking lever.
S4M0463A
(1)
(2)
(3)
(4)
Adjusting screw
Cover (rubber)
Back plate
B4M1774B
(1) Parking brake cable

12) Using a standard screwdriver, raise the retainer. Remove the parking lever and washer from
brake shoe.
PB-9

PARKING BRAKE
B: INSTALLATION
NOTE:
Ensure that the shoe return spring is installed as
CAUTION:
Be sure the lining surface is free from oil contamination.
Brake grease:
725191460)
1) Apply brake grease to the following places.
Six contact surfaces of shoe rim and back plate
packing
Contact surface of shoe wave and anchor pin
Contact surface of lever and strut
Contact surface of shoe wave and adjuster assembly
Contact surface of shoe wave and strut
Contact surface of lever and shoe wave
2) Install in reverse order of removal.
CAUTION:
Use new retainers and clinch them when installing the brake shoes to levers.
Ensure that the parking lever moves smoothly.
Do not confuse the left parking lever with
right one.
Do not confuse the left strut with right one.
NOTE:
Ensure that the adjuster assembly is securely installed with screw in the left side, facing vehicle
front.
S4M0462A
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Back plate
Shoe guide plate
Retainer
Spring washer
Lever
Primary shoe return spring (Blue)
Secondary shoe return spring (Yellow)
3) Adjust the parking brakes. <Ref. to PB-11, ADJUSTMENT, Parking Brake Assembly (Rear Disc
Brake).>
CAUTION:
After replacing the parking brake lining, be sure
to drive the vehicle for break-in purposes.
(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 meter (0.12
mile) in this condition.
(4) Wait 5 to 10 minutes for the parking brake to
cool down. Repeat this procedure once more.
(5) After breaking-in, re-adjust the parking
brakes.
S4M0461A
(1) LEFT
PB-10

PARKING BRAKE
C: INSPECTION
2. LEVER STROKE
1) Measure the brake disc inside diameter. If the

disc is scored or worn, replace the brake disc.
1) Remove the console box lid.

2) Forcibly pull the parking brake lever 3 to 5 times.
3) Adjust the parking brake lever by turning adjuster until parking brake lever stroke is set at 7 to 8
notches with operating force of 196 N (20 kgf, 44
lb).
Disc inside diameter:

Standard
170 mm (6.69 in)
Service limit
171 mm (6.73 in)
2) Measure the lining thickness. If it exceeds the
limit, replace the shoe assembly.
Lining thickness:
Standard
3.2 mm (0.126 in)
Service limit
1.5 mm (0.059 in)
CAUTION:
Replace the brake shoes on the right and left
brake assembly at the same time.
BR0054

(2) Lock nut
(3) Adjusting nut
D: ADJUSTMENT
1. SHOE CLEARANCE
1) Remove the adjusting hole cover from back
plate.
2) Turn the adjusting screw using a slot-type
screwdriver until brake shoe is in close contact with
disc rotor.

5) Install the console box lid.
Lever stroke:
N (20 kgf, 44 lb)
5.9 Nm (0.6 kgf-m, 4.3 ft-lb)
S4M0463A
(1)
(2)
(3)
(4)
Adjusting screw
Cover (rubber)
Back plate
3) Turn back (downward) the adjusting screw 3 or 4

notches.
4) Install the adjusting hole cover to back plate.
PB-11

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-12
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..........................................................................................26
Universal Joint...........................................................................................27
Tilt Steering Column..................................................................................29
Steering Gearbox [LHD MODEL] ..............................................................32
Steering Gearbox [RHD MODEL] .............................................................53
Pipe Assembly [LHD MODEL] ..................................................................73
Pipe Assembly [RHD MODEL]..................................................................81
Oil Pump ...................................................................................................89
Reservoir Tank........................................................................................105
Power Steering Fluid...............................................................................107
GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)
A: SPECIFICATIONS
2.0 L
Model
1.6 L
Minimum turning radius

m (ft)
Steering angle (Inside-Outside)
Whole
Steering wheel diameter
mm (in)
system
Overall gear ratio (Turns, lock to
lock Gear box)
Type
Gearbox Backlash
Valve (Power steering system)
Type
Oil tank
Pump
(Power
steering
system)
Hydraulic fluid control

Hydraulic fluid
Working fluid
(Power
steering
system)
2 (US qt, Imp qt)
Range of revolution
Revolving direction
Name
rpm
Oil tank
Capacity
2 (US qt, Imp qt) Total
TURBO
LHD
RHD
5.4 (17.7)
34 30 30 20
2.5 L
385 (15.16)
3.22
3.02
2.69
3.02
Rack and pinion, Integral

0 (Automatically adjustable)
Rotary valve
Vane pump
Installed on body
7.8 (0.476)
7.2 (0.439)
7.8 (0.476)
7,350 8,036 7,164 7,840

(75 82,
(73 80,
1,067
1,040
1,165)
1,137)
Dropping in response to increased engine revolutions
1,000 rpm: 7
(7.4, 6.2)
1,000 rpm: 7 (7.4, 6.2)
7.5 (7.9, 6.6)*1
3,000 rpm: 5
3,000 rpm: 5 (5.3, 4.4)
7 (7.4, 6.2)*2
(5.3, 4.4)
700 9,000
Clockwise
ATF DEXRON III or equivalent
0.3 (0.3, 0.3)
6,174 6,860
(63 70,
kPa (kg/cm , psi)
896 994)
2
OUTBACK
5.1 (16.7)
37 20 34 25
cm3 (cu in)/rev.
Output
Relief pressure
Except OUTBACK
7,164 7,840
(73 80, 1,040 1,137)
0.7 (0.7, 0.6)
*1: With maximum load.

*2: With no load.
PS-2
GENERAL DESCRIPTION
Model
Steering wheel
Turning angle
Steering shaft
Steering gearbox
(Power steering system)
LHD
Free play
TURBO, OUTBACK, RS
Except TURBO, OUTBACK, RS
Outer tire & TURBO, OUTBACK, RS
wheel
Except TURBO, OUTBACK, RS
Clearance between steering wheel and
column cover
Sliding resistance
Input shaft
play
3.0 (0.118)
Pulley
N (kgf, lb)
mm (in)
Left-turn steering
mm (in)
In radial direction
In axial direction
mm (in)
mm (in)
N (kgf, lb)
Radial play
Pulley shaft
Non-TURBO
Axial play
TURBO
Ditch deflection
Resistance to rotation
Regular pressure
Steering wheel
effort
mm (in)
Right-turn steering
Turning resistance
Oil pump
17 (0.67)
34301.5
37201.5
30201.5
32251.5
Inner tire &

wheel
Rack shaft
play in
radial direction
At standstill with engine idling on a concrete road

At standstill with engine stalled on a
concrete road
Recommended power steering fluid
ATF DEXRON III or equivalent
RHD
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
N (kgf, lb)
304.0 (31.0, 68.4) or less

Horizontal movement:
0.19 (0.0075) or less
0.19 (0.0075) or less
Vertical movement:
0.3 (0.012) or less
Horizontal movement:
0.15 (0.0059) or less
0.19 (0.0075) or less
Vertical movement:
0.3 (0.012) or less
0.18 (0.0071) or less
0.5 (0.020) or less
Maximum allowable value:
Less than 9.33 N (0.95 kgf, 2.10 lb)
Difference between right and left
sliding resistance: Less than 20 %
0.4 (0.016) or less
0.4 (0.016) or less
0.8 (0.031) or less
1.0 (0.039) or less
9.22 (0.94, 2.07) or less
kPa (kg/cm2, psi)
981 (10, 142) or less
N (kgf, lb)
31.4 (3.2, 7.1) or less
N (kgf, lb)
294.2 (30, 66.2) or less
Manufacturer
B.P.
CALTEX
CASTROL
MOBIL
SHELL
TEXACO
PS-3
GENERAL DESCRIPTION
CAUTION:
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 Pipe
(2) DOJ Shaft or joint
(3) DOJ Valve housing
(4) Pipe Pipe
(5) Stabilizer Pipe
(6) Exhaust pipe Pipe
(7) Exhaust pipe Gearbox bolt
(8) Side frame Hose A and B
(9) Cruise control pump Hose A and B
(10) Pipe portion of hose A Pipe portion of hose B
(11) AT cooling hose Joint
Minimum allowance
5 mm (0.20 in)
14 mm (0.55 in)
11 mm (0.43 in)
2 mm (0.08 in)
5 mm (0.20 in)
11 mm (0.43 in)
15 mm (0.59 in)
10 mm (0.39 in)
15 mm (0.59 in)
1.5 mm (0.059 in)
20 mm (0.79 in)
RHD MODEL
ST0001
PS-4
GENERAL DESCRIPTION
LHD MODEL
ST0002
PS-5
GENERAL DESCRIPTION
B: COMPONENT
1. STEERING WHEEL AND COLUMN
(1)
(2)
(3)
T2
T3
(4)
T1
(7)
(5)
(6)
ST0104
(1)
(2)
(3)
(4)
(5)
Bushing
Steering shaft
Steering roll connector
Column cover
Steering wheel
(6)
(7)
Airbag module
Lower steering wheel cover
PS-6

T1: 1.2 (0.12, 0.9)
T2: 25 (2.5, 18.1)
T3: 44 (4.5, 32.5)
GENERAL DESCRIPTION
PS-7
GENERAL DESCRIPTION
2. POWER ASSISTED SYSTEM

LHD MODEL
NON-TURBO MODEL
TURBO MODEL
(5)
(8)
(9)
(4)
(61)
(2)
(5)
(4)
(8)
(61)
(9)
(2)
(6)
(4)
(1)
(6)
(1)
(3)
(4)
(3)
(4)
(4)
(4)
(10)
(57)
(16)
(57)
(10)
(12)
(11)
(16)
(15)
(13)
(13)
(14)
(14)
(20)
(7)
(36)
(19)
(37)
(60)
(18)
(21)
(19)
(22)
(17)
(23)
(39)
(38)
(24)
(25)
(26)
(32) (33) (34) (35)
(40)
(51)
(58)
(41)
(59)
(7)
(42)
(27)
(30)
(50)
(48)
(28)
(29)
(31)
(7)
(36)
(37)
(47)
(43)
(44)
(49)
(45)
(43)
(46)
(46)
(47)
(58)
(38)
(39)
(45)
(56)
(40)
(41)
(44)
(55)
(54)
(53)
(58)
(42)
(52)
ST0105
PS-8
GENERAL DESCRIPTION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
Eye bolt
Pipe C
Gasket
Clip
Pipe D
Clamp E
O-ring
Cap
Reservoir tank
Pulley
Oil pump
Bracket
Belt tension nut
Bush
Belt cover
Pipe E
Pipe F
Clamp plate
Universal joint
Dust seal
Valve housing
Gasket
Oil seal
Ball bearing
Seal ring
Pinion and valve ASSY
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
(47)
(48)
(49)
(50)
(51)
(52)
(53)
(54)
Oil seal
Back-up washer
Ball bearing
Snap ring
Lock nut
Adjusting screw
Spring
Sleeve
Adapter
Clamp
Cotter pin
Castle nut
Dust cover
Clip
Tie-rod end
Clip
Boot
Band
Tie-rod
Lock washer
Pipe B
Pipe A
Steering body
Oil seal
Piston ring
Rack
Rack bushing
PS-9
(55)
(56)
(57)
(58)
(59)
(60)
(61)
Rack stopper
Circlip
Suction hose
Tie-rod end plate
Clamp plate
Hose
Return hose

T1: 6 (0.6, 4.3)
T2: 7.4 (0.75, 5.4)
T3: 8 (0.8, 5.8)
T4: 10 (1.0, 7.2)
T5: 13 (1.3, 9.4)
T6: 15 (1.5, 10.8)
T7: 15.7 (1.6, 11.6)
T8: 22 (2.2, 15.9)
T9: 24 (2.4, 17.4)
T10: 25 (2.5, 18.1)
T11: 27 (2.75, 19.9)
T12: 37.3 (3.8, 27.5)
T13: 39 (4.0, 28.9)
T14: 59 (6.0, 43.4)
T15: 78 (8.0, 57.9)
T16: 83 (8.5, 61.5)
GENERAL DESCRIPTION
RHD MODEL
NON-TURBO MODEL
TURBO MODEL
(8)
(10)
(5)
(9)
(4)
(8)
(9)
(5)
(4)
(56)
(2)
(56)
(6)
(1)
(4)
(4)
(4)
(7)
(54)
(4)
(12)
(55)
(10)
(6)
(4)
(3)
(4)
(2)
(1)
(3)
(4)
(7)
(16)
(56)
(11)
(15)
(16)
(55)
(13)
(13)
(14)
(14)
(17)
(18)
(28)
(19)
(20)
(27)
(29)
(30)
(31)
(21)
(53)
(22)
(33)
(34)
(35)
(53)
(32)
(48)
(24)
(23)
(25)
(36)
(50)
(49)
(52)
(51)
(45)
(44)
(43)
(47)
(46)
(26)
(26)
(42)
(38)
(41)
(39)
(37)
(40)
(36)
(32)
(35)
(34)
(33)
(53)
(27)
(53)
(28)
(29)
(30)
(31)
ST0106
PS-10
GENERAL DESCRIPTION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
Eye bolt
Pipe C
Gasket
Clip
Pipe D
Clamp E
O-ring
Cap
Reservoir tank
Pulley
Oil pump
Bracket
Belt tension nut
Bush
Belt cover
Universal joint
Dust cover
Plug
O-ring
Oil seal
Pinion
Seal ring
Oil seal
Adapter
(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)
Clamp
Castle nut
Cotter pin
Dust seal
Clip
Tie-rod end
Clip
Boot
Wire
Tie-rod
Lock washer
Holder
Bush
Oil seal
Oil seal
O-ring
Rack
Oil seal
Back-up washer
Steering body
Pipe A
Pipe B
Lock nut
Adjusting screw
Spring
PS-11
(51)
(52)
(53)
(54)
(55)
(56)
Sleeve
Seat pad
Tie-rod end plate
Oil cooler
Suction hose
Return hose

T1: 7.4 (0.75, 5.4)
T2: 8 (0.8, 5.8)
T3: 13 (1.3, 9.4)
T4: 15 (1.5, 10.8)
T5: 15.7 (1.6, 11.6)
T6: 20 (2.0, 14.5)
T7: 22 (2.2, 15.9)
T8: 24 (2.4, 17.4)
T9: 25 (2.5, 18.1)
T10: 27 (2.75, 19.9)
T11: 37.3 (3.8, 27.5)
T12: 39 (4.0, 28.9)
T13: 59 (6.0, 43.4)
T14: 64 (6.5, 47.0)
T15: 78 (8.0, 57.9)
T16: 83 (8.5, 61.5)
GENERAL DESCRIPTION
3. OIL PUMP
NON-TURBO MODEL
ST0005
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Pulley
Oil seal
Shaft
Connector
O-ring
Spool valve
Spring
O-ring
Front casing
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Pressure switch
O-ring
O-ring
Pressure plate
Straight pin
Vane
Rotor
Cam ring
Retaining ring
PS-12
(19)
(20)
(21)
O-ring
Rear cover
Suction connector

T1: 21 (2.1, 15.2)
T2: 49 (5.0, 36.2)
T3: 52 (5.3, 38.3)
GENERAL DESCRIPTION
TURBO MODEL
(18)
(19)
(1)
(2)
(3)
(4)
(16)
(5)
(12)
(14)
(6)
(15)
(8)
(7)
(13)
(17)
(11)
(9)
(10)
ST0107
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Lead wire
Pump switch
Rear cover
O-ring
Cam
Pressure plate
O-ring
Front casing
Energy saving valve
Flow control spring
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
Flow control valve

Pulley
Oil seal
Suction connector
O-ring
Retaining ring
O-ring
Connector
O-ring
PS-13

T1: 9.8 (1.0, 7.2)
T2: 11.8 (1.2, 8.7)
T3: 27 (2.75, 19.9)
T4: 27.4 (2.8, 20.3)
T5: 54 (5.5, 39.8)
T6: 59 (6.0, 43.4)
GENERAL DESCRIPTION
C: CAUTION
Use SUBARU genuine steering fluid, grease etc.
or the equivalent. Do not mix steering fluid, grease
etc. with that of another grade or from other manufacturers.
points.
Apply steering fluid onto sliding or revolution surfaces before installation.
Before installing O-rings or snap rings, apply sufficient amount of steering fluid to avoid damage
and deformation.
PS-14
GENERAL DESCRIPTION
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
925700000
DESCRIPTION
WRENCH
REMARKS
Used for removing and installing tie-rod.
Apply this tool to rack.
925711000
PRESSURE
GAUGE
Used for measuring oil pump pressure.
926200000
STAND
Used when inspecting characteristic of gearbox

assembly and disassembling it.
ADAPTER HOSE A
Used with PRESSURE GAUGE (925711000).
B4M2411
B4M2412
B4M2413
34099AC010
B4M2414
PS-15
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
34099FA100
DESCRIPTION
STAND BASE
REMARKS
Used for assembling power steering gearbox.
For LHD model.
ADAPTER HOSE B
Used with PRESSURE GAUGE (925711000).
926230000
SPANNER
For the lock nut when adjusting backlash of

gearbox.
34099PA100
SPANNER
Measurement of rotating resistance of gearbox assembly.
G1H0273
34099AC020
B4M2415
B4M2416
ST0047
PS-16
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
34199AE020
DESCRIPTION
MOUNT
REMARKS
Used for disassembling oil pump.
For Turbo model.
34199AE030
INSTALLER
Used for installing oil seal into oil pump.
34199AE040
OIL CHARGE
GUIDE
Used for charging power steering oil.
927640000
INSTALLER B
Used for installing ball bearing into housing.

For LHD model.
B4M2417
B4M2418
B4M2419
B4M2420
PS-17
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
926370000
DESCRIPTION
INSTALLER A
REMARKS
Used for installing valve assembly into valve
housing assembly.
Used with STAND BASE (927630000).
For LHD model.
926390001
COVER &
REMOVER ASSY
Used for assembling rack assembly.

For LHD model.
926420000
PLUG
When oil leaks from pinion side of gearbox

assembly, remove pipe B from valve housing,
attach this tool and check oil leaking points.
926400000
GUIDE
Right side of rack when installing rack bush.

Used with GUIDE (927660000).
For LHD model.
B4M2421
B4M2422
B4M2423
B4M2424
PS-18
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
927660000
DESCRIPTION
GUIDE
REMARKS
Right side of rack when installing rack bush.
Used with GUIDE (926400000).
For LHD model.
927620000
INSTALLER B
Used for installing oil seal of valve housing.

Used with INSTALLER A (926360000).
926360000
INSTALLER A
Used as a guide to install oil seal.

Used with INSTALLER B (927620000).
INSTALLER
Used for installing oil seal.
B4M2425
B4M2426
B4M2428
34099FA110
B4M2429
PS-19
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
34099FA120
DESCRIPTION
INSTALLER AND
REMOVER SEAL
REMARKS
Used for installing valve housing oil seal.
Used with INSTALLER SEAL. (34099FA130)
Used for installing valve housing ball bearing.
Used for removing oil seal and ball bearing
from valve housing.
34099FA130
INSTALLER SEAL
Used for installing valve housing oil seal.

Used with INSTALLER AND REMOVER
SEAL (34099FA120).
34199AE050
REMOVER OIL
SEAL
Used for removing back-up ring and oil seal.
34099AC030
INSTALLER A
Used for installing retaining ring.

Used with INSTALLER B (34099AC040).
For Non-turbo model.
S1H0030
ST0007
B4M2432
H4M1408
PS-20
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
34099AC040
DESCRIPTION
INSTALLER B
REMARKS
Used for installing retaining ring.
Used with INSTALLER A (34099AC030).
For Non-turbo model.
926250000
GUIDE
Used for installing holder ASSY into rack

housing.
For RHD model.
927490000
INSTALLER A, B, C
Used for installing oil seal into rack assembly.

For RHD model.
927580000
REMOVER
Used for removing back-up ring and oil seal.

For RHD model.
H4M1409
ST0059
ST0063
ST0066
PS-21
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
34099FA010
DESCRIPTION
GUIDE
REMARKS
Used for installing rack and seal into housing
assembly.
For RHD model.
34099FA030
INSTALLER &
REMOVER
Used for removing and installing rack oil seal

(outer & inner).
For RHD model.
34099FA040
INSTALLER
Used for installing rack oil seal (outer).

For RHD model.
34099FA060
PUNCH HOLDER
Used for caulking.

For RHD model.
B4M2500
ST0072
B4M2503
ST0075
PS-22
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
34099FA070
DESCRIPTION
BASE
REMARKS
Used for supporting housing assembly.
For RHD model.
34099FA080
PUNCH
Used for removing caulking.

For RHD model.
34199AE090
PLUG WRENCH
Used for removing plug.
34199AE100
PLUG OIL SEAL

REMOVER
Used for removing plug oil seal.
ST0076
ST0077
B4M2615
B4M2616
PS-23
GENERAL DESCRIPTION
ILLUSTRATION
TOOL NUMBER
34199AE110
DESCRIPTION
PLUG OIL SEAL
INSTALLER
REMARKS
Used for installing plug oil seal.
34199AE120
GEARBOX OIL
SEAL REMOVER
Used for removing gearbox oil seal.
34199AE130
GEARBOX OIL
SEAL INSTALLER
Used for installing gearbox oil seal.
B4M2617
B4M2618
B4M2619
PS-24
GENERAL DESCRIPTION

TOOL NAME
Spring scale
Snap ring pliers
Dial gauge
REMARKS
Used for measuring tightening torque.
Used for measuring steering gearbox.
PS-25
STEERING WHEEL
2. Steering Wheel
C: INSPECTION
A: REMOVAL
1) Check the steering wheel for deformation. If the

deformation is excessive, replace steering wheel.
2) Check the splines on steering wheel for damage.
If the damage is excessive, replace steering wheel.

2) Set the tires to straight-ahead position.
3) Remove the airbag module.<Ref. to AB-12, REMOVAL, Driver's Airbag Module.>
WARNING:
Always refer to AirBag System before performing airbag module service. <Ref. to AB-3,
CAUTION, General Description.>
4) Remove the steering wheel nut, and then draw
out the steering wheel from shaft using steering
puller.
NOTE:
Make matching marks on the steering wheel and
steering column in advance.
B4M2433A
(1) Matching mark
B: INSTALLATION
1) Align the center of roll connector. <Ref. to AB17, ADJUSTMENT, Roll Connector.>
NOTE:
Align matching marks on the steering wheel and
steering column.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
Column cover-to-steering wheel clearance:
2 4 mm (0.08 0.16 in)
WARNING:
CAUTION:
Insert the roll connector guide pin into guide
hole on lower end of surface of steering wheel
to prevent damage. Draw out the airbag system
connector, horn connector and cruise control
connectors from guide hole of steering wheel
lower end.
PS-26
UNIVERSAL JOINT
3. Universal Joint
(2) Align the bolt hole on gearbox side of universal joint with the cutout at serrated section of
gearbox assembly. Lower the universal joint
completely.
(3) Temporarily tighten the bolt on gearbox
side. Raise the universal joint to make sure the
bolt is properly passing through the cutout at
serrated section.
(4) Tighten the bolt.
A: REMOVAL
1) Remove the steering wheel. <Ref. to PS-26, REMOVAL, Steering Wheel.>
2) 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.
Tightening torque:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
CAUTION:
Make sure that the universal joint bolt is tightened through notch in shaft serration.
Excessively large tightening torque of the
universal joint bolts may lead to heavy steering
wheel operation.
Standard clearance between gearbox to DOJ:
Over 14 mm (0.55 in)
B4M1653
B: INSTALLATION
1) Install the universal joint.
(1) Align the cutout at serrated section of the
column shaft and yoke, and then insert the universal joint into column shaft.
CAUTION:
Ensure the front wheel are set straight forward
direction.
3) Install the steering wheel and airbag module.
<Ref. to PS-26, INSTALLATION, Steering Wheel.>
WARNING:
ST0048
(1)
(2)
(3)
(4)
(5)
Cutout
Yoke
Column shaft
Column shaft side
Gearbox side
PS-27
UNIVERSAL JOINT
C: INSPECTION
Clean the disassembled parts with a cloth, and check for wear, damage, or any other faults. If necessary, repair or replace faulty parts.
Inspection
Corrective action
Free play
Swinging torque
Yawing torque
Looseness
Replace if faulty.
G4M0089
Standard value of universal joint free play: 0 mm (0 in)

Max. value of universal joint swinging torque: 0.3 Nm (0.03 kgf-m, 0.2 ft-lb)
Measurement of folding torque of universal joint is

as shown in the figures.
Service limit:
Maximum load; 7.3 N (0.74 kgf, 1.64 lb) or less
Service limit:
S4M0445A
(1) Yoke (Steering column side)
S4M0443A
Service limit:
(1) Yoke (gearbox side)
Service limit:
S4M0446A
(1) Yoke (Steering column side)
S4M0444A
(1) Yoke (gearbox side)
PS-28
TILT STEERING COLUMN

4. Tilt Steering Column

A: REMOVAL
ST0023
(1)
(2)
Tilt steering column

Universal joint

T1: 24 (2.4, 17.4)
T2: 25 (2.5, 18.1)

3) Remove the airbag module. <Ref. to AB-12, REMOVAL, Driver's Airbag Module.>
5) Remove the universal joint. <Ref. to PS-27, REMOVAL, Universal Joint.>

6) Remove the trim panel under instrument panel.
WARNING:
PS-29

7) Remove the screw securing lower steering column cover.
5) Connect the airbag system connector at harness

spool.
NOTE:
Make sure to apply double lock.
6) Install the lower column cover with tilt lever held
in the lowered position.
7) Install the universal joint. <Ref. to PS-27, INSTALLATION, Universal Joint.>
8) Align center of roll connector. <Ref. to AB-17,
ADJUSTMENT, Roll Connector.>
B4M1654
8) Remove all connectors from steering column.

9) Remove the two bolts under instrument panel
securing steering column.
CAUTION:
Ensure the front wheels are set in straight forward direction.
9) Install the steering wheel. <Ref. to PS-26, INSTALLATION, Steering Wheel.>
Set the steering wheel to neutral and install it onto
steering shaft.
CAUTION:
Insert the roll connector guide pin into guide
hole on lower end of surface of steering wheel
to prevent damage. Draw out the airbag system
connector, horn connector and cruise control
connectors from guide hole of steering wheel
lower end.
10) Install the airbag module to steering wheel.
ST0083
10) Pull out the steering shaft assembly from 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.
B: INSTALLATION
WARNING:
Always refer to AirBag System before performing the service operation. <Ref. to AB-3,
C: DISASSEMBLY
Remove the two screws securing upper steering
column covers, and two screws securing combination switch, and then remove the related parts.
D: ASSEMBLY
1) Set the grommet to toe board.
1) Insert the combination switch to upper column

shaft, and then 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:
Dont overtorque the screw.
B4M1656
2) Insert the end of steering shaft into toe board

grommet.
3) Tighten the steering shaft mounting bolts under
instrument panel.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
4) Connect all connectors under instrument panel.
PS-30

E: INSPECTION
1. BASIC INSPECTION
Clean the disassembled parts with a cloth, and check for wear, damage, or any other faults. If necessary, repair or replace faulty parts.
Inspection
Overall length of steering column
Measure the overall length of steering column.
Standard overall length of steering column:
Corrective action
Replace the steering

column assembly.
825.71.5mm (32.510.059in)
ST0024
2. AIRBAG MODEL INSPECTION

WARNING:
For airbag model inspection procedures, refer
to AirBag System. <Ref. to AB-3, CAUTION,
PS-31
STEERING GEARBOX [LHD MODEL]

5. Steering Gearbox [LHD MODEL]

A: REMOVAL
3) Loosen the front wheel nuts.
wheels.
6) Remove the sub frame. <Ref. to FS-25, REMOVAL, Sub Frame.>
7) Remove the front exhaust pipe assembly. (Nonturbo model)
Pipe.>
WARNING:
8) Using a puller, remove the tie-rod end from
knuckle arm after pulling off the cotter pin and removing castle nut.
10) Remove the one pipe joint at center of gearbox,

and connect the vinyl hose to pipe and joint. Discharge the fluid by turning steering wheel fully
clockwise and counterclockwise. Discharge the fluid similarly from other pipe.
S4M0381A
(1) Pipe A
(2) Pipe B
11) Remove the universal joint. <Ref. to PS-27,

REMOVAL, Universal Joint.>
12) Disconnect the pipes C and D from pipe of
gearbox.
CAUTION:
Be careful not to damage these pipes.
NOTE:
Disconnect the upper pipe D first, and lower pipe C
second.
S4M0379A
(1) Castle nut

(2) Tie-rod end
(3) Knuckle arm
S4M0382A
9) Remove the jack-up plate and front stabilizer.
(1) Pipe C
(2) Pipe D
S4M0380A
(1) Jack-up plate
PS-32

13) Remove the clamp bolts securing gearbox to

crossmember, and then remove the gearbox.
(2) Connect the pipes C and D to gearbox.

Connect the upper pipe D first, and lower pipe C
second.
Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
S4M0383A
(1) Clamp
B: INSTALLATION
S4M0382A
1) Insert the gearbox into crossmember, being

careful not to damage the gearbox boot.
2) Tighten the gearbox to crossmember bracket via
clamp with bolt to the specified torque.
Tightening torque:
59 Nm (6.0 kgf-m, 43.4 ft-lb)
(1) Pipe C
(2) Pipe D

5) Connect the tie-rod end and knuckle arm, and
tighten with castle nut. Fit the cotter pin into nut and
bend the pin to lock.
Castle nut tightening torque:
Tighten to 27 Nm (2.75 kgf-m, 19.9 ft-lb), and
tighten further within 60 until cotter pin hole
is aligned with a slot in the nut.
CAUTION:
When connecting, do not hit the cap at bottom
of tie-rod end with hammer.
S4M0383A
(1) Clamp
3) Install the four pipes on gearbox.

(1) Connect the pipes A and B to four pipe joints
of gearbox. Connect the upper pipe B first, and
lower pipe A.
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
S4M0379A
(1) Castle nut

(2) Tie-rod end
(3) Knuckle arm
6) Install the front stabilizer to vehicle.

8) Install the sub frame. <Ref. to FS-25, REMOVAL, Sub Frame.>
PS-33

9) Align the center of roll connector. <Ref. to AB-17,

ADJUSTMENT, Roll Connector.>
CAUTION:
11) Install the tires.
12) Tighten the wheel nuts to specified torque.
Tightening torque:
90 Nm (9.1 kgf-m, 65.8 ft-lb)
14) Pour the fluid into the oil tank, and bleed air.
<Ref. to PS-107, Power Steering Fluid.>
15) Check for fluid leaks.
16) Install the jack-up plate.
18) Check the fluid level in oil tank.
19) After adjusting the toe-in and steering angle,
tighten the lock nut on tie-rod end.
1. RACK HOUSING ASSEMBLY

1) Disconnect the four pipes from gearbox.
NOTE:
Remove the pipes E and F as a single unit being
fixed at clamp plate.
2) Secure the gearbox removed from vehicle in
vice using ST.
ST 926200000
STAND
CAUTION:
Secure the gearbox in a vise using ST as
shown. Do not attempt to secure it without this
ST.
Tightening torque:
83 Nm (8.5 kgf-m, 61.5 ft-lb)
S4M0143A
CAUTION:
When adjusting the 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 plate.
ST0084
4) Remove the tie-rod end and lock nut from gearbox.

5) Remove the small clip from boot using pliers,
and then move the boot to tie-rod end side.
G4M0132
C: DISASSEMBLY
NOTE:
Parts requiring replacement are described in the
smallest unit of spare parts including damaged
parts and spare parts damaged. In actual disassembly work, accidental damage as well as inevitable damage to some related parts must be taken
into account, and spare parts for them must also be
prepared. However, it is essential to pinpoint the
cause of trouble, and limit the number of replacement parts as much as possible.
S4M0144B
(1) Clip
PS-34

6) Using a standard screwdriver, remove the band

from boot.
9) Tighten the adjusting screw until it no longer

tightens.
S4M0145C
S4M0148
10) Using a wrench [32 mm (1.26 in) width across

flats] or adjustable wrench, remove the tie-rod.
(1) Band
7) Extend the rack approx. 40 mm (1.57 in) out. Unlock the lock wire at lock washer on each side of tierod end using a standard screwdriver.
CAUTION:
Be careful not to scratch the rack surface as oil
leaks may result.
CAUTION:
Check the ball joint for free play, and tie-rod
for bends. Replace if necessary.
Check the dust seals used with tie-rod end
ball joint for damage or deterioration. Replace if
necessary.
S4M0149
S4M0146C
11) Loosen the adjusting screw, and then remove

the spring and sleeve.
(1) Lock washer
8) Using the ST, loosen the lock nut.

ST 926230000
SPANNER
CAUTION:
Replace the spring and/or sleeve if damaged.
12) Remove the two bolts securing valve assembly.
S4M0147C
S4M0154
PS-35

13) Carefully draw out the input shaft, and then remove the valve assembly.
16) Remove the rack bushing and rack stopper

from rack assembly.
CAUTION:
Do not reuse the removed rack bushing and circlip.
17) Remove the oil seal from rack.
18) Insert the ST from pinion housing side, and
then remove the oil seal using a press.
ST 34099FA110 INSTALLER
S4M0155
14) Using a sharp pointed pliers, rotate the rack

stopper in direction of the arrow until end of the circlip comes out of stopper. Rotate the circlip in opposite direction and pull it out.
S4M0158B
(1) Rack stopper
15) Pull the rack assembly from cylinder side, and

draw out the rack bushing and rack stopper together with the rack assembly.
CAUTION:
Be careful not to contact the rack to inner wall
of cylinder when drawing out. Any scratch on
the cylinder inner wall will cause oil leakage.
S4M0163B
(1) Press
(2) Oil seal
NOTE:
Discard the removed the oil seal.
S4M0402A
(1) Rack bushing

(2) Rack assembly
(3) Rack stopper
PS-36

2. CONTROL VALVE

1) Disconnect the four pipes from gearbox.

NOTE:
Remove the pipes E and F as a single unit being
fixed at clamp plate.
2) Secure the gearbox removed from the vehicle in
vise using ST.
ST 926200000
STAND
CAUTION:
6) Remove the two bolts securing valve assembly.
CAUTION:
Secure the gearbox in a vise using ST as
shown. Do not attempt to secure it without this
ST.
S4M0154
7) Carefully draw out the input shaft, and then remove the valve assembly.
S4M0143A
3) Using the ST, loosen the lock nut.

ST 926230000
SPANNER
ST0087
8) Slide the dust cover out.
ST0085

tightens.
S4M0156B
(1) Dust cover
ST0086
PS-37

9) Using a press remove the pinion and valve assembly from valve housing.
11) Remove the snap ring using snap ring pliers.

CAUTION:
Do not reuse the removed snap ring.
Be careful not to scratch the pinion and valve
assembly.
S4M0157B
(1) Valve assembly

(2) Valve housing
(3) Cloth
G4M0147
10) Using the ST and press, remove the dust seal,

oil seal and special bearing from valve housing.
ST 34099FA120 INSTALLER & REMOVER
SEAL
CAUTION:
Do not apply force to the end surface of valve
housing.
Do not reuse the oil seal after removal.
12) Press out the bearing together with the back up

washer using pipe of I.D. 38.5 to 39.5 mm (1.516 to
1.555 in) and press.
CAUTION:
Do not reuse the removed bearing.
S4M0159B
(1) Oil seal

(2) Special bearing
S4M0403A
(1)
(2)
(3)
(4)
Bearing
Backing washer
Oil seal
Pipe

CAUTION:
Do not reuse the removed oil seal.
PS-38

D: ASSEMBLY
1. RACK HOUSING ASSEMBLY
CAUTION:
Use only SUBARU genuine grease for the gearbox.
Specified grease for gearbox:
VALIANT GREASE M2 (Part No. 003608001)
1) Clean all parts and tools before reassembling.
2) Force-fit the oil seal using the ST.
ST 34099FA110 INSTALLER
CAUTION:
Be careful not to damage or scratch the cylinder inner wall.
NOTE:
Apply specified power steering fluid to oil seal.
Pay special attention not to install oil seal in
wrong direction.
Push the oil seal until stepped portion of A contacts end face of B.
3) Apply grease to the teeth of rack so that the

grease applied is about as high as teeth, and also
apply a thin film of grease to the sliding portion of
rack shaft.
CAUTION:
When moving the rack to stroke end without
tie-rod attached, prevent shocks from being applied at the end.
Do not apply grease to threaded portion at
the end of rack shaft.
Move the rack shaft to stroke end two or three
times to squeeze grease which accumulates on
both ends. Remove grease to prevent it from
choking air passage hole.
4) Apply grease to the sleeve insertion hole.
5) Apply grease to the dust seal insertion hole.
CAUTION:
Apply clean grease with clean hands. If material
having a sharp edge is used for applying
grease, oil seal at the inside might be damaged.
6) Fixing rack housing
Fix the rack housing in vise using ST.
ST 926200000
STAND
CAUTION:
When fixing the rack housing in vise, be sure
to use this special tool. Do not fix rack housing
in vise using pad such as aluminum plates, etc.
When using the old rack housing, be sure to
clean and remove rust before assembling.
Check pinion housing bushing carefully.
7) Install the oil seal to rack.
8) Fit the ST over toothed portion of rack assembly,
and check for binding or unsmooth insertion. If any
deformation is noted on flats at the end of rack,
shape by using file, and wash with cleaning fluid.
ST 926390001
COVER & REMOVER
S4M0164B
(1) Press
(2) Oil seal
S4M0406A
(1) Rack assembly
PS-39

9) Apply genuine grease to the teeth of thoroughly

washed rack assembly, and then fit the ST over the
toothed portion.
13) Insert the rack stopper into the rack housing,

and then wrap the circlip using a sharp pointed pliers to secure the rack stopper in position.
CAUTION:
Be careful not to block the air passage with
grease. Remove excessive grease.
After fitting cover, check the air passage hole
for clogging. If clogged, open by removing
grease from the hole.
Check the rack shaft for damage.
Apply specified power steering fluid to this
ST and surface of the piston ring to prevent
seal from being damaged.
10) Insert the rack assembly into rack housing from
cylinder side, and then remove the ST after it has
passed completely through oil seal.
CAUTION:
Be careful not to scratch the rack while winding
circlip.
NOTE:
Before inserting the rack assembly, apply a coat of
specified power steering fluid to the surfaces of ST
and rack piston.
ST 926390001
COVER & REMOVER
11) Fit the ST1 and ST2 over the end of rack, and
then install the rack bushing.
ST1 926400000 GUIDE
ST2 927660000 GUIDE
NOTE:
Rotate the wrench another 90 to 180 after end of
circlip has been wrapped in.
S4M0167
14) Fit the mounting rubber onto rack housing.

15) Apply the specified grease to dust cover.
CAUTION:
If burrs, or nicks are found on this guide and
rack shaft portion, remove by filing.
Dip the rack bushing in specified power
steering fluid before installing, and pay attention not to damage O-ring and oil seal.
S4M0166A
16) Install the dust cover on valve assembly.

17) Apply genuine grease to the pinion gear and
bearing of valve assembly.
S4M0407A
(1) Rack bushing assembly
12) Insert the rack stopper into the cylinder tube

until internal groove (on cylinder side) is aligned
with external groove (on rack stopper). Turn the
rack stopper with ST so that the rack stopper hole is
seen through cylinder slits.
PS-40
G4M0158

18) Install the gasket on valve assembly. Insert the

valve assembly into place while facing rack teeth
toward pinion.
CAUTION:
NOTE:
Do not allow packing to be caught when installing
valve assembly.
21) Install the lock washers, and then tighten the

right and left tie-rods into the rack ends.
On condition
L: Approx. 40 mm (1.57 in)
Tightening torque:
78 Nm (8.0 kgf-m, 57.9 ft-lb)
S4M0150B
S4M0155
(1) Tie-rod
19) Tighten the bolts alternately to secure valve assembly.
22) Bend the lock washer using a chisel.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
CAUTION:
Be careful not to scratch the rack when bending
lock washer.
CAUTION:
Be sure to alternately tighten the bolts.
20) Apply grease to the sliding surface of sleeve
and spring seat, then insert the sleeve into pinion
housing. Fit the spring into sleeve screw, pack
grease inside of screw, then install the screw.
S4M0384A
(1) Lock washer
B4M1129B
(1) Adjusting screw

(2) Spring
(3) Sleeve
PS-41

23) Rack and pinion backlash adjustment

(1) Loosen the adjusting screw.
(2) Rotate the input shaft so that the rack is in
straight ahead direction.
(3) Apply grease to the sleeve.
(6) Tighten the adjusting screw.

Tightening torque:
First; 7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
Second; Back off 25
(7) Install the lock nut. While holding adjusting
screw with a wrench, tighten the lock nut using
ST.
ST 926230000
SPANNER
39 Nm (4.0 kgf-m, 28.9 ft-lb)
NOTE:
Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
Make adjustment so that the steering wheel can
be rotated fully from lock to lock without binding.
24) Check for service limit as per article of Service
limit.<Ref. to PS-49, SERVICE LIMIT, INSPECTION, Steering Gearbox [LHD MODEL].> Make replacement and adjustment if necessary.
25) Install the boot to housing.
B4M1130B
(1)
(2)
(3)
(4)
Adjusting screw
Lock nut
Spring
Sleeve
(4) Tighten the adjusting screw by two threads.
NOTE:
Before installing the boot, be sure to apply
grease to the groove of tie-rod.
Install the fitting portions of boots to the following
portions in both sides of assembled steering gearbox.
The groove on gearbox
The groove on the rod
Make sure that the boot is installed without unusual inflation or deflation.
G4M0121

perimeter of the adjusting screw thread.
Liquid packing:
THREE BOND 1141
S4M0151A
S4M0385A

perimeter.
PS-42

26) Using a screwdriver, tighten the screw until the

ends A and B of the band come into contact with
each other.
CAUTION:
Use a new band.
NOTE:
Always tighten the band from underside of gear
box.
28) If the tie-rod end was removed, screw in the

lock nut and tie-rod end to screwed portion of tierod, and tighten the lock nut temporarily in a position as shown in the figure.
Installed tie-rod length: L
15 mm (0.59 in) (WAGON)
25 mm (0.98 in) (SEDAN)
NOTE:
Pay attention to the difference between right and
left tie-rod ends.
S4M0152A
27) Fix the boot end with clip (small).
G4M0126
CAUTION:
After installing, check the boot end is positioned into groove on tie-rod.
29) Install the tie-rod end plate.

Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
30) 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.
S4M0144B
(1) Clip
G4M0127
31) Remove the gearbox from ST.

ST 926200000
STAND
(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)
(2) Connect the pipe E and F to gearbox.
Tightening torque:
Pipe E: 15 Nm (1.5 kgf-m, 10.8 ft-lb)
Pipe F: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
PS-43

2. CONTROL VALVE ASSEMBLY

Specified steering grease:
1) Clean all parts and tools before reassembling.
2) Apply a coat of specified power steering fluid to
the inner wall of valve housing.
4) Using the ST and press, install the special bearing in valve housing.
SEAL
NOTE:
To facilitate installation, attach the ball bearing to
remover and position in valve housing before
pressing it into place.
S4M0162A
3) Attach the ST2 to ST1, and then press the oil

seal into place using a press.
ST1 34099FA120 INSTALLER & REMOVER
SEAL
ST2 34099FA130 INSTALLER SEAL
(1) Face the oil seal in direction shown in the
figure when installing.
(2) To avoid scratching the oil seal, apply a coat
of grease to the contact surface of installer and
oil seal.
(3) To facilitate installation, attach the oil seal to
installer and position in valve housing before
pressing into place.
S4M0161B
(1) Special bearing

(2) Oil seal
5) Put vinyl tape around the pinion shaft splines to

protect oil seal from damage.
6) Fit the pinion and valve assembly into valve
housing.
7) Secure the valve assembly to ST1 and ST2.
S4M0160A
PS-44

8) Put the ST3 over pinion, and insert oil seal, then
force-fit the oil seal into housing using ST4.
ST1 926370000 INSTALLER A
ST2 34099FA100 STAND BASE
ST4 927620000 INSTALLER B
10) Force-fit the ball bearing using ST3.

ST2 34099FA100 STAND BASE
ST3 927640000 INSTALLER B
S4M0405A
(1) Ball bearing

(2) Backing washer
NOTE:
Be careful not to tilt the ball bearing during installation.
11) Install the snap ring using snap ring pliers.
NOTE:
Rotate the snap ring to check for proper installation.
12) Apply the specified grease to dust cover.
S4M0404A
(1) Oil seal
NOTE:
Apply the specified power steering fluid to oil seal
and ST3, being careful not to damage the oil seal
lip.
Push the oil seal until ST3 contacts housing end
face.
9) Remove the ST3, and then fit the backing washer.
S4M0156B
(1) Dust cover
13) Install the dust cover on valve assembly.

14) Apply genuine grease to the pinion gear and
bearing of valve assembly.
G4M0158
PS-45

15) Install the gasket on valve assembly. Insert the

valve assembly into place while facing rack teeth
toward pinion.
CAUTION:
20) Rack and pinion backlash adjustment

(1) Loosen the adjusting screw.
(2) Rotate the input shaft so that the rack is in
(3) Apply grease to the sleeve.
NOTE:
Do not allow the packing to be caught when installing valve assembly.
B4M1130B
(1)
(2)
(3)
(4)
ST0087
16) Tighten the bolts alternately to secure valve assembly.
Adjusting screw
Lock nut
Spring
Sleeve
(4) Tighten the adjusting screw by two threads.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
CAUTION:
Be sure to alternately tighten the bolts.
17) Apply grease to the sleeve insertion hole.
18) Apply grease to the dust seal insertion hole.
CAUTION:
Apply clean grease with clean hands. If material
having a sharp edge is used for applying
grease, oil seal at the inside might be damaged.
19) Apply grease to the sliding surface of sleeve
and spring seat, then insert the sleeve into pinion
housing. Fit the spring into sleeve screw, pack
grease inside of screw, then install the screw.
G4M0121

perimeter of the adjusting screw thread.
Liquid packing:
THREE BOND 1141
B4M1129B
S4M0385A
(1) Adjusting screw

(2) Spring
(3) Sleeve

perimeter.
PS-46

(6) Tighten the adjusting screw.

Tightening torque:
Second; Back off 25
(7) Install the lock nut. While holding adjusting
screw with a wrench, tighten the lock nut using
ST.
ST 926230000
SPANNER
39 Nm (4.0 kgf-m, 28.9 ft-lb)
NOTE:
21) Check for service limit as per article of Service
limit.<Ref. to PS-49, SERVICE LIMIT, INSPECTION, Steering Gearbox [LHD MODEL].> Make replacement and adjustment if necessary.
22) Take off the gearbox from ST.
(1) Connect the pipe A and B to the gearbox.
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
(2) Connect the pipe E and F to gearbox.
Tightening torque:
Pipe E: 15 Nm (1.5 kgf-m, 10.8 ft-lb)
Pipe F: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
PS-47

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 and 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 the turning torque of gearbox and sliding
resistance of rack, check if rack and pinion engage uniformly and smoothly with each other. (Refer to Service
limit.)
(2) Keeping 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-48
Replace.

2. SERVICE LIMIT
Make a measurement as follows. If it exceeds the
specified service limit, adjust or replace.
NOTE:
When making a measurement, vise the gearbox by
using ST. Never vise the gearbox by inserting aluminum plates, etc. between vise and gearbox.
ST 926200000
STAND
Sliding resistance of rack shaft:
3. RACK SHAFT PLAY IN RADIAL DIRECTION

Right-turn steering:
Service limit
0.19 mm (0.0075 in) or less
On condition
L: 5 mm (0.20 in)
P: 122.6 N (12.5 kgf, 27.6 lb)
Service limit
304 N (31 kgf, 68 lb) or less
G4M0111
Left-turn steering:
G4M0109
Service limit
Direction
Direction
0.15 mm (0.0059 in) or less
G4M0110
G4M0112
PS-49

4. INPUT SHAFT PLAY
5. TURNING RESISTANCE OF GEARBOX
In radial direction:
Using the ST, measure the gearbox turning resistance.

ST 34099PA100 SPANNER
Service limit
0.18 mm (0.0071 in) or less
Service limit
Maximum allowable resistance
Less than 9.33 N (0.95 kgf, 2.10 lb)
Difference between right and left sliding resistance: Less than 20 %
On condition
P: 98 N (10 kgf, 22 lb)
G4M0113
In axial direction:
G4M0115
Service limit
On condition
P: 20 49 N (2 5 kgf, 4 11 lb)
G4M0114
PS-50

6. OIL LEAKING
S4M0153A
(1)
(2)
Power cylinder
Cylinder
(3)
(4)
Rack piston
Rack axle
NOTE:
If the gearbox is dismounted without confirming
where the leak is, it must be mounted again to locate the leak point.
1) Even if the location of the leak can be easily
found by observing the leaking condition, it is necessary to thoroughly remove the oil from the suspected portion and turn the steering wheel from
lock to lock about thirty to forty times with engine
running, then make comparison of the suspected
portion between immediately after and several
hours after this operation.
(5)
(6)
Input shaft
Valve housing
2) Inspect leakage from a

The oil seal is damaged. Replace the valve assembly with a new one.
3) Inspect leakage from b
The torsion bar O-ring is damaged. Replace the
valve assembly with a new one.
4) Inspect leakage from c
The oil seal is damaged. Replace the valve assembly or oil seal with a new one.
5) Inspect leakage from d
The pipe is damaged. Replace the faulty pipe or Oring.
PS-51

6) If leak is other than a, b, c, or d, and if oil is leaking from the gearbox, move the right and left boots
toward tie-rod end side, respectively, with the gearbox mounted to the vehicle, and remove oil from
the surrounding portions. Then, turn the steering
wheel from lock to lock thirty to forty times with the
engine running, then 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.
CAUTION:
If leakage from f is noted again:
The oil seal of pinion and valve assembly is
damaged. Replace the pinion and 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.
2) Adjust the steering angle of wheels.

Standard of steering angle:
Model
Inner wheel
Outer wheel
TURBO, 2.5 L and

OUTBACK
3430 1.5
3020 1.5
Others
3720 1.5
3225 1.5
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.
S4M0188A

with vehicle set in the straight ahead position after
this adjustment, correct it by turning the right and
left tie-rods in same direction by same turns.
F: ADJUSTMENT
1) Adjust the front toe.
Standard of front toe:
IN 3 OUT 1 mm (IN 0.12 OUT 0.039 in)
G4M0135
S4M0386A
(1) Lock nut
PS-52
STEERING GEARBOX [RHD MODEL]

6. Steering Gearbox [RHD MODEL]

A: REMOVAL
3) Loosen the front wheel nut.
wheels.
7) Remove the front exhaust pipe assembly. (Nonturbo model)
Pipe.>
WARNING:
8) Using a puller, remove the tie-rod end from
knuckle arm after pulling off cotter pin and removing castle nut.

and connect vinyl hose to pipe and joint. Discharge
fluid by turning the steering wheel fully clockwise
and counterclockwise. Discharge fluid similarly
from the other pipe.
ST0008
(1) Pipe A
(2) Pipe B
11) Remove the universal joint. <Ref. to PS-27,

REMOVAL, Universal Joint.>
12) Disconnect the pipes C and D from pipe of
gearbox.
CAUTION:
Be careful not to damage these pipes.
NOTE:
Disconnect the lower pipe C first, and upper pipe D
second.
S4M0379A
(1) Castle nut

(2) Tie-rod end
(3) Knuckle arm
ST0009
9) Remove the jack-up plate and front stabilizer.

(1) Pipe C
(2) Pipe D
S4M0380A
(1) Jack-up plate
PS-53

13) Remove the clamp bolts securing gearbox to

crossmember, and then remove the gearbox.

5) Connect the tie-rod end and knuckle arm, and
tighten with castle nut. Fit the cotter pin into nut,
and then bend the pin to lock.
Castle nut tightening torque:
Tighten to 27 Nm (2.75 kgf-m, 19.9 ft-lb), and
tighten further within 60 until cotter pin hole
is aligned with a slot in the nut.
CAUTION:
When connecting, do not hit the cap at bottom
of tie-rod end with hammer.
ST0010
(1) Clamp
B: INSTALLATION
1) Insert the gearbox into crossmember, being
careful not to damage the gearbox boot.
2) Tighten the gearbox to crossmember bracket via
clamp with bolt to specified torque.
Tightening torque:
59 Nm (6.0 kgf-m, 43.4 ft-lb)
S4M0379A
(1) Castle nut

(2) Tie-rod end
(3) Knuckle arm
6) Install the front stabilizer to vehicle.

8) Install the sub frame.
ST0010
(1) Clamp
3) Connect the pipe D first from control valve, and

pipe C second.
Tightening torque:
T: 15 Nm (1.5 kgf-m, 10.8 ft-lb)
ST0026
(1) Pipe C
(2) Pipe D
Tightening torque:
45 Nm (4.6 kgf-m, 33.3 ft-lb)
CAUTION:
12) Install the tires.
13) Tighten the wheel nuts to specified torque.
Tightening torque:
90 Nm (9.1 kgf-m, 65.8 ft-lb)
15) Pour fluid into the oil tank, and bleed air.
<Ref. to PS-107, Power Steering Fluid.>
16) Check for fluid leaks.
19) Check the fluid level in oil tank.
PS-54

20) After adjusting the toe-in and steering angle,

tighten the lock nut on tie-rod end.
Tightening torque:
83 Nm (8.5 kgf-m, 61.5 ft-lb)
3) Remove the tie-rod end and lock nut from gearbox.

4) Pry off the clip from outer end of boot, and the
slide the boot toward tie-rod end.
CAUTION:
When adjusting the toe-in, hold boot as shown
to prevent it from being rotated or twisted. If
twisted, straighten it.
S4M0389A
(1) Clip
5) Using standard screwdriver, remove the band

from boot.
G4M0132
C: DISASSEMBLY
1) Secure the gearbox removed from vehicle in
vise using the ST.
ST 926200000
STAND
CAUTION:
Secure the gearbox assembly in a vise using
the ST as shown. Do not attempt to secure it
without this ST.
S4M0145C
(1) Band
6) Extend the rack approx. 40 mm (1.57 in) out. Unlock the lock wire at lock washer on each side of tierod end using a standard screwdriver.
CAUTION:
Be careful not to scratch the rack surface as oil
leaks may result.
S4M0388A
(1) Clamp
2) Remove the tie-rod end plate.
G4M0791
ST0084
PS-55

7) Using the ST, loosen lock nut.

ST 926230000
SPANNER

CAUTION:
11) Disconnect the pipes A and B from steering
body and control valve housing.
CAUTION:
Replace the pipes and/or flare nuts if damaged.
S4M0391A
(1) Lock nut

tightens.
S4M0394A
(1) Pipe A
(2) Pipe B
12) Slide the dust cover out.

CAUTION:
Be careful not to scratch the housing or input
shaft during dust cover removal. Also do not allow foreign matter to enter the housing interior.
Replace the dust cover with a new one if its
inside bore or lips are worn or damaged.
S4M0392A
(1) Adjusting screw
9) Using a wrench (32 mm width across flats) or adjustable wrench, remove the tie-rod.
CAUTION:
Check the ball joint for free play, and tie-rod
for bends. Replace if necessary.
Check the dust seals used with tie-rod end
ball joint for damage or deterioration. Replace if
necessary.
S4M0409A
(1) Dust cover
S4M0393A
(1) Tie-rod
PS-56

13) Using the ST, remove the plug.

ST 34199AE090 PLUG WRENCH
14) Remove the valve assembly.
NOTE:
Make sure to align the ST pin to plug hole.
CAUTION:
Be careful not to scratch the seal ring.
B4M2603A
B4M2602A
(1) Valve assembly

(2) Seal ring
(1) Plug
15) Remove the holder using a 32 mm wrench or

adjustable wrench.
CAUTION:
Discard the old holder and replace with a new
one.
G4M0820
PS-57

16) Install ST the on valve side of rack and press

outer side oil seal out.
CAUTION:
Block the pipe connection of steering body to
prevent fluid from flowing out.
Do not allow the rack to come in contact with
inner wall of cylinder. Otherwise, cylinder wall
may be scratched, resulting in oil leaks.
Remove the holder and rack as a unit.
Check the rack and steering body for bends
or cracks; replace as required.
Discard the oil seal after removal and replace
with new ones.
17) Insert the ST from valve side and press backup ring and oil seal out.
CAUTION:
Discard the back-up ring and oil seal after removal and replace with new ones.
ST 927580000
REMOVER
G4M0822
S4M0411A
(1) Rack piston

(2) Outer side oil seal
PS-58

18) Using the ST1 and ST2, repair the cylinder's

clinched sections.
ST1 34099FA080 PUNCH
ST2 34099FA070 BASE
20) Remove the oil seal using ST and press from

plug.
ST 34199AE100 PLUG OIL SEAL REMOVER
CAUTION:
Do not apply force on the plug edge surface.
Replace the plug circumference O-rings with
new ones.
B4M2604A
(1) Oil seal

(2) O-ring
21) Set the ST on drawing dimension.

ST 34199AE120 GEARBOX OIL SEAL REMOVER
S4M0412A
(1) Cylinder
19) If the cylinder edge is deformed in a convex

shape, repair using an oil stone.
B4M2605A
(1) 70 mm (2.76 in)
G4M0889
PS-59

22) Insert the ST into gearbox, while setting stopper in advance.
24) While fixing the 2-surface width, pull out the oil
seal by rotating nut.
B4M2606A
B4M2608A
(1) Stopper
(2) Oil seal
(1) 2-surface width

(2) Nut
23) By fixing the 2-surface width, press in by rotating the rod and attach to oil seal.
B4M2607A
(1) Rod
(2) 2-surface width
PS-60

D: ASSEMBLY
Specified steering grease:
1) Apply grease inside and outside of the oil seal
and press in using the ST and press.
ST 34199AE130 GEARBOX OIL SEAL INSTALLER
3) Using the STB and STC, attach the oil seal to

STA. Insert the STA into rack from gear side. Remove the oil seal from STA when it approaches
piston and remove STs from rack.
ST 927490000
INSTALLER; ABC
NOTE:
Face the oil seal in direction shown in the figure.
CAUTION:
Pay attention to the oil seal direction, and attaching position.
Be careful no to scratch the gearbox inside surface.
S4M0427A
(1) Oil seal

(2) Rack
4) Install the back-up ring from gear side of rack.

B4M2609A
(1) Oil seal
2) Attach the steering body to ST as shown in the

figure. Apply a coat of grease to needle bearing.
ST 926200000
STAND
CAUTION:
Use the ST to support steering body.
Ensure the needle bearing is free from defects. If it is faulty, replace the steering body
with a new one.
NOTE:
If the steering body is removed from vehicle, be
sure to remove rust and clean.
S4M0426A
(1) Steering body
PS-61
S4M0428A
(1) Oil seal

(2) Back-up ring
(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
CAUTION:
Be careful not to scratch the oil seal lips with
piston's knurl section.
7) Slowly press the inner side oil seal until distance

between ST and end of rack is 65 mm (2.56 in).
ST 34099FA010 GUIDE (Oil seal)
CAUTION:
Ensure the ST's inner wall is free of scratches.
Otherwise, it may damage the oil seal during installation.
S4M0429A
S4M0431A
(1) Rack piston inner ring

(3) Rack
(1) Rack piston

(2) Inner side oil seal
(3) Back-up ring
6) Apply a coat of grease to the grooves in rack,

sliding surface of sleeve and sealing surface of piston. Install the ST on end of steering body cylinder.
Then insert the rack into steering body from cylinder side.
ST 34099FA010 GUIDE (Oil seal)
8) Pass the ST2 and pipe through rack and press

outer side oil seal until ST1 is in contact with ST2.
ST1 34099FA010 GUIDE (Oil seal)
ST2 34099FA040 INSTALLER (Oil seal)
CAUTION:
Be sure to apply grease so that it covers the
entire surface of rack gear teeth.
Do not allow grease to block the air vent hole
on rack.
S4M0432A
(1) Pipe
S4M0430A
(1)
(2)
(3)
(4)
Cylinder side of steering body

Air vent hole
Oil seal
Rack
PS-62

9) Install the holder from cylinder side of steering

body.
11) Using the ST, clinch steering body cylinder at a

point less than 3 mm (0.12 in) from holder.
Tightening torque:
64 Nm (6.5 kgf-m, 47.0 ft-lb)
CAUTION:
Be careful not to deform the holder.
ST 34099FA060 PUNCH HOLDER
G4M0820
10) Attach the ST to rack cylinder. Using a press,

install the back-up ring and oil seal.
NOTE:
Press the ST until its groove is aligned with end of
holder.
S4M0434B
12) Roll the vinyl tape on serration part of valve assembly, and then apply grease on the tape surface.
B4M2610A
(1) Vinyl tape

S4M0433A
(1)
(2)
(3)
(4)
(5)
Installer guide
Holder
Rack piston
Oil seal
Back-up ring
PS-63

13) Apply grease on the gear teeth of valve assembly and then attach the valve assembly.
CAUTION:
Be careful not to scratch the oil seal on valve
gear teeth.
Be careful not to scratch the seal ring of valve
circumference.
14) Apply grease on the oil seal circumference, and

then press into the plug using ST and a press. Replace the plug circumference O-rings with new
ones.
ST 34199AE110 PLUG OIL SEAL INSTALLER
CAUTION:
Pay attention to the oil seal direction, and attaching position.
B4M2612A
(1) Plug
(2) O-ring
(3) Oil seal
15) Using the ST, install plug.

ST 34199AE090 PLUG WRENCH
Tightening torque:
64 Nm (6.5 kgf-m, 47.0 ft-lb)
B4M2611A
(1) Seal ring

(2) Oil seal
B4M2613A
(1) Plug
PS-64

16) Install the dust cover.
20) Install the tie-rod and lock washer into rack

end.
Tightening torque:
78 Nm (8.0 kgf-m, 57.9 ft-lb)
S4M0409A
(1) Dust cover
17) Apply a coat of grease to the sliding surface of

seat pad, 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.
S4M0150B
(1) Tie-rod
21) Bend the lock washer.

CAUTION:
Be careful not to scratch the rack when bending
lock washer.
S4M0274A
(1)
(2)
(3)
(4)
(5)
Seat pad
Sleeve
Spring
Adjusting screw
Lock nut
18) Extend the rack L beyond pinion side of steering body.

On condition
L: Approx. 40 mm (1.57 in)
19) Tighten the adjusting screw until it will no longer tighten.
S4M0599A
(1) Lock washer
22) Loosen the adjusting screw.

23) Move the rack shaft fully to right and left several
times.
PS-65

24) Apply liquid packing to at least 1/3 of the entire

perimeter of adjusting screw thread.
Liquid packing:
THREE BOND 1141
28) Install the boot to housing.

NOTE:
Before installing the boot, be sure to apply
grease to the groove of tie-rod.
Install the fitting portions of boots to following
portions in both sides of assembled steering gearbox.
The groove on gearbox
The groove on the rod
Make sure that the boot is installed without unusual inflation or deflation.
S4M0385A

perimeter.
25) Tighten the adjusting screw.

Tightening torque:
Second; Back off 25
26) Install the lock nut. While holding the adjusting
screw with a wrench, tighten lock nut using ST.
ST 926230000
SPANNER
39 Nm (4.0 kgf-m, 28.9 ft-lb)
NOTE:
27) Check for the service limit as per article of Service limit.<Ref. to PS-68, INSPECTION, Steering
Gearbox [RHD MODEL].> Make replacement and
adjustment if necessary.
S4M0151A
29) Using a screwdriver, tighten the screw until

ends A and B of band come into contact with
each other.
CAUTION:
Use a new band.
NOTE:
Always tighten the band from the underside of gear
box.
S4M0152A
PS-66

30) Fix the boot end with clip (small).
CAUTION:
After installing, check the boot end is positioned into groove on tie-rod.
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
34) 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.
S4M0144B
(1) Clip

G4M0127
35) Remove the gearbox from ST.

ST 926200000
STAND
ST0084
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
32) If the tie-rod end was removed, screw in the
lock nut and tie-rod end to screwed portion of tierod, and then tighten the lock nut temporarily in a
position as shown in the figure.
Installed tie-rod length: L
15 mm (0.59 in) (WAGON)
25 mm (0.98 in) (SEDAN)
NOTE:
Pay attention to the difference between right and
left tie-rod ends.
G4M0126
PS-67

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 and 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, 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 and 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-68
Replace.

2. SERVICE LIMIT
specified service limit, adjust or replace.
NOTE:
When making a measurement, vise gearbox by using ST. Never vise the gearbox by inserting aluminum plates, etc. between vise and gearbox.
ST 926200000
STAND
Sliding resistance of rack shaft:
3. RACK SHAFT PLAY IN RADIAL DIRECTION

Left-turn steering:
Service limit
0.19 mm (0.0075 in) or less
On condition
L: 5 mm (0.20 in)
P: 98 N (10 kgf, 22 lb)
Service limit
304 N (31 kgf, 68 lb) or less
G4M0111
Right-turn steering:
G4M0109
Service limit
Direction
Direction
0.19 mm (0.0075 in) or less
G4M0110
G4M0112
PS-69

4. INPUT SHAFT PLAY
5. TURNING RESISTANCE OF GEARBOX
In radial direction:
Using the ST, measure gearbox turning resistance.

ST 34099PA100 SPANNER
Service limit
0.18 mm (0.0071 in) or less
Service limit
Maximum allowable resistance
Less than 9.33 N (0.95 kgf, 2.10 lb)
On condition
P: 98 N (10 kgf, 22 lb)
Difference between right and left sliding resistance:

Less than 20%
G4M0113
In axial direction:
Service limit
G4M0115
On condition
P: 20 49 N (2 5 kgf, 4 11 lb)
G4M0114
PS-70

6. OIL LEAKING
a
b
B4M2614A
(1)
(2)
Power cylinder
Cylinder
(3)
(4)
Rack piston
Rack
NOTE:
If the gearbox is dismounted without confirming
where the leak is, it must be mounted again to locate the leak point.
1) Even if the location of the leak can be easily
found by observing the leaking condition, it is necessary to thoroughly remove the oil from the suspected portion and turn the steering wheel from
lock to lock about thirty to forty times with engine
running, then make comparison of the suspected
portion between immediately after and several
hours after this operation.
(5)
(6)
Input shaft
Valve housing
2) Inspect leakage from a

The oil seal is damaged. Replace the valve assembly with a new one.
3) Inspect leakage from b
The torsion bar O-ring is damaged. Replace the
valve assembly with a new one.
4) Inspect leakage from c
The oil seal is damaged. Replace the oil seal with a
new one.
5) Inspect leakage from d
The pipe is damaged. Replace the faulty pipe or Oring.
PS-71

F: ADJUSTMENT

with vehicle set in the straight ahead position after
this adjustment, correct it by turning the right and
left tie-rods in the same direction by the same
turns.
1) Adjust the front toe.

Standard of front toe:
IN 3 OUT 1 mm (IN 0.12 OUT 0.039 in)
S4M0386A
G4M0135
(1) Lock nut
2) Adjust the steering angle of wheels.

Standard of steering angle:
Model
Inner wheel
Outer wheel
TURBO, 2.5 L and

OUTBACK
3430 1.5
3020 1.5
Others
3720 1.5
3225 1.5

when wheels are set in the straight ahead position,
and error is more than 5 on the periphery of steering wheel, correctly re-install the steering wheel.
S4M0188A
PS-72
PIPE ASSEMBLY [LHD MODEL]

7. Pipe Assembly [LHD MODEL]
4) Remove the clamp E from pipes C and D.
A: REMOVAL
2) Lift-up the vehicle, and then remove the jack-up
plate.
S4M0380A
(1) Jack-up plate

and then connect the vinyl hose to pipe and joint.
Discharge fluid by turning the steering wheel fully
clockwise and counterclockwise. Discharge fluid
similarly from the other pipe.
CAUTION:
Improper removal and installation of parts often
causes fluid leak trouble. To prevent this, clean
the surrounding portions before disassembly
and reassembly, and pay special attention to
keep dirt and other foreign matter from mating
surfaces.
S4M0437A
(1)
(2)
(3)
(4)
(5)
Return hose
Pressure hose
Clamp E
Pipe C
Pipe D
5) Disconnect the pipes C and D from pipe (on the

gearbox side).
CAUTION:
When disconnecting the pipes C and D, use
two wrenches to prevent deformities.
Be careful to keep the pipe connections free
from foreign matter.
S4M0381A
(1) Pipe A
(2) Pipe B
S4M0382A
G4M0101
(1) Pipe C
(2) Pipe D
PS-73

6) Non-turbo MODEL:
(1) Remove the air intake duct. <Ref. to IN-7,
REMOVAL, Air Intake Duct.>
(2) Remove the bolt A.
(3) Disconnect the pipe C from oil pump. Disconnect the pipe D from return hose.
CAUTION:
Do not allow fluid from the hose end to come
into contact with pulley belt.
To prevent foreign matter from entering the
hose and pipe, cover the open ends of them
with a clean cloth.
7) Turbo MODEL:
(1) Remove the air intake duct, air cleaner upper cover and air intake boot.
<Ref. to IN(TURBO)-8, REMOVAL, Air Intake
Duct.> and <Ref. to IN(TURBO)-7, REMOVAL,
Air Cleaner.>
(2) Remove the two bolts fixing pipe C and D.
(3) Remove the coolant filler tank.
ST0011
(1) Bolt A
(2) Pipe C
(3) Pipe D
EN0126
CAUTION:
with a clean cloth.
ST0012
(1) Pipe C
(2) Pipe D
PS-74

B: INSTALLATION
2) Install the coolant filler tank. (Turbo model)
1) Temporarily tighten the two bolts fixing pipe C

and D. (bolt A for Non-turbo model.)
Tightening torque:
T1: 19 Nm (1.9 kgf-m, 13.7 ft-lb)
T2: 21 Nm (2.1 kgf-m, 15.2 ft-lb)
CAUTION:
Visually check that the hose between tank and
pipe D is free from bending or twisting.
Non-turbo MODEL
T1
ST0011
(1) Bolt A
(2) Pipe C
(3) Pipe D
Turbo MODEL
T2
EN0127
ST0012
(1) Pipe C
(2) Pipe D
(1) Connect the pipe D to oil tank.

(2) Install the pipe C to oil pump.
CAUTION:
Use a new gasket.
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
(3) Tighten the two bolts fixing pipe C and D.
(bolt A for Non-turbo model.)
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
PS-75

3) Temporarily connect the pipes C and D to pipes

(on the gearbox side).
5) Tighten the clamp E firmly.

Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
6) Tighten the joint nut.
Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
7) Connect the pipes A and B to four pipe joints of
gearbox. Connect the upper pipe B first, and lower
pipe A second.
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
S4M0381A
S4M0438A
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(1) Pipe A
(2) Pipe B
Return hose
Pressure hose
Approx. 30 mm (1.18 in)
Clamp E
Pipe C
Pipe D
Pipe (on gearbox side)
4) Temporarily install the clamp E on pipes C and

D.
CAUTION:
Ensure the letter 8 on each clamp are diagonally opposite each other as shown in figure.

9) Install the air intake duct. (Non-turbo model)
10) Install the air intake duct, air intake boot and air
cleaner upper cover. (Turbo model)
<Ref. to IN(TURBO)-7, INSTALLATION, Air Cleaner.> and <Ref. to IN(TURBO)-8, INSTALLATION,
Air Intake Duct.>
B4M0667C
(1) Clamp E
(2) Pipe C
PS-76

12) Feed the specified fluid.

NOTE:
Never start the engine before feeding the fluid; otherwise vane pump might be seized up.
S4M0272B
(1)
(2)
High-pressure hose
No interference is allowed
between hoses.
(3)
Clearance between crossmember

and pipe: 3 8 mm (0.12 0.31
in)
13) Finally check the clearance between pipes and/

or hoses, as shown above.
If the clearance between cruise control pump and
power steering hose is less than 10 mm (0.39 in),
proceed as follows:
(1) Move the clamped section (A) (refer to the
figure above.) down to a point where pipe is
close to crossmember.
Pipe-to-crossmember clearance:
10 mm (0.39 in), min.
(2) Check that the clearance between cruise
control pump and power steering hose is at least
10 mm (0.39 in). If it is not, bend the section (B)
down until a clearance of at least 10 mm (0.39
in) is obtained.
PS-77

C: INSPECTION
Check all disassembled parts for wear, damage or other abnormalities. Repair or replace faulty parts as required.
Part name
Pipe
Clamp
Hose
Inspection
O-ring fitting surface for
damage
Nut for damage
Pipe for damage
Clamps for weak clamping
force
Flared surface for damage
Flare nut for damage
Outer surface for cracks
Outer surface for wear
Clip for damage
End coupling or adapter for
degradation
Remedy
Replace with
a new one.
Replace with
a new one.
Replace with
a new one.
CAUTION:
Although the surface layer materials of rubber hoses have excellent weathering resistance, heat resistance and resistance for low temperature brittleness, they are likely to be damaged chemically by
brake fluid, battery electrolyte, engine oil and automatic transmission fluid and their service lives are
to be very shortened. It is very important to keep the hoses free from before mentioned fluids and to
wipe out immediately when the hoses are adhered with the fluids.
Since the 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 the careful inspection frequently when the vehicle is used in hot
weather areas, cold weather area and/or a driving condition in which many steering operations are
required in short time.
Particularly, continuous work of relief valve over 5 seconds causes to reduce service lives of the hoses, the oil pump, the fluid, etc. due to over heat.
So, avoid to keep this kind of condition when servicing as well as driving.
Trouble
Pressure hose burst
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 for return hose clip

Power steering fluid, brake fluid, engine oil, electrolyte adhere on the hose surface
Too many times use in extremely cold weather
PS-78
Corrective action
Instruct the customers.
Replace the oil pump.
Replace the fluid.
Correct.
Retighten.
Replace the fluid.
Replace the hose.
Replace the defective parts.
Replace.
Instruct the customer.
Replace.
Replace.
Pay attention on service work.
Replace.

CAUTION:
It is likely that although one judges fluid leakage, there is actually no leakage. This is because the fluid spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid thoroughly after maintenance.
ST0014
PS-79

Fluid leaking area
Leakage from connecting portions of

pipes and hoses, numbered with (1)
through (10) in figure
Possible cause
Insufficient tightening of flare nut, catching
dirt or the like, damage to flare or flare nut or
eye bolt
Poor insertion of hose, poor clamping
Corrective action
Loosen and retighten, if ineffective,
replace.
Crack or damage in hose

Crack or damage in hose hardware
Damaged O-ring
Retighten or replace the clamp.

Replace the O-ring or gasket pipe or
hose with new one, if ineffective, replace
the gearbox also.
Replace with a new one.
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.
Damaged O-ring or gasket

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
NOTE:
Fluid level is specified at optimum position (range) for ordinary use. Accordingly, if the vehicle is used often
under hard conditions such as on very rough roads or in mountainous areas, fluid may bleed out from cap air
vent hole. This is not a problem. If a customer complains strongly and is not likely to be satisfied with the leakage, lower the fluid level to the extent that fluid will not bleed out under the conditions described, and have
the customer check the fluid level and its quality more frequency than usual.
PS-80
PIPE ASSEMBLY [RHD MODEL]

8. Pipe Assembly [RHD MODEL]
4) Remove the clamp E from pipes C and D.
A: REMOVAL
2) Lift-up the vehicle, and then remove the jack-up
plate.
S4M0380A
(1) Jack-up plate
3) Remove the one pipe joint at the center of gearbox, and then connect the vinyl hose to pipe and
joint. Discharge fluid by turning steering wheel fully
clockwise and counterclockwise. Discharge fluid
similarly from the other pipe.
CAUTION:
Improper removal and installation of the parts
often causes fluid leak trouble. To prevent this,
clean the surrounding portions before disassembly and reassembly, and pay special attention to keep dirt and other foreign matter from
mating surfaces.
B4M2509A
(1) Return hose

(2) Pressure hose
(3) Clamp E
5) Disconnect the pipes C and D from pipe (on the

gearbox side).
CAUTION:
When disconnecting the pipes C and D, use
two wrenches to prevent deformities.
Be careful to keep the pipe connections free
from foreign matter.
ST0008
(1) Pipe A
(2) Pipe B
ST0051
(1) Pipe C
(2) Pipe D
PS-81

6) Non-turbo MODEL:
(1) Remove the air intake duct. <Ref. to IN-7,
REMOVAL, Air Intake Duct.>
(2) Remove the bolt A.
CAUTION:
with a clean cloth.
7) Turbo MODEL:
(1) Remove the air intake duct, air cleaner upper cover and air intake boot.
<Ref. to IN(TURBO)-8, REMOVAL, Air Intake
Duct.> and <Ref. to IN(TURBO)-7, REMOVAL,
Air Cleaner.>
(2) Remove the two bolts fixing pipe C and D.
(3) Remove the coolant filler tank.
ST0011
(1) Bolt A
(2) Pipe C
(3) Pipe D
EN0126
(4) Disconnect the pipe C from oil pump. Disconnect pipe D from return hose.
CAUTION:
with a clean cloth.
ST0012
(1) Pipe C
(2) Pipe D
PS-82

B: INSTALLATION
2) Install the coolant filler tank. (Turbo model)
1) Temporarily tighten the two bolts fixing pipe C

and D. (bolt A for Non-turbo model.)
Tightening torque:
T1: 19 Nm (1.9 kgf-m, 13.7 ft-lb)
T2: 21 Nm (2.1 kgf-m, 15.2 ft-lb)
CAUTION:
Visually check that the hose between tank and
pipe D is free from bending or twisting.
Non-turbo MODEL
T1
ST0011
(1) Bolt A
(2) Pipe C
(3) Pipe D
Turbo MODEL
T2
EN0127
ST0012
(1) Pipe C
(2) Pipe D
(1) Connect the pipe D to oil tank.

(2) Install the pipe C to oil pump.
CAUTION:
Use a new gasket.
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
(3) Tighten the two bolts fixing pipe C and D.
(bolt A for Non-turbo model.)
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
PS-83

3) Temporarily connect the pipes C and D to pipes

(on the gearbox side).
6) Tighten the joint nut.

Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
7) Connect the pipes A and B to four pipe joints of
gearbox. Connect the upper pipe B first, and lower
pipe A second.
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
ST0008
(1) Pipe A
(2) Pipe B
ST0050
(1)
(2)
(3)
(4)
Return hose
Pressure hose
Approx. 30 mm (1.18 in)
Clamp E
4) Temporarily install the clamp E on pipes C and

D.
CAUTION:
Ensure the letter 8 on each clamp are diagonally opposite each other as shown in the figure.

9) Install the air intake duct. (Non-turbo model)
10) Install the air intake duct, air cleaner upper cover and air intake boot.
<Ref. to IN(TURBO)-7, INSTALLATION, Air Cleaner.> and <Ref. to IN(TURBO)-8, INSTALLATION,
Air Intake Duct.>
B4M0667C
(1) Clamp E
(2) Pipe C
5) Tighten the clamp E firmly.

Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
PS-84

12) Feed the specified fluid.

NOTE:
Never start the engine before feeding the fluid; otherwise vane pump might be seized up.
(2)
(1)
(3)
(4)
(5)
ST0108
(1)
(2)
Clearance between blow-by hose

and pipe: 3 5 m (0.12 0.20
in)
No interference is allowed
between hoses.
(3)
(4)
Clearance between side frame

and hose: 15 mm (0.59 in) or
more
Clearance between crossmember
and pipe: 5 13 mm (0.20
0.51 in)
13) Finally check clearance between pipes and/or

hoses, as shown above.
Pipe-to-crossmember clearance:
10 mm (0.39 in), min.
(1) Check that the clearance between cruise
control pump and power steering hose is at least
10 mm (0.39 in). If it is not, bend the section (B)
down until a clearance of at least 10 mm (0.39
in) is obtained.
PS-85
(5)
Steering gearbox

C: INSPECTION
Check all disassembled parts for wear, damage or other abnormalities. Repair or replace faulty parts as required.
Part name
Pipe
Clamp
Hose
Inspection
O-ring fitting surface for
damage
Nut for damage
Pipe for damage
Clamps for weak clamping
force
Flared surface for damage
Flare nut for damage
Outer surface for cracks
Outer surface for wear
Clip for damage
End coupling or adapter for
degradation
Remedy
Replace with
a new one.
Replace with
a new one.
Replace with
a new one.
CAUTION:
Although the surface layer materials of rubber hoses have excellent weathering resistance, heat resistance and resistance for low temperature brittleness, they are likely to be damaged chemically by
brake fluid, battery electrolyte, engine oil and automatic transmission fluid and their service lives are
to be very shortened. It is very important to keep the hoses free from before mentioned fluids and to
wipe out immediately when the hoses are adhered with the fluids.
Since the 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 the careful inspection frequently when the vehicle is used in hot
weather areas, cold weather area and/or a driving condition in which many steering operations are
required in short time.
Particularly, continuous work of relief valve over 5 seconds causes to reduce service lives of the hoses, the oil pump, the fluid, etc. due to over heat.
So, avoid to keep this kind of condition when servicing as well as driving.
Trouble
Pressure hose burst
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 for return hose clip

Power steering fluid, brake fluid, engine oil, electrolyte adhere on the hose surface
Too many times use in extremely cold weather
PS-86
Corrective action
Replace the fluid.
Correct.
Retighten.
Replace the fluid.
Replace the hose.
Replace.
Instruct customer.
Replace.
Replace.
Pay attention on service work.
Replace.

CAUTION:
It is likely that although one judges fluid leakage, there is actually no leakage. This is because the fluid spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid thoroughly after maintenance.
ST0013
*: Turbo model only.
PS-87

Fluid leaking area
Leakage from connecting portions of

pipes and hoses, numbered with (1)
through (10) in figure
Possible cause
Insufficient tightening of flare nut, catching
dirt or the like, damage to flare or flare nut or
eye bolt
Poor insertion of hose, poor clamping
Corrective action
Loosen and retighten, if ineffective,
replace.
Crack or damage in hose

Crack or damage in hose hardware
Damaged O-ring
Retighten or replace the clamp.

Replace the O-ring or gasket pipe or
hose with new one, if ineffective, replace
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.
Damaged O-ring or gasket

Leakage from hose (11), (12) and
(13) and oilcooler (22) 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
NOTE:
Fluid level is specified at optimum position (range) for ordinary use. Accordingly, if the vehicle is used often
under hard conditions such as on very rough roads or in mountainous areas, fluid may bleed out from cap air
vent hole. This is not a problem. If a customer complains strongly and is not likely to be satisfied with the leakage, lower the fluid level to the extent that fluid will not bleed out under the conditions described, and have
the customer check the fluid level and its quality more frequency than usual.
PS-88
OIL PUMP
9. Oil Pump
6) Disconnect the pipe C and suction hose from oil

pump.
A: REMOVAL
1. NON-TURBO MODEL
2) Remove the pulley belt cover.
3) Loosen oil pump pulley nut, then remove the
bolts which secure alternator.
CAUTION:
hose, cover the open ends of them with a clean
cloth.
ST0015
H4M1076A
4) Loosen the lock bolt and slider bolt, and then remove the power steering pump drive V-belt.
(1) Suction hose

(2) Pipe C
7) Remove the bolts which install power steering

pump bracket.
G2M0286
5) Disconnect the connector from power steering

pump switch.
B2M3151
8) Place the oil pump bracket in a vise, remove the

two bolts from front side of oil pump.
CAUTION:
Do not place the oil pump bracket directly in the
vise; use soft pads and hold oil pump lightly to
protect the pump.
ST0016
9) Remove the bolt from the rear side of oil pump.
PS-89
OIL PUMP
10) Disassemble the oil pump and bracket by inserting a screwdriver as shown in the figure.
6) Remove the bolts which install power steering

pump bracket.
B4M1661
B2M3151
2. TURBO MODEL
2) Remove the pulley belt cover.
3) Loosen the lock bolt and slider bolt, and then remove the power steering pump drive V-belt.
7) Place the oil pump bracket in a vise, remove the

two bolts from front side of oil pump.
CAUTION:
protect the pump.
G2M0286
ST0018
4) Disconnect the connector from power steering

pressure switch.
5) Disconnect the pipe C and suction hose from oil
pump.
8) Remove the bolt from the rear side of oil pump.

9) Disassemble the oil pump and bracket by inserting a screwdriver as shown in the figure.
CAUTION:
with a clean cloth.
B4M1661
ST0017
(1) Suction hose

(2) Pipe C
PS-90
OIL PUMP
B: INSTALLATION
(2) Tighten the bolt which installs oil pump to

bracket.
1. NON-TURBO MODEL
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 is in contact with the
oil pump mounting surface.
Tightening torque:
15.7 (1.6 kgf-m, 11.6 ft-lb)
CAUTION:
protect the pump.
ST0016
Tightening torque:
37.3 (3.8 kgf-m, 27.5 ft-lb)
B4M1670B
(1)
(2)
(3)
(4)
(5)
Bush
Nut
21 mm
14 mm
Bolt
ST0019
2) Tighten the bolt which installs power steering

pump bracket.
B2M3151
PS-91
OIL PUMP
3) Interconnect the pipe C and suction hose.
2. TURBO MODEL
Tightening torque:
Joint nut
39 Nm (4.0 kgf-m, 28.9 ft-lb)
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 is in contact with the
oil pump mounting surface.
CAUTION:
If a hose is twisted at this step, the hose may
come into contact with some other parts.
CAUTION:
protect the pump.
ST0015
(1) Suction hose

(2) Pipe C
B4M1670B
4) Connect the connector to power steering pump

switch.
5) Install the pulley belt to oil pump.
6) Tighten the oil pump pulley nut to the specified
torque.
Tightening torque:
52 Nm (5.3 kgf-m, 38 ft-lb)
7) Check the pulley belt tension.
<Ref. to ME-45, INSPECTION, V-belt.>
8) Tighten the bolt belt tension.
Tightening torque:
8 (0.8 kgf-m, 5.8 ft-lb)
9) Install the pulley belt cover.
11) Feed the specified power steering fluid. <Ref.
to PS-107, Power Steering Fluid.>
CAUTION:
Never start the engine before feeding the fluid;
otherwise vane pump might be seized up.
PS-92
(1)
(2)
(3)
(4)
(5)
Bush
Nut
21 mm
14 mm
Bolt
OIL PUMP
(2) Tighten the bolts which install oil pump to

bracket.
Tightening torque:
37.3 Nm (3.8 kgf-m, 27.5 ft-lb)
3) Interconnect the pipes C and suction hose.

Tightening torque:
Joint nut
39 Nm (4.0 kgf-m, 28.9 ft-lb)
CAUTION:
If a hose is twisted at this step, the hose may
come into contact with some other parts.
ST0020
Tightening torque:
15.7 Nm (1.6 kgf-m, 11.6 ft-lb)
ST0017
(1) Suction hose

(2) Pipe C
4) Connect the connector to power steering oil

pressure switch.
5) Install the pulley belt to oil pump.
6) Check the pulley belt tension. <Ref. to ME(TURBO)-45, INSPECTION, V-belt.>
7) Tighten bolt belt tension.
ST0018
2) Tighten the bolts which install power steering

pump bracket.
Tightening torque:
22 Nm (2.2 kgf-m, 15.9 ft-lb)
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
8) Install the pulley belt cover.
10) Feed the specified power steering fluid <Ref. to
PS-107, Power Steering Fluid.>
CAUTION:
Never start the engine before feeding the fluid;
otherwise vane pump might be seized up.
B2M3151
PS-93
OIL PUMP
C: DISASSEMBLY
6) Remove the following parts from front casing.
1. NON-TURBO MODEL
CAUTION:
Discard old seal washer; replace with a new
one.
1) Remove the nut and detach oil pump pulley.

2) Remove the stay from oil pump.
3) Remove the four bolts which secure rear cover.
H4M1230B
ST0088
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(1) Rear cover
4) Using a screwdriver, pry the retaining ring off.

(1)
O-ring
Straight pin (2 ea.)
Cam ring
Rotor
Vane (10 ea.)
Pressure plate
O-ring (2 ea.)
7) Pry off the oil seal using a screwdriver.

CAUTION:
Be careful not to scratch the inner surface of
casing.
(1)
(2)
(2)
ST0089
(1) Retaining ring

(2) Screwdriver
5) Extract the shaft from front casing.
ST0091
(1) Oil seal

(2) Screwdriver
8) Remove the pressure switch.
PS-94
OIL PUMP
9) Slightly loosen the outlet connector, and the remove connector.
4) Remove the following parts from front casing.

(A)
(D)
(1)
(2)
(C)
(3)
(B)
(E)
(4)
(F)
(G)
ST0056
ST0092
(1)
(2)
(3)
(4)
(A)
(B)
(C)
(D)
(E)
(F)
(G)
Flow control spring

Spool valve assembly
O-ring
Connector
2. TURBO MODEL
1) Using the ST, place the oil pump in a vise and remove four bolts which secure rear cover.
ST 34199AE020 MOUNT
O-ring
Straight pin (2 ea.)
Cam ring
Rotor
Vane (10 ea.)
Pressure plate
O-ring (2 ea.)
5) Place the oil pump in a vise.

CAUTION:
Do not place the oil pump directly in the vise,
use soft pads and hold oil pump lightly to protect the pump.
6) Pry off the oil seal using a screwdriver.
CAUTION:
Be careful not to scratch the inner surface of
casing.
ST0054
2) Using a screwdriver, pry the retaining ring off.

CAUTION:
Do not remove the cam ring, rotor, etc.
ST0042
ST0055
3) Extract the oil pump pulley from front casing.
PS-95
OIL PUMP
D: ASSEMBLY
6) Install the side plate to front casing.
1. NON-TURBO MODEL
CAUTION:
Use care not to let side plate gall.
1) Reassembly precautions
(1) Whenever O-rings, oil seals, and snap rings
are removed, they must be replaced with new
ones.
(2) Thoroughly wash parts and allow to dry.
They must be kept free from cleaning oil and
dust.
(3) Reassembly procedure must be performed
in clean place. Ensure the parts are kept away
from waste threads or other dust particles.
(4) Cleaning oil tends to stay inside the front
casing. Remove it completely by blowing compressed air.
(5) Ensure the parts are free from rust. (Use
specified hydraulic oil for rust prevention after
cleaning and drying.)
(6) Reverse the sequence of disassembly procedures.
2) Apply grease to the oil seal and inner surface of
front casing (at bearing location).
(2)
(1)
(3)
ST0094
(1) Front casing

(2) O-ring
(3) Side plate
7) Install the cam ring to front casing with alignment

mark facing forward.
CAUTION:
Make sure that the front body internal surfaces
are free from damage.
3) Attach the ST to front body. Using a press, install
the oil seal.
ST 34199AE030 INSTALLER
(1)
(2)
ST0095
(1) Front
(2) Alignment mark
8) Install the rotor to front casing with groove facing

rearward.
B4M1667A
4) Press-fit the shaft assembly into front body.

5) Apply the specified hydraulic oil to O-rings and fit
them into front casing.
(2)
(1)
ST0096
(1) Rear
(2) Groove
9) Install the ten vanes into rotor with their nose radius facing toward cam ring.
PS-96
OIL PUMP
10) Install the cam ring to front casing, securing

with knock pins.
12) Using the ST, press the retaining ring into shaft
groove.
CAUTION:
Do not use a hammer to fit knock pins in position.
11) Mount the O-ring on front casing.
CAUTION:
Discard the retaining ring and replace with a
new one.
(5)
(1)
NOTE:
Use the ST2, bending its top edge slightly toward
the inside.
ST1 34099AC030 INSTALLER RETAINING
RING CAP
ST2 34099AC040 INSTALLER RETAINING
RING PIPE
(2)
(4)
(3)
ST0097
(1)
(2)
(3)
(4)
(5)
Rotor
Vane
Radius facing
Cam ring
O-ring
H4M1236A
CAUTION:
Make sure the retaining ring is fit in the second
groove of the shaft.
(3)
(1)
(4)
(2)
(5)
ST0099
(1)
(2)
(3)
(4)
(5)
PS-97
First groove
Second groove
Shaft
Retaining ring
Rotor
OIL PUMP
13) Mount on the pressure switch on front casing.

14) With the knock pin positions aligned, install the
rear cover.
CAUTION:
Loosely tighten the bolts in the sequence (A),
(B), (C), and (D) shown in figure. Then, tighten
in the same sequence.
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
19) When reassembly procedures have been completed, turn the shaft by hand to ensure it turns
smoothly. If it binds or other unusual conditions are
evident, disassemble again and check for foreign
matter trapped on sliding surfaces and improper installation. Eliminate the cause of trouble.
20) Check the followings by referring to CHECK
article.
Excessive play in pulley shaft
Ditch deflection of pulley
Resistance to rotation of pulley
Measurement of generated oil pressure
ST0100
(1) Rear cover
15) Install the spring into front casing. Then, with

the spool valve dipped in specified hydraulic oil, install it into the front casing.
16) Using a 5-mm dia. round bar, ensure the valve
moves smoothly.
17) Set the O-ring, with grease applied to it, onto
connector and secure connector to front casing.
CAUTION:
Use care to prevent damage to O-ring at installation.
When tightening the connector, ensure the Oring does not protrude or get caught.
Tightening torque:
49 Nm (5.0 kgf-m, 36.2 ft-lb)
(1)
(2)
(3)
(4)
ST0092
(1)
(2)
(3)
(4)
Flow control spring

Spool valve assembly
O-ring
Connector
18) Fix the oil pump pulley temporarily.
PS-98
OIL PUMP
2. TURBO MODEL
7) Install following parts to casing.
1) Reassembly precautions
(1) Whenever O-rings, oil seals, and snap rings
are removed, they must be replaced with new
ones.
(2) Thoroughly wash parts and allow to dry.
They must be kept free from cleaning oil and
dust.
(3) Reassembly procedure must be performed
in clean place. Ensure the parts are kept away
from waste threads or other dust particles.
(4) Cleaning oil tends to stay inside the front
casing. Remove it completely by blowing compressed air.
(5) Ensure the parts are free from rust. (Use
specified hydraulic oil for rust prevention after
cleaning and drying.)
(6) Reverse the sequence of disassembly procedures.
2) Apply grease to the oil seal and inner surface of
front casing (at bearing location).
CAUTION:
Make sure that the front body internal surfaces
are free from damage.
3) Attach the ST to front body. Using a press, install
oil seal.
ST 34199AE030 INSTALLER
(G)
(C)
(E)
(F)
(D)
(B)
(A)
ST0057
(A)
(B)
(C)
(D)
(E)
(F)
(G)
O-ring
Pressure plate
Rotor
Vane
Cam ring
Straight pin
O-ring
NOTE:
Install the rotor with the mark facing the rear case
side.
(1)
(2)
ST0080
(1) Mark
(2) Rear
B4M1667A
4) Install the pump pulley to front body.

5) Using the ST, place oil pump in a vise.
ST 34199AE020 MOUNT
6) Remove the rear cover.
8) Using the 8-mm box wrench, tap retaining ring

into shaft groove.
ST0044
9) Install the O-ring to rear cover.
PS-99
OIL PUMP
10) Install the rear cover.

Tightening torque:
27.4 Nm (2.8 kgf-m, 20.3 ft-lb)
CAUTION:
Loosely tighten the bolts in the sequence (A),
(B), (C), and (D) shown in figure. Then tighten in
the same sequence.
C
A
D
ST0046
11) When reassembly procedures have been completed, turn the shaft by hand to ensure it turns
smoothly. If it binds or other unusual conditions are
evident, disassemble again and check for foreign
matter trapped on the sliding surfaces and improper installation. Eliminate the cause of trouble.
12) Check the followings by referring to CHECK
article.
Excessive play in pulley shaft
Ditch deflection of pulley
Resistance to rotation of pulley
Measurement of generated oil pressure
PS-100
OIL PUMP
E: INSPECTION
1. BASIC INSPECTION
Perform the following inspection procedures and repair or replace defective parts.
Part name
Description
1) Damage on body surfaces
2) Excessive wear on hole, into which spool
valve is inserted.
3) Wear and damage on cartridge assembly
mounting surface
4) Wear and damage on surfaces in contact with
shaft and oil seal
1) Damage on body surfaces
2) Wear and damage on sliding surfaces
1) Shaft bend
2) Wear and damage on surfaces in contact with
bushing and oil seal
3) Wear and damage on rotor mounting surfaces
4) Bearing damage
Wear and damage on sliding surfaces
Ridge wear on sliding surfaces
Excessive wear on nose radius and side surfaces
1) Wear and damage on sliding surfaces
2) Ridge wear on vane sliding grooves (If light
leaks with vane in slit against light source)
1. Front casing
2. Rear cover
3. Shaft
4. Pressure plate
5. Cam ring
6. Vane
7. Rotor
3) Damage resulting from snap ring removal

8. Connector
9. Spring
10. Bolts and nuts
Damage on threads
Damage
Damage on threads
Remedy
Replace with a new one together with spool

valve as selective fit is made.
If damage is serious, replace with a new cartridge assembly.
Correct with oil stone. If damage is serious,

replace with a new cartridge assembly.
In accordance with the following table, check all removed parts for wear and damage, and make repair or
replacement if necessary.
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
PS-101
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.
Replace it 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 rotation of pulley.
If it is past 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 with a string put around its pulley,
replace the oil pump with a new one.
OIL PUMP
2. SERVICE LIMIT
2) Ditch deflection of pulley

specified service limit, replace the parts with new
ones.
Service limit:
CAUTION:
Fix the oil pump on a vise to make a measurement. At this time, hold the oil pump with least
possible force between two wood pieces.
Do not set outside of flow control valve or
pulley on a vise; otherwise outside or pulley
might be deformed. Select properly sized wood
pieces.
1) Play of the pulley shaft
NOTE:
Read the value for one surface of V ditch, and then
the value for another off the dial.
On condition:
P: 9.8 N (1.0 kgf, 2.2 lb)
Service limit:
Radial play (Direction
)
S4M0441A
(1) Dial indicator
3) Resistance to rotation of pulley

Service limit:
Maximum load; 9.22 N (0.94 kgf, 2.07 lb) or
less
S4M0439A
NOTE:
A rather higher value may be indicated when pulley starts turning.
Measure the load during rotation and make a
judgment.
(1) Dial indicator
Axial play (Direction

)
Non-turbo model
Turbo model
S4M0442A
(1) Spring balance
S4M0440A
(1) Dial indicator
PS-102
OIL PUMP
3. HYDRAULIC PRESSURE
Turbo MODEL
CAUTION:
Be sure to complete all items aforementioned
in INSPECTION, prior to measuring hydraulic
pressure. Otherwise, pressure can not be measured correctly. <Ref. to PS-109, Inspection.>
Do not leave the valve of pressure gauge
closed or hold the steering wheel at stop end
for 5 seconds or more in any case, as the oil
pump may be damaged due to long keep of
these conditions.
Put a cotton cloth waste at a place where fluid
drops before the pressure gauge is installed.
Wipe off split fluid thoroughly after the measurement.
ST0012
(1) Pipe C
(2) Pipe D
(5) Disconnect the pipe C from pipe (on gearbox side).

(6) Install the ST3 to pipe C.
NOTE:
Keep the engine idling during measurement.
1) REGULAR PRESSURE MEASUREMENT
(1) Connect the ST1, ST2 and ST3.
ST1 92511000
PRESSURE GAUGE
ST2 34099AC020 ADAPTER HOSE B
ST3 34099AC010 ADAPTER HOSE A
(2) Remove the air intake duct.
(3) Disconnect the pipe C from the pump.
(4) Using the gasket (Part No. 34621AC021)
and bolt (Part No. 34620AC010), install the ST2
to the pump instead of pipe C.
Non-turbo MODEL
S4M0382A
(1) Pipe C
(2) Pipe D
ST0011
(7) Replenish power steering fluid up to the

specified level.
(8) Open the valve, and start the engine.
(9) Measure the regular pressure.
ST1 925711000 PRESSURE GAUGE
(1) Bolt A
(2) Pipe C
(3) Pipe D
B4M1675A
Service limit:
981 kPa (10 kg/cm2, 142 psi) or less
PS-103
OIL PUMP
(10)If it is not within the specified value, replace

the troubled part caused by the following symptoms; pipe or hose clogged, leaks from fluid line,
and mix of foreign objects in fluid line.
2) Measure the relief pressure.
(1) Using the STs, measure the relief pressure.
(2) Close the valve.
(3) Measure the relief pressure.
3) Measure the working pressure.

(1) Using the STs, measure the working pressure.
(2) Open the valve.
(3) Measure the working pressure of control
valve by turning wheel from stop to stop.
B4M1675A
ST0109
Service limit:
2.0 L Turbo model
7,350 8,036 kPa
(75 82 kg/cm2, 1,067 1,165 psi)
2.5 L, 2.0 L Non-turbo model
7,164 7,840 kPa
(73 80 kg/cm2, 1,040 1,137 psi)
1.6 L model
6,174 6,860 kPa
(63 70 kg/cm2, 896 994 psi)
(4) If it is not within the specified value, replace
the oil pump.
Service limit:
2.0 L Turbo model
7,350 8,036 kPa
(75 82 kg/cm2, 1,067 1,165 psi)
2.5 L, 2.0 L Non-turbo model
7,164 7,840 kPa
(73 80 kg/cm2, 1,040 1,137 psi)
1.6 L model
6,174 6,860 kPa
(63 70 kg/cm2, 896 994 psi)
(4) If it is within the specified value, measure
the steering effort. <Ref. to PS-113, Measurement of Steering Effort.> 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-104
RESERVOIR TANK
10.Reservoir Tank
3) Disconnect the return hose and suction hose

from reservoir tank.
A: REMOVAL
1. NON-TURBO MODEL
1) Remove the air intake duct. <Ref. to IN-7, REMOVAL, Air Intake Duct.>
2) Drain fluid from the reservoir tank.
3) Disconnect the pipe D from return hose and suction hose from oil pump.
CAUTION:
hose, cover the open ends of them with a clean
cloth.
CAUTION:
with a clean cloth.
ST0022
(1) Suction hose

(2) Pipe D
(3) Return hose
4) Remove the reservoir tank from bracket by pulling it upwards.

ST0021
B: INSTALLATION
1. NON-TURBO MODEL
(1) Suction hose

(2) Pipe D
(3) Return hose
4) Remove the reservoir tank from bracket by pulling it upwards.
1) Install the reservoir tank to bracket.

2) Connect the pipes D to return hose and suction
hose to oil pump.
2. TURBO MODEL
1) Remove the air intake duct. <Ref. to IN(TURBO)-9, REMOVAL, Intake Duct.>
2) Drain fluid from the reservoir tank.
ST0021
(1) Suction hose

(2) Pipe D
(3) Return hose
3) Feed the specified power steering fluid. <Ref. to

PS-105
RESERVOIR TANK
2. TURBO MODEL
1) Install the reservoir tank to bracket.
2) Connect the pressure hose and suction hose to
oil pump.
ST0022
(1) Suction hose

(2) Pipe D
(3) Return hose
3) Feed the specified power steering fluid. <Ref. to

C: INSPECTION
Check the reservoir tank for cracks, breakage, or
damage. If any cracks, breakage, or damage is
found, replace the reservoir tank.
PS-106
POWER STEERING FLUID

11.Power Steering Fluid
C: INSTALLATION
A: SPECIFICATION
1) Set the ST on top of reservoir tank and fill it

about half way with the specified fluid.
ST 34199AE040 OIL CHARGE
Recommended power steering fluid
DEXRON III or equivalent
Manufacturer
B.P.
CALTEX
CASTROL
MOBIL
SHELL
TEXACO
B: INSPECTION
1) Check the power steering fluid for deterioration
or 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 lower point or below, add fluid to
keep the level in the specified range of the indicator. If at upper point or above, drain fluid by using a
syringe or the like.
(1) Check at temperature 20C (68F) on the
reservoir surface of oil pump; read the fluid level
on the COLD side.
(2) Check at temperature 80C (176F) on the
reservoir surface of oil pump; read the fluid level
on the HOT side.
B4M1674A
B4M1673A
2) Continue to turn the steering wheel slowly from

lock to lock until bubbles stop appearing in the tank
while keeping the fluid at that level.
3) In case the air is absorbed to deliver bubbles into
piping because the fluid level is lower, leave it
about half an hour and then do the step 2) all over
again.
4) Start the engine and let it idle.
5) Continue to turn the steering wheel slowly from
lock to lock again until bubbles stop appearing in
the tank while keeping the fluid at that level.
It is normal that bubbles stop appearing after three
times turning of steering wheel.
6) In case the bubbles do not stop appearing in the
tank, leave it about half an hour and then do the
step 5) all over again.
7) Stop the engine, and then take out the safety
stands after jacking up vehicle again.
Then lower the vehicle, and then idle the engine.
8) Continue to turn the steering wheel from lock to
lock until bubbles stop appearing and change of the
fluid level is within 3 mm (0.12 in).
9) In case the following happens, leave it about half
an hour and then do step 8) again.
(1) The fluid level changes over 3 mm (0.12 in).
(2) Bubbles remain on the upper surface of the
fluid.
(3) Grinding noise is generated from oil pump.
PS-107
POWER STEERING FLUID

10) Check the fluid leakage at flare nuts after turning steering wheel from lock to lock with engine
running.
CAUTION:
Before checking, wipe off any fluid on flare
nuts and piping.
In case the fluid leaks from flare nut, it is
caused by dust (or the like) and/or damage between flare and tapered seat in piping.
So remove the flare nut, tighten again it to the
specified torque after cleaning flare and tapered seat. If flare or tapered seat is damaged,
PS-108


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 rim
Improper tires out of specification
Improper rims out of specification
Tires not properly inflated*1
3. Fluid
Low fluid level
Aeration
Dust mix
Deterioration of fluid
Poor warming-up of fluid *2
4. Idling speed
Lower idling speed
Excessive drop of idling speed at start or at turning steering
wheel *3
5. Measure hydraulic pressure.<Ref. to PS-101, INSPECTION, Oil Pump.>
6. Measure steering effort.<Ref. to PS-109, INSPECTION,
1. Fluid line
Folded hose
Flattened pipe
2. Tire and rim
Flat tire
Mix use of different tires
Mix use of different rims
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
One-sided weight
5. Measure steering effort.<Ref. to PS-109, INSPECTION,
Corrective action
Adjust or replace.
Replace or reinflate.
Refill, bleed air, replace or

instruct the customer.
Adjust or instruct the customer.

Adjust or replace.
Reform or replace.
Fix or replace.
Adjust or retighten.
Replace, adjust or instruct the

customer.
Adjust or replace.
*1 If tires and/or rims are wider, the load to power steering system is the more. Accordingly, in a condition, for example before
fluid warms-up, relief valve may work before maximum turning angle. In this case, steering effort may be heavy. When measured
hydraulic pressure is normal, there is no abnormal thing.
*2 In cold weather, steering effort may be heavy due to increased flow resistance of cold fluid. After warming-up engine, turn
steering wheel from stop to stop several times to warm-up fluid. Then if steering effort reduces normally, there is no abnormal
thing.
*3 In cold weather or with insufficient warm-up of engine, steering effort may be heavy due to excessive drop of idling when turning steering wheel. In this case, it is recommended to start the vehicle with increasing engine speed than usual. Then if steering
effort reduces normally, there is no abnormal thing.
PS-109

1. NOISE AND VIBRATION

CAUTION:
Dont keep the relief valve operated over 5 seconds at any time or inner parts of the oil pump
may be damaged due to rapid increase of fluid
temperature.
NOTE:
Grinding noise may be heard immediately after
the engine start in extremely cold condition. In this
case, if the noise goes off during warm-up there is
no abnormal function in the system. This is due to
the fluid characteristic in extremely cold condition.
Oil pump makes whine or growl noise slightly
due to its mechanism. Even if the noise can be
heard when steering wheel is turned at stand still
there is no abnormal function in the system provided that the noise eliminates when the vehicle is
running.
When stopping with service brake and/or parking
brake applied, power steering can be operated
easily due to its light steering effort. If doing so, the
disk rotates slightly and makes creaking noise. The
noise is generated by creaking between the disk
and pads. If the noise goes off when the brake is released, there is no abnormal function in the system.
There may be a little vibration around the steering devices when turning steering wheel at standstill, even though the component parts are properly
adjusted and have no defects.
Hydraulic systems are likely to generate this kind of
vibration as well as working noise and fluid noise
because of combined conditions, i.e., road surface
and tire surface, engine speed and turning speed of
steering wheel, fluid temperature and braking condition.
This phenomena does not indicate there is some
abnormal function in the system.
The vibration can be known when steering wheel is
turned repeatedly at various speeds from slow to
rapid step by step with parking brake applied on
concrete road and in D range for automatic transmission vehicle.
PS-110

Trouble
Hiss noise (continuous)
While engine is running.
Possible cause
Relief valve emits operating sound when steering wheel is
completely turned in either direction. (Don't keep this condition over 5 seconds.)
Relief valve emits operating sound when steering wheel is
not turned. This means that the relief valve is faulty.
Interference with adjacent parts
Rattling noise (intermittent) While

engine is running.
Sound generates from the inside of gearbox or oil pump.
Replace the faulty parts of gearbox or oil pump.
Vane pump seizing

Pulley bearing seizing of oil pump
Folded hose, flat pipe
Maladjustment of pulley belt
Damaged or charged pulley belt
Unequal length of pulley belts
Run out or soilage of V-groove surface of oil pump pulley
Fluid aeration
Sizzling noise (continuous)

Whistle (continuous)
Whine or growl (continuous or
intermittent)
While engine is running with/
without steering turned.
Creaking noise (intermittent)

While engine is running with
steering turned.
Defective
Check the clearance.
Correct if necessary.
<Ref. to PS-78, INSPECTION,
Pipe Assembly [LHD
MODEL].><Ref. to PS-86,
INSPECTION, Pipe Assembly
[RHD MODEL].>
Retighten.
Vane pump aeration
Squeal, squeak (intermittent or

continuous)
Normal
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
Knocking
Excessive backlash
When turning steering wheel in
Loosened lock nut for adjusting backlash
both direction with small angle
Loosened tightening or play of tie-rod, tie-rod end
repeatedly at engine ON or OFF.
Grinding noise (continuous)

Corrective action
Damaged pipe of gearbox

Abnormal inside of hose or pipe
Flat hose or pipe
Abnormal inside of oil tank
Removed oil tank cap
Retighten.
Adjust and retighten.

Inspect and retighten the fluid
line connection.
Refill fluid and vent air.
Replace.
Adjust or replace.
(Replace two belts as a set.)
Clean or replace.
Fix the wrong part causing aeration.
Replace the fluid and vent air.
Replace the pipe.
Rectify or replace.
Replace.
Install the cap.
Replace the faulty parts of gearAbnormal pipe of gearbox or abnormal inside of hose
box or hose.
Loosened installation of oil pump, oil pump bracket
Retighten.
Replace the oil pump, hose, if the
Abnormal inside of oil pump, hose
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.
PS-111

Trouble
Vibration
While engine is running with/
without steering turned.
Possible cause
Too low engine speed at start
Vane pump aeration
Damaged valve in oil pump, gearbox
Looseness of play of steering, suspension parts
PS-112
Corrective action
Adjust and instruct customers.
Fix the wrong part.
Vent air.
Replace the oil pump, faulty parts
of gearbox.
Retighten.

2. MEASUREMENT OF STEERING EFFORT

1
10
Step
Check
CHECK STEERING EFFORT.
Is the steering effort 29.4 N
1)Stop the vehicle on a concrete road.
(3.0 kgf, 6.6 lb) or less?
2)Start the engine.
3)Idle the engine.
4)Install the spring scale on the steering wheel.
5)Pull the spring scale at an right angle to
steering wheel, and measure both right and left
steering wheel effort.
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 a problem.
CHECK STEERING EFFORT.
1)Stop the engine.
2)Pull the spring scale at an right angle to the
steering wheel, and measure both right and left
steering wheel effort.
CHECK STEERING WHEEL EFFORT.
1)Remove the universal joint.
2)Measure the steering wheel effort.
CHECK STEERING WHEEL EFFORT.
Measure the steering wheel effort.
CHECK UNIVERSAL JOINT.
Measure the folding torque of the joint (yoke of
steering column side). <Ref. to PS-28,
INSPECTION, Universal Joint.>
CHECK UNIVERSAL JOINT.
Measure the folding torque of the joint (yoke of
gearbox side). <Ref. to PS-28, INSPECTION,
Universal Joint.>
CHECK FRONT WHEEL.
Yes
Go to step 2.
No
Adjust the backlash.
Is the steering effort 314 N (35 Go to step 3.

kgf, 77 lb) or less?
Perform adjustment.
Is the maximum force steering Go to step 4.

wheel effort 2.26 N (0.23 kgf,
0.51 lb) or less?
Is the fluctuation width 1.08 N Go to step 5.
(0.11 kgf, 0.24 lb) or less?
Check, adjust and

replace if necessary.
Check, adjust and
Replace with new
one.
Is the folding torque 7.3 N

(0.74 kgf, 1.64 lb) or less?
Go to step 6.
Is the folding torque 7.3 N

(0.74 kgf, 1.64 lb) or less?
Go to step 7.
Replace with new

one.
Inspect, readjust
and replace if necessary.
Inspect and
Inspect and
Go to step 11.
Go to step 8.
Are the front wheels for

unsteady revolution or rattling
and brake for dragging?
CHECK TIE-ROD ENDS.
Are the tie-rod ends of suspenRemove the tie-rod ends.
sion for unsteady revolution or
ratting?
CHECK BALL JOINT.
Are the ball joints of suspension for unsteady revolution or
ratting?
CHECK GEARBOX.
Is the rotating resistance 12.7
Measure the rotating of gearbox.
N (1.3 kgf, 2.9 lb) or less in all
LHD: <Ref. to PS-50, TURNING RESISpositions within 20 % differTANCE OF GEARBOX, INSPECTION, Steer- ence between clockwise and
ing Gearbox [LHD MODEL].>
counterclockwise?
RHD: <Ref. to PS-70, TURNING RESISTANCE OF GEARBOX, INSPECTION, Steering Gearbox [RHD MODEL].>
PS-113
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.
LHD: <Ref. to PS-49, SERVICE LIMIT,
INSPECTION, Steering Gearbox [LHD
MODEL].>
RHD: <Ref. to PS-69, SERVICE LIMIT,
INSPECTION, Steering Gearbox [RHD
MODEL].>
Check
Yes
Is rotating resistance 304 N
Steering effort is
(31 kgf, 68 lb) or less with 20 % normal.
difference between left and
right direction?
PS-114
No
Readjust the backlash, and if ineffective, replace the
faulty parts.
BODY SECTION

of SUBARU vehicles.

approval.
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)
AC
HVAC SYSTEM (AUTO A/C)

(DIAGNOSTICS)
AC
AIRBAG SYSTEM
AB
AIRBAG SYSTEM (DIAGNOSTICS)
AB
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
IMMOBILIZER (DIAGNOSTICS)
IM
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)
SR
EXTERIOR/INTERIOR TRIM
EI
G1840GE6
BODY SECTION
EXTERIOR BODY PANELS
EB
CRUISE CONTROL SYSTEM
CC

(DIAGNOSTICS)
CC
G1840GE6
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.
Page
Refrigerant Pressure with Manifold Gauge Set.........................................20
Refrigerant Recovery Procedure...............................................................21
Refrigerant Charging Procedure ...............................................................22
Refrigerant Leak Check ............................................................................25
Compressor Oil .........................................................................................26
Blower Motor Unit Assembly .....................................................................27
Power Transistor (Auto A/C Model) ..........................................................28
Blower Resistor (Manual A/C Model) ........................................................29
Heater Core...............................................................................................30
Control Unit ...............................................................................................31
Compressor...............................................................................................32
Condenser.................................................................................................34
Heater and Cooling Unit............................................................................35
Evaporator.................................................................................................36
Hose and Tube..........................................................................................37
Relay and Fuse .........................................................................................38
Pressure Switch (Dual Switch)..................................................................39
Ambient Sensor (Auto A/C Model) ............................................................40
Sun-load Sensor (Auto A/C Model)...........................................................41
Air Vent Grille ............................................................................................42
Heater Duct ...............................................................................................43
Heater Vent Duct.......................................................................................44
General Diagnostics..................................................................................45
GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
A: SPECIFICATIONS
1. HEATER SYSTEM
Item
Specifications
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
5.0 kW (4,300 kcal/h, 17,062

BTU/h) or more
Air flow rate
280 m3 (9,888 cu ft)/h
Heat mode (FRESH), FULL HOT at 12.5 V
Max air flow rate
450 m3 (15,892 cu ft)/h
Temperature control switch: FULL COLD

Blower fan speed: 4th position
Mode selector lever: RECIRC
Heater core size

(height length width)
Blower
motor
Type
Fan type and size
(diameter width)
LHD model
RHD model
163.9 200 25.0 mm

(6.45 7.87 0.984 in)
181.5 160 27 mm
(7.15 6.30 1.06 in)
Magnet motor 200 W or less
Sirocco fan type
150 75 mm (5.91 2.95 in)
AC-2
at 12 V
GENERAL DESCRIPTION
2. A/C SYSTEM
AUTO A/C MODEL
Item
Specifications
Reheat air-mix type
5.1 kW
(4,385 kcal/h, 17,402 BTU/h)
HFC-134a (CH2FCF3)
[0.50.05 kg (0.990.11 lb)]
Vane rotary, fix volume (CR-14)
Type of air conditioner

Cooling capacity
Refrigerant
Type
Compressor
Discharge
Magnet clutch
Max. permissible speed

Type
Power consumption
Type of belt
Pulley dia. (effective dia.)
Pulley ratio
Type
Core thickness
0.21 m2 (2.26 sq ft)

16 mm (0.63 in)
Radiation area
6.52 m2 (70 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)
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
Dual switch
(Pressure switch)
High-pressure switch
operating pressure
144 cm3 (8.79 cu in)/rev

7,000 rpm
Dry, single-disc type
47 W
V-Ribbed 4 PK
125 mm (4.92 in)
1.064
Corrugated fin (Sub cool type)
250 cm3 (15.26 cu in)

Internal equalizing
Single tank
255 200 48 mm
(10 7.87 1.89 in)
Sirocco fan
150 75 mm (5.91 2.95 in)
200 W at 12 V
Magnet
70 W at 12 V
320 mm (12.6 in)
Magnet
70 W at 12 V
320 mm (12.6 in)
850100 rpm
27829 kPa
(2.830.3 kg/cm2, 40.34.2 psi)
287+39/25 kPa
OFF ON
(2.9+0.4/0.25 kg/cm2, 42+5.7/3.6 psi)

2,800100 kPa
(291 kg/cm2, 40615 psi)
600200 kPa
(6.122 kg/cm2, 8729 psi)
ON OFF
DIFF
Thermo control amplifier working temperature

(Evaporator outlet air)
ON
OFF
HV0045
AC-3
GENERAL DESCRIPTION
MANUAL A/C MODEL

Item
Specifications
Reheat air-mix type
5.1 kW (4,385 kcal/h, 17,402 BTU/h)
HFC-134a (CH2FCF3)
[0.50.05 kg (1.100.11 lb)]
Vane rotary, fix volume (CR-14)
Type of air conditioner

Cooling capacity
Refrigerant
Type
Compressor
Discharge
Magnet clutch
Max. permissible speed

Type
Power consumption
Type of belt
Pulley dia. (effective dia.)
Pulley ratio
Type
Core thickness
0.21 m2 (2.26 sq ft)

16 mm (0.63 in)
Radiation area
5.34 m2 (57.48 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)
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
Dual switch
(Pressure switch)
High-pressure switch
operating pressure
144 cm3 (8.79 cu in)/rev

7,000 rpm
Dry, single-disc type
47 W
V-Ribbed 4 PK
125 mm (4.92 in)
1.064
Corrugated fin (Sub cool type)
250 cm3 (15.26 cu in)

Externally equalizing
Single tank
255 200 48 mm
(10 7.87 1.89 in)
Sirocco fan
150 75 mm (5.91 2.95 in)
200 W at 12 V
Magnet
70 W at 12 V
320 mm (12.6 in)
Magnet
70 W at 12 V
320 mm (12.6 in)
850100 rpm
27829 kPa
(2.830.3 kg/cm2, 40.34.2 psi)
287+39/25 kPa
OFF ON
(2.9+0.4/0.25 kg/cm2, 42+5.7/3.6 psi)

2,800100 kPa
(291 kg/cm2, 40615 psi)
600200 kPa
(6.122 kg/cm2, 8729 psi)
ON OFF
DIFF
Thermo control amplifier working temperature

(Evaporator outlet air)
G4M0938
AC-4
GENERAL DESCRIPTION
B: COMPONENT
1. HEATER COOLING UNIT
AUTO A/C MODEL
(25)
(21)
(22)
(24)
(27)
(17)
(26)
(18)
(23)
(16)
(8)
(7)
(6)
(4)
(5)
(20)
(14)
(15)
(3)
(19)
(2)
(17)
(20)
(20)
(1)
(10)
(13)
(11)
(12)
(9)
HV0047
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Unit cover
Mode acutuator
Side link
Mode acutuator lever
Foot lever
Spring
Mode acutuator link
Defroster lever
Foot nozzle
Unit duct cover
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Heater core clamp

Heater core
Drain hose
Mix acutuator
Mix acutuator lever
Unit assembly
Aspirator hose
Aspirator
Foot duct
Clip
AC-5
(21)
(22)
(23)
(24)
(25)
(26)
(27)
Packing
Cooling unit block
O-ring
Expansion valve
Evaporator
Evaporator cover
Thermistor

T: 7.35 (0.750, 5.421)
GENERAL DESCRIPTION
MANUAL A/C MODEL
(20)
(16)
(17)
(19)
(22)
(21)
(18)
(13)
(7)
(6)
(5)
(8)
(4)
(15)
(12)
(3)
(2)
(14)
T
(15)
(11)
(1)
(9)
(10)
(8)
HV0052
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Unit cover
Side link
Mode acutuator lever
Foot lever
Spring
Mode acutuator link
Defroster lever
Foot nozzle
Unit duct cover
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Heater core
Drain hose
Mix acutuator lever
Unit assembly
Foot duct
Clip
Packing
Cooling unit block
O-ring
AC-6
(19)
(20)
(21)
(22)
Expansion valve
Evaporator
Evaporator cover
Thermistor

T: 7.35 (0.750, 5.421)
GENERAL DESCRIPTION
2. BLOWER MOTOR UNIT

AUTO A/C MODEL
(4)
(10)
(3)
(6)
(2)
(5)
(7)
T
(8)
(11)
(1)
(12)
(13)
T
(9)
HV0048
(1)
(2)
(3)
(4)
(5)
(6)
Upper case
Servo motor
Blower link
Blower link lever A
Blower link lever B
Blower link lever C
(7)
(8)
(9)
(10)
(11)
(12)
Clip
Filter cover
Filter
Blower motor assembly
Hose
Power transistor
AC-7
(13)
Power transistor cover

T: 7.35 (0.750, 5.421)
GENERAL DESCRIPTION
MANUAL A/C MODEL
(8)
(2)
(4)
(3)
(5)
(6)
T
(9)
(1)
(10)
T
(7)
HV0053
(1)
(2)
(3)
(4)
(5)
Upper case
Blower link
Blower link lever A
Blower link lever B
Clip
(6)
(7)
(8)
(9)
(10)
Filter cover
Filter
Blower motor assembly
Hose
Blower resistor
AC-8

T: 7.35 (0.750, 5.421)
GENERAL DESCRIPTION
3. CONTROL UNIT
AUTO A/C MODEL
(9)
(7)
(6)
(10)
(8)
(2)
(4)
(5)
(3)
(1)
(2)
HV0049
(1)
(2)
(3)
(4)
(5)
Switch
Control lever
Control panel
Incar sensor
Hose
(6)
(7)
(8)
(9)
(10)
Switch assembly
Control base
Electronic control unit
Bulb
Control case
AC-9
GENERAL DESCRIPTION
MANUAL A/C MODEL
(14)
(13)
(10)
(11)
(9)
(15)
(7)
(12)
(8)
(4)
(1)
(6)
(1)
(5)
(3)
(1)
(2)
HV0054
(1)
(2)
(3)
(4)
(5)
Dial
Fan control plate
Temperature control plate
Mode control plate
Heater control knob
(6)
(7)
(8)
(9)
(10)
Heater control panel

Air conditioner knob
Plug knob
Heater control base
Intake cable
AC-10
(11)
(12)
(13)
(14)
(15)
Mode cable
Temperature cable
Bulb
Fan switch ASSY
Harness
GENERAL DESCRIPTION
4. AIR CONDITIONING UNIT

LHD MODEL
(5)
(8)
(10)
(7)
T2
(6)
(2)
(6)
(6)
T1
(6)
(6)
(4)
T1
T1
T2
T1
(6)
T1
(1)
(9)
(3)
T2
(7)
(6)
T1
HV0055
(1)
(2)
(3)
(4)
(5)
Condenser
Hose (High-pressure)
Hose (Low-pressure)
Bracket
Compressor
(6)
(7)
(8)
(9)
(10)
O-ring
Clamp A
Clamp B
Tube (To condenser)
Tube (To evaporator)
AC-11

T1: 7.4 (0.75, 5.4)
T2: 15 (1.5, 10.8)
GENERAL DESCRIPTION
RHD MODEL
(5)
T2
(6)
(2)
(6)
(6)
(6)
(6)
(3)
T2
T2
T2
T2
(1)
(4)
(6)
T1
HV0050
(1)
(2)
(3)
Condenser
Hose (High-pressure)
Hose (Low-pressure)
(4)
(5)
(6)
Tube
Compressor
O-ring
AC-12

T1: 7.4 (0.75, 5.4)
T2: 15 (1.5, 10.8)
GENERAL DESCRIPTION
5. COMPRESSOR
T5
(4)
(5)
T5
T3
T5
(9)
(2)
(3)
(1)
T2
T1
(6)
(7)
T1
T4
(8)
HV0051
(1)
(2)
(3)
(4)
(5)
(6)
Idler pulley bracket

Idler pulley adjuster
Idler pulley
Compressor bracket upper
Compressor
Compressor bracket lower
(7)
(8)
(9)
V-belt
Compressor belt cover
Compressor belt cover bracket
AC-13

T1: 7.4 (0.75, 5.4)
T2: 22.6 (2.3, 16.6)
T3: 23.0 (2.35, 17.0)
T4: 28.9 (2.95, 21.3)
T5: 35 (3.6, 26)
GENERAL DESCRIPTION
6. HEATER DUCT
(2)
(1)
(3)
(4)
(5)
(7)
(6)
HV0056
(1)
(2)
(3)
Front defroster nozzle

Side defroster duct (LH)
Side defroster duct (RH)
(4)
(5)
(6)
Side ventilation duct (LH)

Side ventilation duct (RH)
Rear heater duct (LH)
AC-14
(7)
Rear heater duct (RH)
GENERAL DESCRIPTION
C: CAUTION
4. HANDLING OF REFRIGERANT
1. HFC-134A A/C SYSTEM

Unlike the old conventional HFC-12 system components, the cooling system components for the
HFC-134a system such as the refrigerant and compressor oil are incompatible.
Vehicles with the HFC-134a system can be identified by the label A attached to the vehicle.
Before maintenance, check which A/C system is installed in the vehicle.
B4M1817A
2. COMPRESSOR OIL
HFC-134a compressor oil has no compatibility
with that for R12 system.
Use only the manufacturer-authorized compressor oil for the HFC-134a system; only use DH-PR.
Do not mix multiple compressor oils.
If HFC-12 compressor oil is used in a HFC-134a
A/C system, the compressor may become stuck
due to poor lubrication, or the refrigerant may leak
due to swelling of rubber parts.
On the other hand, if HFC-134a compressor oil is
used in a HFC-12 A/C system, the durability of the
A/C system will be lowered.
HFC-134a compressor oil is very hygroscopic.
When replacing or installing/removing A/C parts,
immediately isolate the oil from the atmosphere using a plug or tape. In order to avoid moisture, store
the oil in a container with its cap tightly closed.
The refrigerant boils at approx. 30C (22F).

When handling it, be sure to wear safety goggles
and protective gloves. Direct contact of the refrigerant with skin may cause frostbite.
If the refrigerant gets into your eye, avoid rubbing
your eyes with your hands. Wash your eye with
plenty of water, and receive medical treatment from
an eye doctor.
Do not heat a service can. If a service can is directly heated, or put into boiling water, the inside
pressure will become extremely high. This may
cause the can to explode. If a service can must be
warmed up, use hot water in 40C (104F) max.
Do not drop or impact a service can. (Observe
the precautions and operation procedure described
on the refrigerant can.)
When the engine is running, do not open the
high-pressure valve of the manifold gauge. The
high-pressure gas will back-flow resulting in an explosion of the can.
The refrigerant is non-toxic and harmless under
normal operating circumstance, but it may change
to phosgene (a noxious fume) under open flames
or high temperatures (caused by a cigarette or
heater).
Provide good ventilation and do not work in a
closed area.
Never perform a gas leak test using a halide
torch-type leak tester.
In order to avoid destroying the ozone layer, prevent HFC-134a from being released into the atmosphere. Using a refrigerant recovery system,
discharge and reuse it.
3. REFRIGERANT
The HFC-12 refrigerant cannot be used in the
HFC-134a A/C system. The HFC-134a refrigerant,
also, cannot be used in the HFC-12 A/C system.
If an incorrect or no refrigerant is used, poor lubrication will result and the compressor itself may
be damaged.
G4M0979
AC-15
GENERAL DESCRIPTION
5. O-RING CONNECTIONS
Use new O-rings.
In order to keep the O-rings free of lint which will
cause a refrigerant gas leak, perform operations
without gloves and shop towels.
Apply the compressor oil to the O-rings to avoid
sticking, then install them.
Use a torque wrench to tighten the O-ring fittings:
Over-tightening will damage the O-ring and tube
end distortion.
If the operation is interrupted before completing a
pipe connection, recap the tubes, components, and
fittings with a plug or tape to prevent contamination
from entering.
Use the oil specified in the service manual to lubricate the O-rings.
Apply the oil to the top and sides of the O-rings before installation.
Apply the oil to the area including the O-rings and
tube beads.
HV0062
After tightening, use a clean shop towel to remove excess oil from the connections and any oil
which may have run on the vehicle body or other
parts.
If any leakage is suspected after tightening, do
not retighten the connections, Disconnect the connections, remove the O-rings, and check the Orings, threads, and connections.
G4M0581
Visually check the surfaces and mating surfaces

of O-rings, threads, and connecting points. If a failure is found, replace the applicable parts.
Install the O-rings at right angle to the tube
beards.
O-ring
O.K.
Bead
Not O.K.
Not O.K.
S4M0586A
AC-16
GENERAL DESCRIPTION
D: PREPARATION TOOL
CAUTION:
When working on vehicles with the HFC-134a
system, only use HFC-134a specified tools and
parts. Do not mix with CFC-12 tools and parts. If
HFC-134a and CFC-12 refrigerant or compressor oil is mixed, poor lubrication will result and
the compressor itself may be destroyed.
In order to help prevent mixing HFC-134a and

CFC-12 parts and liquid, the tool and screw
type and the type of service valves used are different. The gas leak detectors for the HFC-134a
and CFC-12 systems must also not be interchanged.
Tool & screw type
Valve type
Tools and Equipment

Wrench
Various WRENCHES will be required to service any A/C system. A 7
to 40 Nm (0.7 to 4.1 kgf-m, 5 to 30 ft-lb) torque wrench with various
crowfoot wrenches will be needed. Open end or flare nut wrenches will
be needed for back-up on the tube and hose fittings.
HFC-134a
Millimeter size
Quick joint type
CFC-12
Inch size
Screw-in type
Description
G4M0571
Applicator bottle
A small APPLICATOR BOTTLE is recommended to apply refrigerant
oil to the various parts. They can be obtained at a hardware or drug
store.
G4M0572
Manifold gauge set

A MANIFOLD GAUGE SET (with hoses) can be obtained from either a
commercial refrigeration supply house or from an auto shop equipment
supplier.
G4M0573
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.
G4M0574
AC-17
GENERAL DESCRIPTION
Tools and Equipment
Syringe
A graduated plastic SYRINGE will be needed to add oil back into the
system. The syringe can be found at a pharmacy or drug store.
Description
G4M0575
Vacuum pump
A VACUUM PUMP (in good working condition) is necessary, and may
be obtained from either a commercial refrigeration supply house or an
automotive equipment supplier.
G4M0576
Can tap
A CAN TAP for the 397 g (14 oz) can is available from an auto supply
store.
G4M0577
Thermometer
Pocket THERMOMETERS are available from either industrial hardware store or commercial refrigeration supply houses.
G4M0578
Electronic leak detector

An ELECTRONIC LEAK DETECTOR can be obtained from either a
specialty tool supply or an A/C equipment supplier.
G4M0579
AC-18
GENERAL DESCRIPTION
Tools and Equipment
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.
Description
G4M0580
AC-19
REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET

2. Refrigerant Pressure with Manifold Gauge Set

A: OPERATION
1) Place the vehicle in the shade and draftless condition.
2) Connect the manifold gauge set.
3) Open the front windows and close all doors.
4) Open the hood.
5) Increase 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 35 C (86 95 F)
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 fan
Too much refrigerant
Air inside the system
Defective receiver dryer
Defective compressor
Not enough refrigerant
Clogged expansion valve
Expansion valve frozen temporarily by
moisture
Defective compressor
Defective expansion valve
Too much refrigerant
Not enough refrigerant
Clogged expansion valve
Expansion valve frozen temporarily by
moisture
Saturated receiver dryer
AC-20
Repair order
Replace the fan motor.
Clean the condenser fin.
Discharge refrigerant.
Replace the receiver dryer.
Replace the compressor.

Check for leaks.
Replace the expansion valve.
Replace the compressor.

Replace the expansion valve.
Discharge refigerant.
Check for leaks.
Replace the expansion valve
Replace the receiver dryer.
REFRIGERANT RECOVERY PROCEDURE

3. Refrigerant Recovery Procedure

A: OPERATION
CAUTION:
During operation, be sure to wear safety goggles and protective gloves.
Connect the refrigerant recovery system with
the manifold gauge set to discharge the refrigerant from the A/C system and reuse it.
When reusing the discharged refrigerant,
keep service cans on hand. Because the discharge rate with the recovery system is approx.
90%, service cans are necessary to charge the
refrigerant.
Follow the detailed operation procedure described in the operation manual attached to the
refrigerant recovery system.
1) Perform the compressor oil return operation.
<Ref. to AC-26, OPERATION, Compressor Oil.>
2) Stop the engine.
3) Close the valves on the low-/high-pressure sides
of the manifold gauge set.
G4M0585
4) Install the low-/high-pressure hoses to the service ports on the low-/high-pressure sides of the
vehicle respectively.
G4M0586
5) Connect the center hose to the refrigerant recovery system.

6) Follow the operation manual to activate the refrigerant recovery system.
AC-21
REFRIGERANT CHARGING PROCEDURE

4. Refrigerant Charging Procedure
4) Carefully open the valves on the low-/high-pressure sides to activate the vacuum pump.
A: OPERATION
CAUTION:
During operation, be sure to wear safety goggles and protective gloves.
Before charging the refrigerant, evacuate the
system to remove small amounts of moisture
remaining in the system.
The moisture in the system can be completely
evacuated only under the minimum vacuum
level. The minimum vacuum level affects the
temperature in the system.
The list below shows the vacuum values necessary to boil water in various temperature. In
addition, the vacuum levels indicated on the
gauge are approx. 3.3 kPa (25 mmHg, 0.98 inHg)
lower than those measured at 304.8 m (1,000 ft)
above sea level.
Vacuum level required to boil water (at sea level)
Temperature
Vacuum
1.7C (35F)
100.9 kPa (757 mmHg, 29.8 inHg)
7.2C (45F)
100.5 kPa (754 mmHg, 29.7 inHg)
12.8C (55F)
99.8 kPa (749 mmHg, 29.5 inHg)
18.3C (65F)
99.2 kPa (744 mmHg, 29.3 inHg)
23.9C (75F)
98.5 kPa (739 mmHg, 29.1 inHg)
29.4C (85F)
97.2 kPa (729 mmHg, 28.7 inHg)
35C (95F)
95.8 kPa (719 mmHg, 28.3 inHg)
G4M0597
5) After the low-pressure gauge reaches 100.0 kPa

(750 mmHg, 29.5 inHg) or higher, evacuate the
system for approx. 15 minutes.
G4M0598
1) Close the valves on low-/high-pressure sides of

the manifold gauge.
6) After 15 minutes of evacuation, if the reading

shows 100.0 kPa (750 mmHg, 29.5 inHg) or higher,
close the valves on the both sides to stop the vacuum pump.
G4M0599
7) Note the low-pressure gauge reading.
G4M0596
2) Install the low-/high-pressure hoses to the corresponding service ports on the vehicle respectively.
3) Connect the center hose of the manifold gauge
set with the vacuum pump.
G4M0600
AC-22

8) Leave it at least 5 minutes, and then check the

low-pressure gauge reading for any changes.
When a gauge indicator shows near to zero point,
this is a sign of leakage. Check pipe connector
points, repair them, make sure there is no leakage
by air bleeding.
9) Following the can tap operation manual instructions, install it to the refrigerant can.
15) Carefully open the high-pressure valve with the

engine stopping.
CAUTION:
Do not open the low-pressure valve.
G4M0604
G4M0980
10) Disconnect the center manifold hose from the

vacuum pump, and connect the hose to the tap
valve.
11) When a 13.6 kg (30 lb) refrigerant container is
used, measure the refrigerant amount in use using
a weighting scale.
CAUTION:
Never run the engine during charging from the
high-pressure side.
16) Close the high-pressure valve when the lowpressure gauge reaches 98 kPa (1 kg/cm2, 14 psi).
Using a leak tester, check the system for leaks.
If any leakage is found after the refrigerant recovery is completed, repair the applicable area.
17) After confirming that there are no leaks with the
leak test, charge the required amount of refrigerant.
CAUTION:
Never run the engine during charging from the
high-pressure side.
18) Close the high-pressure valve when;
the readings of low-/high-pressure gauges become almost equal, after the charging speed is reduced,
the HFC-134a source becomes empty, or
the system is filled with the gas.
G4M0981
12) Confirm that all the 3 hoses are tightly connected to the manifold gauge set.
G4M0605
G4M0603
13) Open the valve on the HFC-134a source.

14) Loosen the center hose connection on the
manifold gauge set (if applicable, press a purge
valve on the manifold gauge set) only for a couple
of seconds to allow the air in the center hose to escape by the refrigerant.
AC-23

19) If the HFC-134a source is empty, close the

high-pressure valve, close the valve on the can tap,
and replace the HFC-134a source with a new one
to restart the operation.
27) Disconnect the hose from the service port, and

install the service port cap.
G4M0606
20) Confirm that both the low-/high-pressure

valves can be closed. Start the engine with the A/C
switch OFF.
21) Quickly repeat ON-OFF cycles a few times to
prevent initial compressor damage.
22) Set up the vehicle to the following status:
A/C switch ON
Engine running at 1,500 rpm
Blower speed setting to HI
Temperature setting to MAX COOL
Air inlet setting to RECIRC
Windows open
23) While reading the low-pressure gauge, carefully open the low-pressure valve with the refrigerant
source connected and the service hose purged.
CAUTION:
Never open the high-pressure valve with the engine running.
G4M0608
24) Adjust the refrigerant flow to maintain the pressure on the low-pressure side at 276 kPa (2.81 kg/
cm2, 40 psi) max.
25) After the system is fully charged, close the lowpressure valve.
26) Close the valve on the refrigerant source.
Refrigerant amount
Refrigerant
Minimum
LHD
0.6 kg (1.3 lb)
HFC-134a
RHD
0.4 kg (0.9 lb)
Maximum
0.7 kg (1.5 lb)
0.5 kg (1.1 lb)
AC-24
REFRIGERANT LEAK CHECK

5. Refrigerant Leak Check

A: INSPECTION
1) Operate the A/C system for approx. 10 minutes,
and confirm that the high-pressure side shows at
least 690 kPa (7.03 kg/cm2, 100 psi). Then stop the
engine to start the leak test.
2) Starting from the connection between the highpressure tube and evaporator, check the system
for leaks along the high-pressure side through the
compressor. The following items must be checked
thoroughly.
3) Check the joint and seam between the pressure
switch (dual switch) and receiver dryer.
4) Check the connections between the condenser
and tubes, and welded joints on the condenser.
The leak tester may detect the oil on the condenser
fins as a leak.
5) Check the joint between the compressor and
hoses.
6) Check the machined area of compressor and
other joints on the compressor.
7) Check the thermal limiter (if equipped) on the
compressor housing.
8) Check the compressor shaft seal at the area
near the center of compressor clutch pulley.
Some shaft seals show a slight amount of leakage
about 28 g (1.0 oz) per year. This is not a problem.
9) Starting from the connection between the lowpressure tube and evaporator, check the system
for leakage along the high-pressure side through
the compressor. The following items must be
checked thoroughly.
Connection between the tube and tube fitting
Connection between two parts
Connection between the tube and nut
10) Visually check the rubber area of the flexible

hose for cracks.
Check the entire length of the flexible hose, especially the connection with the metal hose end.
CAUTION:
Carefully check the external surface of hoses
and tubes at approx. 25 mm (0.98 in) per second.
G4M0617
11) Disconnect the drain hose from the evaporator

case, and check the hose end for at least 10 seconds.
After the test is finished, reconnect the drain hose.
12) Turn the ignition key to ON position, and run
the blower at high speed for 1 minute. Stop the
blower to check the ventilation 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.
G4M0618
13) Check the valve in the service port.

14) Visually check the rubber seal in the service
port cap.
S4M0038
G4M0619
AC-25
COMPRESSOR OIL
6. Compressor Oil
A: OPERATION
NOTE:
Before making repairs, conduct the oil return operation to return the compressor oil in circulation with
the refrigerant to the compressor.
1) Increase engine 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 is replaced, add an appropriate
amount of compressor oil.
When replacing the compressor, the new compressor will already have the specified amount of
oil in it. Install the new compressor after removing
the same amount of oil that is remaining in the compressor removed.
Replacement parts
Evaporator
Condenser
Hose
Amount of oil replenishment

114 m2 (3.9 US fl oz, 4.0 Imp fl oz)
7 m2 (0.24 US fl oz, 0.25 Imp fl oz)
1 m2 (0.03 US fl oz, 0.04 Imp fl oz)
AC-26
BLOWER MOTOR UNIT ASSEMBLY

7. Blower Motor Unit Assembly

A: REMOVAL
6) Loosen the bolt and nut to remove blower motor

unit assembly.

2) Remove the glove box. <Ref. to EI-38, REMOVAL, Glove Box.>
3) Loosen the nut to remove the support beam
stay.
HV0013
B: INSTALLATION
HV0006
4) Disconnect the blower motor connector.
Tightening torque:
Refer to COMPONENT in General Description. <Ref. to AC-5, HEATER COOLING UNIT,
COMPONENT, General Description.> and
<Ref. to AC-7, BLOWER MOTOR UNIT,
COMPONENT, General Description.>
C: INSPECTION
Connect the motor connector terminal 1 from the
battery to the positive (+) lead and terminal 2 to the
negative () lead. Make sure the motor runs
smoothly.
HV0014
5) Disconnect the power transistor connector.
B4M2404
HV0009
AC-27
POWER TRANSISTOR (AUTO A/C MODEL)

8. Power Transistor (Auto A/C

Model)
A: REMOVAL
2) Disconnect the power transistor connector.
3) Loosen the two screws to remove power transistor.
HV0009
B: INSTALLATION
AC-28
BLOWER RESISTOR (MANUAL A/C MODEL)

9. Blower Resistor (Manual A/C

Model)
A: REMOVAL
2) Disconnect the blower resistor connector.
3) Loosen the two screws to remove blower resistor.
HV0009
B: INSTALLATION
C: INSPECTION
(1)
(2)
(4)
(3)
HV0057
Measure the blower resistor resistance.

Terminal No.
3 and 1
3 and 2
3 and 4
Standard
Approx. 0.51
Approx. 2.70
Approx. 1.43
If NG, replace the blower resistor.
AC-29
HEATER CORE
10.Heater Core
A: REMOVAL
1) Remove the heater and cooling unit. <Ref. to
AC-35, REMOVAL, Heater and Cooling Unit.>
2) Loosen the screws to remove heater core cover.
HV0001
3) Remove the heater core.
HV0002
B: INSTALLATION
AC-30
CONTROL UNIT
11.Control Unit
A: REMOVAL
2) Remove the center console panel.
3) Disconnect the connector and aspirator hose
(A).
(A)
HV0010
B: INSTALLATION
AC-31
COMPRESSOR
12.Compressor
8) Disconnect the compressor harness from body

harness.
9) Loosen the bolts to remove compressor bracket.
A: INSPECTION
1. MAGNETIC CLUTCH CLEARANCE
1) Check the clearance of the entire circumference
around the drive plate and pulley.
Standard:
0.450.15 mm (0.01770.0059 in)
2. MAGNETIC CLUTCH OPERATION

1) Disconnect the compressor connector.
2) Connect the battery positive (+) terminal to the
No.3 terminal of the compressor connector.
B4M2311
10) Remove the bolts and then separate compressor and bracket.
B4M2407
3) Make sure the magnet clutch engages.

If NG, replace the compressor.
HV0011
B: REMOVAL
1) Perform the compressor oil return operation.
<Ref. to AC-26, OPERATION, Compressor Oil.>
2) Turn the A/C switch OFF and stop the engine.
3) Using the refrigerant recovery system, discharge refrigerant. <Ref. to AC-21, OPERATION,
Refrigerant Recovery Procedure.>
V-belt.> or <Ref. to ME(TURBO)-44, REMOVAL,
V-belt.>
6) Remove the generator. <Ref. to SC-14, REMOVAL, Generator.>
7) Remove the low-pressure hose and high-pressure hose.
HV0012
AC-32
COMPRESSOR
C: INSTALLATION
2) Replace the O-rings on low-/high-pressure hoses with new ones, then apply compressor oil.
3) When replacing compressor, adjust amount of
compressor oil. <Ref. to AC-26, OPERATION,
Compressor Oil.>
4) Charge refrigerant. <Ref. to AC-22, OPERATION, Refrigerant Charging Procedure.>
Tightening torque:
Refer to COMPONENT in General Description. <Ref. to AC-11, AIR CONDITIONING
UNIT, COMPONENT, General Description.>
and <Ref. to AC-13, COMPRESSOR,
AC-33
CONDENSER
13.Condenser
B: INSTALLATION
A: REMOVAL
3) Disconnect the pressure hose and pipe from
condenser.
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.
B4M1822A
HV0003
4) Remove the radiator bracket (A).
Tightening torque:
and <Ref. to CO-5, RADIATOR AND
RADIATOR FAN, COMPONENT, General Description.>
C: INSPECTION
B4M1820A
5) Remove the two bolts. While lifting the condenser, pull it out through the space between radiator
and radiator panel.
1) Confirm that no dust or insects are found on the

condenser fins. Air-blow or flush fins with water as
needed.
2) Confirm that no oil leaks from condenser. If a
failure is found, replace the condenser with a new
one.
HV0004
CAUTION:
Be careful not to damage the condenser fins. If
a damaged fin is found, repair it using a thin
screwdriver.
If the condenser is replaced, add appropriate
amount of compressor oil to the compressor.
<Ref. to AC-26, REPLACEMENT, Compressor
Oil.>
AC-34
HEATER AND COOLING UNIT

14.Heater and Cooling Unit
9) Loosen the bolt and nuts to remove the heater

and cooling unit.
A: REMOVAL
3) Drain LLC from the radiator.
4) Remove the bolt securing expansion valve and
pipe in engine compartment. Release the heater
hose clamps in engine compartment to remove the
hoses.
LHD MODEL
HV0016
B: INSTALLATION
Tightening torque:
Refer to COMPONENT in General Description. <Ref. to AC-5, HEATER COOLING UNIT,
HV0060
RHD MODEL
HV0015
5) Remove the instrument panel. <Ref. to EI-41,

REMOVAL, Instrument Panel Assembly.>
6) Remove the support beam.
7) Remove the blower motor unit assembly. <Ref.
to AC-27, REMOVAL, Blower Motor Unit Assembly.>
8) Disconnect the servo motor connectors.
AC-35
EVAPORATOR
15.Evaporator
A: REMOVAL
1) Remove the heater and cooling unit. <Ref. to
AC-35, REMOVAL, Heater and Cooling Unit.>
2) Loosen the screws and clip to remove evaporator cover.
HV0024
3) Remove the evaporator.
HV0025
4) Loosen the two bolts to remove expansion valve.
HV0026
CAUTION:
If the evaporator is replaced, add appropriate
amount of compressor oil to evaporator. <Ref.
to AC-26, REPLACEMENT, Compressor Oil.>
B: INSTALLATION
AC-36
HOSE AND TUBE

16.Hose and Tube
B: INSTALLATION
A: REMOVAL
CAUTION:
When disconnecting/connecting hoses, do
not apply an excessive force to them. Confirm
that no torsion and excessive tension exists after installing.
Seal the disconnected hose with a plug or vinyl tape to prevent contamination from entering.
CAUTION:
When disconnecting/connecting hoses, do
not apply excessive force to them. Confirm that
no torsion and excessive tension exists after
installing.
Seal the disconnected hose with a plug or vinyl tape to prevent contamination from entering.
3) Remove the evaporator unit mounting bolt (A).
4) Remove the low-pressure hose attaching bolts
(B).
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 bolts
(C).
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 tube attaching bolt
(D).
13) Remove the high-pressure tube from vehicle.
Tightening torque:
C: INSPECTION
NOTE:
If cracking, damage, or swelling is found on a hose,
(A)
(C)
(B)
(C)
(D)
HV0023
AC-37
RELAY AND FUSE

17.Relay and Fuse
B: INSPECTION
A: LOCATION
(H)
Joint box
(A)
(B)
(C)
(D)
(E)
(F)
(G)
S4M0577A
Main fuse box

HV0022
Main Fan Relay 1

Main Fan Relay 2
Sub Fan Relay 1
Sub Fan Relay 2
A/C Relay
Main Fan Fuse
Sub Fan Fuse
A/C Fuse
A
B
C
E
D
F
G
H
(3) (4): Continuity exists.

(1) (2): No continuity
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-38
PRESSURE SWITCH (DUAL SWITCH)

18.Pressure Switch (Dual

Switch)
2) Remove the pressure switch harness connector.

Using a circuit tester, inspect the ON-OFF operation of the pressure switch.
A: INSPECTION
1) Connect the manifold gauge to the service valve
on the high-pressure side.
1
HV0021
Terminal
No.
High and low pressure switch
1 and 2
Standard
kPa (kg/cm2, psi)
Operation
Increasing to
2,800100 (291, 40615)
Turns OFF.
Decreasing to
27829 (2.830.3, 40.34.2)
Increasing to
287+39/25 (2.9+0.4/0.25, 42+5.7/3.6)
Turns ON.
Decreasing to
2,200200 (22.42, 31929)
AC-39
AMBIENT SENSOR (AUTO A/C MODEL)

19.Ambient Sensor (Auto A/C

Model)
A: REMOVAL
1) Open the front hood.
3) Disconnect the ambient sensor connector.
4) Remove the ambient sensor from radiator lower
panel.
HV0020
B: INSTALLATION
C: INSPECTION
<Ref. to AC-38, AMBIENT SENSOR, Diagnostic
Procedure for Sensors.>
AC-40
SUN-LOAD SENSOR (AUTO A/C MODEL)

20.Sun-load Sensor (Auto A/C

Model)
A: REMOVAL
2) Remove the front defroster grille.
3) Disconnect the sunload sensor connector (A).
(A)
HV0005
CAUTION:
Be careful not to damage the sensors and interior trims when removing them.
B: INSTALLATION
C: INSPECTION
<Ref. to AC-44, SUNLOAD SENSOR, Diagnostic
Procedure for Sensors.>
AC-41
AIR VENT GRILLE

21.Air Vent Grille

A: REMOVAL
1. CENTER GRILLE
2) Remove the center console panel (A).
3) Loosen the two screws to remove the center air
vent grille (B).
(B)
(A)
HV0018
2. SIDE GRILLE
2) Remove the heater vent duct. <Ref. to AC-44,
REMOVAL, Heater Vent Duct.>
3) Loosen the screws to remove the side air vent
grille.
HV0019
B: INSTALLATION
C: INSPECTION
The direction and amount of air should be adjusted
smoothly.
The adjustment should be kept in each position.
AC-42
HEATER DUCT
22.Heater Duct
A: REMOVAL
1) Remove the heater unit. <Ref. to AC-35, Removal.>
2) Remove the front seat. <Ref. to SE-6, REMOVAL, Front Seat.>
3) Remove the front side sill cover.
4) Pull off the floor mat to remove heater duct.
B4M2309
B: INSTALLATION
AC-43
HEATER VENT DUCT

23.Heater Vent Duct

A: REMOVAL
1) Remove the instrument panel. <Ref. to EI-41,
REMOVAL, Instrument Panel Assembly.>
2) Remove the screws.
3) Remove the heater vent duct.
HV0017
B: INSTALLATION
AC-44
GENERAL DIAGNOSTICS
24.General Diagnostics
A: INSPECTION
Symptom
Blower motor
Doesn't move.
Strange noise.
Doesn't move.
Compressor
Strange noise
Cold air not emitted.
Warm air not emitted.
Temperature of air from vents does not change.
Unable to switch blow vents.
Unable to switch suction vents.
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
Engine coolant
Mode actuator
Wire harness
Mode actuator
Air flow switch
Wire harness
Air inlet select switch
FRESH/RECIRC actuator
Wire harness
AC-45
GENERAL DIAGNOSTICS
AC-46
HVAC SYSTEM (AUTO A/C)

(DIAGNOSTICS)
AC
1.
2.
3.
4.
5.
6.
7.
8.
9.
Page
A/C Control Module I/O Signal ....................................................................8
Diagnostics Chart for Diagnosis System ...................................................18
Diagnostics for A/C System Failure ..........................................................22
Diagnostic Procedure for Actuators ..........................................................32
Diagnostic Procedure for Sensors ............................................................38
Symptom Related Diagnostic....................................................................46

HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

A: PROCEDURE
1
Step
START INSPECTIONS.
1)Perform the pre-inspection.
2)Perform the self-diagnosis. <Ref. to AC-18,
SELF-DIAGNOSIS MODE, Diagnostics Chart
for Diagnosis System.>
Check
Does the self-diagnosis operate?
CONFIRM MALFUNCTION PART.

Can the malfunction part be
Confirm the malfunction part with self-diagno- confirmed?
sis.
Yes
Go to step 2.
No
<Ref. to AC-22, A/
C AND/OR SELFDIAGNOSIS SYSTEMS DO NOT
OPERATE, Diagnostics for A/C
System Failure.>
Go to step 3.
Repair the malfunction part

according to each
diagnostics chart.
CHECK COMPARTMENT TEMPERATURE. Is the compartment tempera- Go to step 4.
<Ref. to AC-26,
ture changed?
COMPARTMENT
2)Set the temperature at maximum cold posiTEMPERATURE
tion.
IS NOT
3)Check the compartment temperature
CHANGED OR A/
changes.
C SYSTEM DOES
NOT RESPOND
QUICKLY, Diagnostics for A/C
System Failure.>
CHECK A/C SYSTEM RESPONSE.
Does the A/C system respond A/C system is OK. <Ref. to AC-26,
Change the temperature setting, and check the quickly?
COMPARTMENT
response of A/C system.
TEMPERATURE
IS NOT
CHANGED OR A/
C SYSTEM DOES
NOT RESPOND
QUICKLY, Diagnostics for A/C
System Failure.>
AC-2
GENERAL DESCRIPTION
B: INSPECTION
A: CAUTION
Before performing diagnosis, check the following

items which might affect engine problems.

The Auto A/C control module will be destroyed
instantly.
engine is running.
electronic parts such as A/C control module.
sensor and the A/C control module, be sure to turn
off the ignition switch.
Otherwise, the Auto A/C control module may be
damaged.
4) Every Auto A/C-related part is a precision part.
Do not drop them.
A/C control panel (A/C control module) and junction
box.
CAUTION:
wiring harness when servicing the A/C control
panel (A/C control module) and junction box.
1. BATTERY
of electrolyte.
2) Check the condition of the fuses for A/C, heater
and other fuses.
3) Check the condition of the harnesses and harness connectors connection.
2. ASPIRATOR HOSE
1) Make sure that the aspirator hose is securely
connected to the heater unit by inserting a hand
from the driver's compartment and secure as necessary.
2) Turn the ignition switch to ON and push the
A/C switch.
3) Turn the temperature control dail to maximum
hot position.
4) Turn the air flow control dial to DEF position.
5) Turn the fan speed control dial to 4th position.
6) Firmly hold a thin thread (b) in front of the in-vehicle sensor suction port (a) for the auto A/C control
unit and check that the thread moves towards the
port indicating that air is being sucked into the port.
NOTE:
Ensure the thread does not get sucked into the
port.
Hold the thread approx. 5 mm (0.02 in) away
from port when the suction force is not very strong.
25
20
30
HV0027
AC-3
GENERAL DESCRIPTION
7) If the thread does not move at all, remove the

auto A/C control unit <Ref. to AC-31, REMOVAL,
Control Unit.> and check for improper connection
of the aspirator hose (a) and auto A/C control unit
and secure as necessary.
3. REFRIGERANT LINE
Check contact for refrigerant line (A).
(A)
(a)
HV0029
HV0028
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-4
GENERAL DESCRIPTION
5. CONTROL SWITCHES
Start and warm up the engine completely.
1) Inspection using switches.
No.
1
3
4
Point to check
Switch operation
Judgement standard
A/C switch LED goes out.
OFF position
Fan speed: OFF
Fan speed control dial
Compressor: OFF
Fan speed control dial 1st 2nd 3rd 4th
Fan speed changes 1st 2nd 3rd 4th
A. Fan speed control dial auto position.
Outlet air: Cool
B. Temperature control dial maximum cold posi Fan speed: 4th
tion
Compressor: ON
Fan speed control dial C. Turn the temperature control dial from maxi Outlet air: Cool Hot
and temperature con- mum cold position to maximum hot position grad- Fan speed: AUTO
trol dial
ually.
Compressor: ON
Outlet air: Hot
D. Temperature control dial maximum hot posi Fan speed: 4th
tion
Compressor: ON
Air flow control dial VENT BI-LEVEL HEAT Air flow outlet changes from VENT BIAir flow control dial
DEF/HEAT DEF
LEVEL HEAT DEF/HEAT DEF.
FRESH/RECIRC
Changes from RECIRC FRESH, or FRESH
FRESH/RECIRC switch ON
switch
RECIRC.
2) Compressor operation inspection

No.
1
Point to check
Compressor
Switch operation
A. A/C switch ON
B. Fan speed control dial 1st-4th
Judgement standard
Compressor: ON
3) Illumination control inspection

No.
1
Point to check
Illumination
Switch operation
Lighting switch ON
AC-5
Judgement standard
Illumination light illuminates.


A: LOCATION
1. ENGINE COMPARTMENT
(2)
(1)
(3)
(2)
(1)
(3)
(4)
HV0030
(1)
(2)
A/C compressor
A/C relay
(3)
(4)
Pressure switch
Ambient sensor
AC-6

2. PASSENGER COMPARTMENT
(7)
(6)
(8) (5) (3)
(4)
(2)
(1)
(4)
(6)
(5)
(3)
(1)
(2)
(7)
HV0031
(1)
(2)
(3)
Evaporator sensor
Blower motor
Blower motor resistor
(4)
(5)
(6)
Intake door actuator

Air mix door actuator
Mode door actuator
AC-7
(7)
(8)
Sunload sensor
In-vehicle sensor
(built-in Auto A/C control module)
A/C CONTROL MODULE I/O SIGNAL

4. A/C Control Module I/O Signal

10 9
16 15 14 13 12 11 10 9
20 19 18 17 16 15 14 13 12 11
To B283 : b
To B282 : a
HV0032
Content
Connector &
Terminal No.
Battery power supply (Memory

back-up)
b1b12
IGN power supply
a8b12
ACC power supply

(OFF: ignition in START or diagnosis system reset)
A/C control module ground circuit
Sensor ground circuit
Ambient sensor
Evaporator sensor
Thermometer
Sunload sensor
Air mix door actuator
Air mix door actuator P.B.R.
Mode door actuator
Mode door actuator P.B.R.
Intake door FRS voltage
Intake door CIRC voltage
Blower fan relay
b2b12
b12body
b17body
b9b17
b7b17
b15b12
b16b17
b5b1
a4b17
b6b17
a12b17
a15a7
a7a15
b14body
A/C relay
b3b12
Illumination control signal

Rear defogger
b10b20
a13b12
Signal (V)
Battery voltage,
13 14 (engine running)
Battery voltage (ignition switch ON),
13 14 (engine running)
Battery voltage, 0 (engine cranking), Battery voltage (during engine starts)
0 (ignition switch ON) circuit constantly grounded
0 (ignition switch ON) continuity exists
Approx. 3.3 (disconnect connector, and ignition switch ON)
Approx. 4.2 (disconnect connector, and ignition switch ON)
Battery voltage (ignition switch ON)
Approx. 5.5
Approx. 5.5
Battery voltage (CIRC switch OFF)
Battery voltage (CIRC switch ON)
0 (ignition and A/C switches ON)
Battery voltage (A/C switch OFF)
Battery voltage (ignition and lighting switches ON)
0 (IGN ON, R Def SW ON)
AC-8

B: SCHEMATIC
A/C(ALH)-01
A/C(ALH)-01
1. AIR CONDITIONER AUTO A/C LHD MODEL
FB-34
F/B FUSE NO. 1 (B)
F/B FUSE NO. 2 (B)
RW
GOr
FB-20
F/B FUSE NO. 17
(IG)
GOr
TO POWER SUPPLY ROUTING

FB-19
F/B FUSE NO. 17
(IG)
TB
TB
NA
NA
: NON-TURBO ENGINE MODEL
BLOWER MOTOR
RELAY
AIR
CONDITIONING
RELAY
RW
10 GOr
11 BrY
12
Br
BrY 16
Br
GR
BR
BrY
15
GOr
Br
B50
F45
F31
B62
BLOWER MOTOR
A: B134
F79
B: B135
RL
FAN
B275 CONTROL
AMP
NA
MAGNET
CLUTCH
A: B282
B: B283
A16 RL
B4
LY
F24
B11 BY
NA
BY
GOr
1
C: B136
ENGINE
CONTROL
A17 Br
MODULE
B27 LY
(NON-TURBO
ENGINE
C30 GR
MODEL)
B14 GR
A8 GOr
BrY
TB
B3 BrY
2
1
BY
B87
LY
D27 Br
TB
PRESSURE SWITCH
BR
NA
D: B137
A9 GR
A6
TB
A: B134
ENGINE
CONTROL
MODULE
(TURBO
ENGINE
MODEL)
AUTO A/C
CONTROL MODULE
REF. TO GND-03
COMPRESSOR
B87
F79
1
2
1 2
(GRAY)
F24
1 2 3
A: B134 : TB
6 7
1 2 3 4 5
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
(GRAY)
B275
1 2
3 4
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
5 6 9 13 14 17 21 22 25
7
10
15
18
23
26
8 11 12 16 19 20 24 27 28
A: B282 (GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B135 : NA
F45
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
29
30
B: B283 (GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
C: B136 : NA
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
26 27
28 29 30
A: B134 : NA
D: B137 : TB
F31
1
B50
1 2
3 4 5 6 7 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
RELAY HOLDER (BLACK)
GL46-21A
AC-9
LR
YG
GB
B17
AT
GB
GY C17
LR
C: B56
TRANSMISSION
CONTROL
MODULE (AT)
FB-17
F/B FUSE NO. 18
(IG)
GY
FB-27
F/B FUSE NO. 9
(ACC)
FB-9
F/B FUSE NO. 2
(B)
FB-8
M/B FUSE NO. 2
(B)
A/C(ALH)-02
VEHICLE SPEED
SENSOR (MT)
BR
A/C(ALH)-02
MT
B209
SMJ
16
F60
E3
B22
E3
NA
BR
16
BR
BR
F76
BR
BR
N2
BR
NA
TB
TB
TB
NA
NA
BR
REF. TO ILM(L)-01
REF. TO R/DEF(L)-01
TB
B19 GY
B1
YG
LR
B20
B2
B10
R
A13
A14 RL
GE
A: B282
B17 : NA
1 2 3
B17 : TB
B22 (BROWN)
1 2
3 4
F60
1
5
9
13
2
6
10
14
3
7
11
15
(BROWN)
4
8
12
16
B: B283
AUTO A/C CONTROL MODULE
B: B283 (GRAY)
A: B282 (GRAY)
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
C: B56 (GREEN)
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7 8
16 17
22 23
9
18
24
GL46-21B
AC-10
BP
A/C(ALH)-03
YB A11
12
22
YB
i1
YB
BP
B8
BL
R
BL
B36
I/F
I/F
i51
B256
2
F78
B12 YB
BL B17
BL
2
GR
BL
BL
BL
BP
BP
F45
GR
B62
B11 BP
GR B16
BL
BL
BP
GR
B7
B: B283
BP
B9
A: B282
21
A/C(ALH)-03
-COM
LCD(OUT TEMP)
AMBIENT SENSOR
A: B282 (GRAY)
B256
F78
(BLACK)
i51
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
EVAPORATION
THERMO SWITCH
SUNLOAD
SENSOR
B: B283 (GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
F45
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
B:
i11
COMBINATION
METER
B36 (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
1 2
B:
i11
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
GL46-21C
AC-11

A/C(ALH)-04
RY A12
LW B6
A4
B12
GY B5
WG B15
B: B283
BL A15
A: B282
LgR A7
A/C(ALH)-04
WG
J1 WG
NA
TB
B209
SMJ
F76
AIR MIX
ACTUATOR
MODE ACTUATOR
GY
LW
RY
E2
15 WG
WG
B21
F61
B77
B293
E2
NA
WG
10 WG
WG
TB
B293
1
2
3
E8
1 2
3
(LIGHT GRAY)
FRESH/RECIRC
ACTUATOR
B91 (BLACK)
1
2
3 4 5 6
BL
B77
B91
REF. TO GND-02
REF. TO GND-02
THERMOMETER
LgR
E8
A: B282 (GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B283 (GRAY)
F61
(BLACK)
B21 (LIGHT GRAY)
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
11 12
9 10
14 15
13
16
19 20
17 18
5
GL46-21D
AC-12

A/C(ARH)-01
A/C(ARH)-01
2. AIR CONDITIONER AUTO A/C RHD MODEL
FB-34
F/B FUSE NO. 1 (B)
F/B FUSE NO. 2 (B)
RW
GOr
FB-20
F/B FUSE NO. 17
(IG)
GOr

FB-19
F/B FUSE NO. 17
(IG)
TB
TB
NA
NA
BLOWER MOTOR
RELAY
AIR
CONDITIONING
RELAY
10 GOr
12 BrY
Br
Br
16
BrY
BrR
GR
BR
B50
F45
F31
B62
BLOWER MOTOR
ENGINE
CONTROL
MODULE
(TURBO
ENGINE
MODEL)
A: B134
D: B137
PRESSURE SWITCH
2
2
1
A9 GR
A6
1
2
B87
PB
D27 BrR
BR
BW
TB
NA
11
BrY
RW
GOr
GOr
B: B135
NA
BW
RL
FAN
B275 CONTROL
AMP
NA
Lg
BrY
C: B136
ENGINE
CONTROL
A17 BrR
MODULE
B27 PB
(NON-TURBO
ENGINE
C30 GR
MODEL)
TB
A: B134
TB
Lg
F79
A: B282
B: B283
A16 RL
B11 BW
B14 GR
A8 GOr
MAGNET
CLUTCH
B3 BrY
B4
PB
F24
AUTO A/C
CONTROL MODULE
REF. TO GND-08
COMPRESSOR
B87
F79
1
2
1 2
(GRAY)
A: B134 : TB
6 7
1 2 3 4 5
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
D: B137 : TB
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
F24
1 2 3
(GRAY)
B50
B275
1 2
3 4
1 2
3 4
A: B282 (GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B135 : NA
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
B: B283 (GRAY)
F45
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
C: B136 : NA
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
26 27
28 29 30
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
F31
5 6 9 13 14 17 21 22 25
15
18
26
7
10
23
8 11 12 16 19 20 24 27 28
29
30
A: B134 : NA
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
AC-13
GR46-21A
GR46-21A
B17
A/C(ARH)-02
AT
GB
GY C17
GB
C: B56
TRANSMISSION
CONTROL
MODULE (AT)
1
YG
VEHICLE SPEED
SENSOR (MT)
GY
FB-17
F/B FUSE NO. 18
(IG)
FB-27
F/B FUSE NO. 9
(ACC)
MB-10
M/B FUSE NO. 2
(B)
LR
GW
A/C(ARH)-02
BR
16 GW
MT
E3
: WITH ILLUMINATION CONTROL

MODEL : YL
: WITHOUT ILLUMINATION CONTROL
MODEL : B
TB : TURBO ENGINE MODEL
REF. TO ILM(ROI)-01
ILM(RWI)-01
REF. TO R/DEF(R)-01
*1
B22
BR
NA : NON-TURBO ENGINE MODEL
LR
B1
B19 GY
YG
1
B20
B2
V
B10
R
A13
A14 RL
GE
A: B282
B17 (BLACK) : NA
B17 (BLACK) : TB
1 2
3 4
1 2 3
B: B283
B22 (BROWN)
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
A: B282 (GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B283
(GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
C: B56 (GREEN)
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7 8
16 17
22 23
9
18
24
GR46-21B
AC-14
W A11
W
YB B17
Or
GR B16
YB
B7
24
23
B11 Or
B8
B12 W
YB
I/F
I/F
i51
1
B256
2
F78
Or
i2
YB
YB
26
GR
YB
F45
GR
25
B37
14
Or
YB
Or
YB
13
B62
A/C(ARH)-03
B: B283
YB
Or
Or
B9
A: B282
GR
A/C(ARH)-03
-COM
LCD(OUT TEMP)
AMBIENT SENSOR
F78
(BLACK)
B256
A: B282 (GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
i51
SUNLOAD
SENSOR
EVAPORATION
THERMO SWITCH
B: B283 (GRAY)
F45
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
B:
i11
COMBINATION
METER
B:
i11
(GREEN)
1 2 3 4 5 6 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
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
GR46-21C
AC-15

A/C(ARH)-04
RY A12
B12
B
LW B6
A4
L
WG B15
GY B5
B: B283
BL A15
A: B282
LgR A7
A/C(ARH)-04
E2
15 WG
B21
WG
WG
10 WG
NA
TB
AIR MIX
ACTUATOR
B21
MODE ACTUATOR
GY
LW
RY
E2
B77
NA
B293
LgR
BL
NA
B91
TB
WG
TB
E8
FRESH/RECIRC
ACTUATOR
REF. TO GND-07
THERMOMETER
B77
B293
1
2
3
E8
1 2
3
(LIGHT GRAY)
B91 (BLACK)
1
2
3 4 5 6
A: B282 (GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B283 (GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B21
1 2
TB
: (BLACK)
NA
: (LIGHT GRAY)
3 4
6 7
8
11 12
9 10
14 15
13
16
19 20
17 18
5
GR46-21D
AC-16

AC-17
DIAGNOSTICS CHART FOR DIAGNOSIS SYSTEM

5. Diagnostics Chart for Diagnosis System

A: SELF-DIAGNOSIS MODE
(2)
(3)
(4)
(1)
(5)
(6)
HV0033
(1)
(2)
Air flow control dial

Rear window defogger switch
(3)
(4)
A/C switch
FRESH/RECIRC switch
Step
SELECT CONTROL PANEL TO SELF-DIAGNOSIS MODE.
1)Turn the fan speed control dial to OFF position.
2)Start the engine and press rear window
defogger switch for at least 5 seconds. The
rear window defogger switch must be pressed
within 10 seconds after starting engine.
CHECK LED ILLUMINATION.
Make sure that all switch LED illuminates
(RHD model) or blink (LHD model) on control
panel.
CHECK SENSORS MALFUNCTION.
1)Turn the fan speed control dial to AUTO
position.
2)If the system has trouble for each sensor,
rear window defogger switch LED is turned off.
3)If the system has no trouble, rear window
defogger switch LED is illuminated.
CONFIRM MALFUNCTIONING SENSOR.
1)Turn the fan speed control dial to 1st position.
2)Turn the air flow control dial to each mode
position, check each switch LED illumination
according to sensor check table. <Ref. to AC20, SENSOR CHECK TABLE, SELF-DIAGNOSIS MODE, Diagnostics Chart for Diagnosis
System.>
Check
Does the self-diagnosis mode
operate?
(5)
(6)
Temperature control dial

Fan speed control dial
Yes
Go to step 2.
No
<Ref. to AC-22, A/
C AND/OR SELFDIAGNOSIS SYSTEMS DO NOT
OPERATE, Diagnostics for A/C
System Failure.>
Do all LED illuminate or blink? Go to step 3.
Check the switch

LED.
Does the rear window defogger switch LED illuminate?
Go to step 5.
Go to step 4.
Do FRESH/RECIRC and A/C

switch LED illuminate when
turning the dial to each mode
position?
Go to step 5.
Repair the malfunctioning sensor.

<Ref. to AC-38,
Diagnostic Procedure for Sensors.>
AC-18

Step
CHECK MODE DOOR POSITION SIGNAL.
1)Turn the fan speed control dial to 2nd position.
2)If the system has trouble for mode door position signal, rear window defogger switch LED
is turned off.
3)If the system has no trouble, rear window
defogger switch LED is illuminated.
CHECK BLOWER FAN OPERATION.
1)Turn the fan speed control dial to 3rd position.
2)Turn the temperature control dial, check that
blower fan speed changes depending on set
temperature.
Check
Does the rear window defogger switch LED illuminate?
Does the blower fan speed

change?
CHECK OPERATION OF EACH ACTUATOR, Does the operation of each

BLOWER FAN AND COMPRESSOR
mode match to the operating
CLUTCH.
mode table?
1)Turn the fan speed control dial to 4th position.
2)Select the operating mode by turning air flow
control dial.
3)Check the operation of each mode according
to operating mode table. <Ref. to AC-20,
OPERATING MODE TABLE, SELF-DIAGNOSIS MODE, Diagnostics Chart for Diagnosis
System.>
Air inlet:
Air outlet:
Air mix door:
Blower fan:
A/C compressor:
AC-19
Yes
Go to step 6.
No
Check the mode
door actuator circuit. <Ref. to AC34, MODE DOOR
ACTUATOR,
Diagnostic Procedure for Actuators.>
Go to step 7.
Check the blower
to AC-24,
BLOWER MOTOR
IS NOT
ROTATED, Diagnostics for A/C
System Failure.>
Push the A/C
Repair the malswitch or turn igni- function part
tion switch OFF,
according to each
and finish the self- diagnostics chart.
diagnosis.

1. SENSOR CHECK TABLE

NOTE:
When the sunload sensor is checked indoors or in the shade, open circuit might be indicated. Always check
the sunload sensor at a place where sun shines directly on it.
Air flow control
dial position
Checked sensor
VENT
Ambient sensor
BI-LEVEL
In-vehicle sensor
HEAT
Evaporator sensor
DEF/HEAT
Sunload sensor
DEF
Air mix door motor (Potentio

balance resistor)
No trouble
A/C switch LED and FRESH/
RECIRC switch LED illuminate
Short circuit
Open circuit
A/C switch LED illuminate
FRESH/RECIRC
switch LED illuminate
FRESH/RECIRC
FRESH/RECIRC
FRESH/RECIRC
2. OPERATING MODE TABLE

Operation
Air outlet
Air inlet
Air mix door
VENT
VENT
RECIRC
FULL COOL
Air flow control dial position

BI-LEVEL
HEAT
BI-LEVEL
HEAT
RECIRC
RECIRC
FULL COOL
FULL HOT
DEF/HEAT
DEF/HEAT
FRESH
FULL HOT
Blower fan
5V
5V
8V
10V
A/C compressor
ON
OFF
OFF
ON
AC-20
DEF
DEF
FRESH
FULL COOL
Power supply
voltage
ON

AC-21
DIAGNOSTICS FOR A/C SYSTEM FAILURE

6. Diagnostics for A/C System Failure

A: A/C AND/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:
IGNITION
SWITCH
F/B NO. 17
SBF-4
SBF-1
100A
BATTERY
F/B NO. 9
A: B282
B12
B1
B2
A8
F/B NO. 2
B: B283
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
HV0034
AC-22

Step
CHECK FUSE.
2)Remove the fuse No. 2 from main fuse box.
CHECK FUSE.
2)Remove the fuses No. 9 and No. 17 from
fuse & relay box.
CHECK A/C CONTROL MODULE POWER
CIRCUIT.
1)Pull out the A/C control module connector.
2)Measure the voltage between A/C control
module connector terminal and chassis ground
when turning ignition switch to OFF.
CIRCUIT.
Measure the voltage between A/C control
when turning ignition switch to ACC.
CIRCUIT.
Measure the voltage between A/C control
when turning ignition switch to ON.
CHECK A/C CONTROL MODULE GROUND
CIRCUIT.
A/C control module and chassis ground.
CHECK POOR CONTACT.
Check poor contact in A/C control module.
Check
Yes
Replace the fuse.
No
Go to step 2.
Replace the fuse.
Go to step 3.
Repair the short

circuit in harness
for power supply
line.
Repair the short

circuit in harness
for power supply
line.
Repair the short

circuit in harness
for power supply
line.

?
Go to step 7.
Repair the short

circuit in harness
for ground line.
Is there poor contact in A/C

control module?
Repair the poor

Contact with your
contact in A/C con- Subaru distributor
trol module.
service.
AC-23

B: BLOWER MOTOR IS NOT ROTATED

TROUBLE SYMPTOM:
Blower motor is not rotated.
Blower motor is not rotated in HI.
WIRING DIAGRAM:
BATTERY
F/B NO. 1
SBF-1
SBF-3
F/B NO. 2
IGNITION
SWITCH
BLOWER MOTOR
RELAY
F/B NO. 17
SBF-4
2
1
3
4
B50
BLOWER MOTOR
1
2
B87
BLOWER MOTOR
RESISTOR
2
1
4
A: B282
B14
B11
A16
B275
B: B283
B87
B275
B50
1
2
1 2
3 4
1 2
3 4
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
HV0035
AC-24

Step
CHECK FUSE.
1)Remove the No.1, No. 2 and No. 17 fuses in
fuse & relay box.
2)Check the condition of fuses.
CHECK POWER SUPPLY TO BLOWER FAN
MOTOR.
2)Turn the blower switch to ON.
3)Measure the voltage between blower fan
motor and chassis ground.
CHECK BLOWER FAN MOTOR RELAY.
2)Remove the blower fan motor relay.
3)Connect the battery to No. 1 and No. 3 terminals of blower fan motor connector.
4)Measure the resistance between No. 2 and
No. 4 terminals.
Terminals:
No. 2 No. 4
CHECK BLOWER FAN MOTOR.
1)Disconnect the connector from blower fan
motor.
2)Connect the battery to connector terminals of
blower fan motor.
3)Make sure that the blower fan motor is operated.
CHECK POOR CONTACT.
Check
Are any of the fuses blownout?
Yes
Replace the fuse.
No
Go to step 2.
Repair the open

circuit in harness
for blower fan
motor power supply line.

?
Go to step 4.
Replace the
blower fan motor
relay.
Does the blower fan motor

operate?
Go to step 5.
Replace the
blower fan motor.

control module?
Repair poor con- Contact with your

tact in A/C control Subaru distributor
module.
service.
AC-25

C: COMPARTMENT TEMPERATURE IS NOT CHANGED OR A/C SYSTEM DOES

NOT RESPOND QUICKLY
WIRING DIAGRAM FOR TURBO ENGINE MODEL:
F/B No.17
F27
IGNITION
SWITCH
BATTERY
SBF-4
SBF-1
30A
F/B No.18
30A
F30
F28
F29
F31
MAIN FAN
RELAY-1
MAIN FAN
MOTOR
23
21
22
24
MAIN FAN
RELAY-2
2
1
7
5
6
8
SUBFAN
RELAY-1
F17
SUB FAN
MOTOR
SUBFAN
RELAY-2
18
20
19
17
AIR
CONDITIONING
RELAY
10
1
2
9
2
1
F16
3
4
5
6
F66
26
28
27
25
F45
B62
PRESSURE
SWITCH
2
1
F79
1 : LHD MODEL: 11
: RHD MODEL: 12
2 : LHD MODEL: 12
: RHD MODEL: 11
COMPRESSOR
3 : LHD MODEL: 15
: RHD MODEL: 16
4 : LHD MODEL: 16
: RHD MODEL: 6
B4
B3
B14
A9
A6
D27
D17
D28
5 : LHD MODEL: 2
3
MAGNET
CLUTCH
F79
F24
F16
1 2
1 2 3
F17
A: B134
F24
D: B137
B: B283
ENGINE
CONTROL
MODULE
F45
A: B282
B: B283
RHD
6 : LHD MODEL: 12
: RHD MODEL: 17
F45
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
: RHD MODEL: 7
AUTO A/C
CONTROL
MODULE
LHD
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
F27
F28
F31
F29
F30
F66
5 6 9 13 14 17 21 22 25
29
7
10
15
18
23
26
8 11 12 16 19 20 24 27 28 30
A: B134
1 2 3 4 5
6 7
8 9 10 11 12 13 14 15
16 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
29 30 31
22 23 24 25 26
27 28
HV0065
AC-26

WIRING DIAGRAM FOR NON-TURBO ENGINE MODEL:
F/B No.17
F27
IGNITION
SWITCH
BATTERY
SBF-4
SBF-1
20A
F/B No.18
20A
F66
F29
F30
26
28
27
25
MAIN FAN
RELAY
MAIN FAN
MOTOR
18
20
19
17
MAIN FAN
RELAY
1
F17
10
1
2
9
AIR
CONDITIONING
RELAY
SUB FAN
MOTOR
3
4
5
6
F31
F45
B62
1
PRESSURE
SWITCH
F16
2
1
1 : LHD MODEL: 11
F79
: RHD MODEL: 12
2 : LHD MODEL: 12
: RHD MODEL: 11
COMPRESSOR
3 : LHD MODEL: 15
: RHD MODEL: 16
MAGNET
CLUTCH
4 : LHD MODEL: 16
B4
B3
B14
C30
B27
A17
A3
A12
: RHD MODEL: 6
5 : LHD MODEL: 2
A: B134
F24
B: B135
A: B282
ENGINE
CONTROL
MODULE
B: B283
: RHD MODEL: 7
AUTO A/C
CONTROL
MODULE
6 : LHD MODEL: 12
: RHD MODEL: 17
C: B136
F79
F16
F24
1 2
F17
1 2 3
F45
B: B283
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
F45
RHD
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
LHD
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
2 1
B: B135
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
20 21
24 25 26
27 28
22 23
F27
F28
F31
F29
F30
F66
5 6 9 13 14 17 21 22 25
29
7
10
15
18
23
26
8 11 12 16 19 20 24 27 28 30
C: B136
A: B134
4 5
1 2 3
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
26 27
21 22
28 29 30
23 24 25
3 4
1 2
7 8
5 6
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
34 35
26 27 28 29
30 31 32 33
HV0066
Step
1
CHECK FUSE.
2)Remove the No. 2 fuse in main fuse box.
Check
AC-27
Yes
Replace the fuse.
No
Go to step 2.

Step
CHECK POWER SUPPLY TO MAGNET
CLUTCH OF A/C COMPRESSOR.
1)Start the engine, and turn A/C switch to ON.
2)Set the temperature control dial to maximum
cold position.
3)Measure the voltage between magnet clutch
CHECK SIGNAL VOLTAGE TO A/C RELAY.
2)Turn the A/C switch to ON.
3)Measure the signal voltage to A/C relay and
chassis ground.
CHECK A/C RELAY.
1)Remove the A/C relay in main fuse box.
2)Check the A/C relay. <Ref. to AC-38,
INSPECTION, Relay and Fuse.>
CHECK OPERATION OF MAIN FAN MOTOR.
1)Start the engine.
2)Turn the A/C switch to ON.
3)Check the operation of main fan motor.
CAUTION:
repair.
motor.
(203F).
ON.
Turbo engine model:
(F17) No. 2, 3 (+) Chassis ground ():
Non-turbo engine model:
MOTOR.
CHECK POOR CONTACT.
Check
Yes
No
Repair the open
circuit in harness
for power supply
line of the A/C
compressor.
Repair the open

circuit in harness
for power supply
line.
Is the operation of the relay

OK?
Go to step 5.
Replace the A/C

relay.
Does the radiator main fan

operate?
Go to step 10.
Go to step 6.
Repair the open

circuit in harness
for power supply
circuit.

?
Go to step 8.

Repair the poor

Go to step 9.
contact in main fan
motor connector.
AC-28
Repair the open

circuit in harness
between main fan
motor connector
and chassis
ground.

10
11
12
13
14
15
16
17
Step
Connect the battery positive (+) terminal to terminal No. 2 and 3 (turbo engine model) or 2
(non-turbo engine model), and ground () terminal to terminal No. 1 of main fan motor connector.
CHECK OPERATION OF SUB FAN MOTOR.
Check the operation of sub fan motor.
CAUTION:
repair.
motor.
(212F).
ON.
Turbo engine model:
(F16) No. 2, 3 (+) Chassis ground ():
MOTOR.
CHECK POOR CONTACT.
Connect the battery positive (+) terminal to terminal No. 2 and 3 (turbo engine model) or 2
(non-turbo engine model), and ground () terminal to terminal No. 1 of sub fan motor connector.
CHECK EACH SENSOR AND POTENTIOMETER.
Check the sensors and potentiometer for
proper operation using the self-diagnostic
function. <Ref. to AC-18, Diagnostics Chart for
Diagnosis System.>
CHECK CONNECTION OF ASPIRATOR
DUCT.
Make sure that the connection of aspirator duct
is correct.
CHECK EACH ACTUATOR.
Check the actuators for proper operation using
the self-diagnostic function.<Ref. to AC-18,
Diagnostics Chart for Diagnosis System.>
Check
Yes
No
Repair the poor
Replace the main
contact in main fan fan motor with a
motor connector. new one.
Does the radiator sub fan oper- Go to step 15.

ate?
Go to step 11.

?
Repair the open

circuit in harness
between sub fan
motor connector
and chassis
ground.
Go to step 13.
Repair the open

circuit in harness
for power supply
circuit.

motor connector?
contact in sub fan
motor connector.
Does the sub fan rotate?
Repair the poor
contact in sub fan
motor connector.
Go to step 14.
Is the operation of each sensor Go to step 16.

and potentiometer normal?
Check the sensor

and circuit. <Ref.
to AC-38, Diagnostic Procedure
for Sensors.>
Is the connection of aspirator

duct correct?
Repair the aspira- Go to step 17.

tor duct connection.
Is the operation of each actua- Go to step 18.

tor normal?
AC-29
Replace the sub

fan motor with a
new one.
Check the actuator

and circuit. <Ref.
to AC-32, Diagnostic Procedure
for Actuators.>

18
Step
CHECK POOR CONTACT.
Check
control module?
AC-30
Yes
No
Repair the poor
Contact with your
trol module.
service.

AC-31
DIAGNOSTIC PROCEDURE FOR ACTUATORS

7. Diagnostic Procedure for Actuators

A: INTAKE DOOR ACTUATOR
TROUBLE SYMPTOM:
FRESH/RECIRC mode is not changed.
WIRING DIAGRAM:
AUTO A/C
CONTROL MODULE
A7
B: B283
A15
A: B282
B91
INTAKE DOOR
ACTUATOR
B91
1
2
3 4 5 6
A: B282
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
HV0038
AC-32

Step
CHECK FUSE.
1)Remove the No. 17 fuse in fuse & relay box.
CHECK SIGNAL VOLTAGE.
1)Change the air intake to RECIRC by pushing
FRESH/RECIRC switch.
module and chassis ground.
CHECK SIGNAL VOLTAGE.
1)Change the air intake to FRESH with pushing FRESH/RECIRC switch.
module and chassis ground.
A/C CONTROL MODULE AND FRESH/RECIRC ACTUATOR.
2)Disconnect the connector from A/C control
module and intake door actuator.
A/C control module and intake door actuator.
(B282) No. 15 (B91) No. 1
A/C CONTROL MODULE AND FRESH/RECIRC ACTUATOR.
A/C control module and intake door actuator.
(B282) No. 7 (B91) No. 2
CHECK POOR CONTACT.
Check
Yes
Replace the fuse.
No
Go to step 2.
Go to step 3.
Repair the short

circuit in harness
for power supply
line.
Go to step 4.
Repair the short

circuit in harness
for power supply
line.

?
Go to step 5.
Repair the open

circuit in harness
between A/C control module and
intake door actuator.

?
Go to step 6.
Repair the open

circuit in harness
intake door actuator.

control module?
Repair the poor

Contact with your
trol module.
service.
AC-33

B: MODE DOOR ACTUATOR

TROUBLE SYMPTOM:
Air flow outlet is not changed.
WIRING DIAGRAM:
B6
B12
AUTO A/C
CONTROL MODULE
B: B283
A12
A: B282
B77
MODE DOOR ACTUATOR
B77
1
2
3
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
HV0039
AC-34

Step
CHECK POWER SUPPLY FOR AUTO A/C
CONTROL MODULE SIDE.
3)Measure the voltage between auto A/C control module harness connector terminal and
chassis ground.
CHECK POWER SUPPLY FOR ACTUATOR
SIDE.
Measure the voltage between mode door actuator harness connector terminal and chassis
ground.
CHECK SIGNAL FOR AUTO A/C CONTROL
MODULE SIDE.
Measure the voltage between auto A/C control
module harness connector terminal and chassis ground with oscilloscope.
CHECK SIGNAL FOR ACTUATOR SIDE.
Measure the voltage between mode door actuator harness connector terminal and chassis
ground.
CHECK GROUND CIRCUIT OF ACTUATOR.
1)Turn the ignition switch and A/C switch OFF.
2)Measure the resistance between mode door
actuator harness connector terminal and chassis ground.
CHECK POOR CONTACT.
Check poor contact in auto A/C control module
and mode door actuator.
Check
Yes
Is the voltage more than 10V? Go to step 2.
No
Replace the auto
A/C control module.
Repair the open

circuit in harness
between auto A/C
control module
and mode door
actuator.
Is the voltage approx. 5.5V?
Go to step 4.
Replace the auto

A/C control module.
Go to step 5.

?
Go to step 6.
Repair the open

circuit in harness
between auto A/C
control module
and mode door
actuator.
Repair the open
circuit in harness
between mode
door actuator and
chassis ground.
Repair the poor

contact.
AC-35
Contact with your

Subaru distributor
service.

C: AIR MIX DOOR ACTUATOR

TROUBLE SYMPTOM:
Outlet air temperature is not changed.
WIRING DIAGRAM:
A4
B12
AUTO A/C
CONTROL MODULE
B: B283
B5
A: B282
B293
AIR MIX DOOR ACTUATOR
B293
1
2
3
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
HV0040
AC-36

Step
CHECK POWER SUPPLY FOR AUTO A/C
CONTROL MODULE SIDE.
3)Measure the voltage between auto A/C control module harness connector terminal and
chassis ground.
CHECK POWER SUPPLY FOR ACTUATOR
SIDE.
Measure the voltage between air mix door
CHECK SIGNAL FOR AUTO A/C CONTROL
MODULE SIDE.
Measure the voltage between auto A/C control
module harness connector terminal and chassis ground with oscilloscope.
CHECK SIGNAL FOR ACTUATOR SIDE.
Measure the voltage between air mix door
actuator harness connector terminal and chassis ground with oscilloscope.
1)Turn the ignition switch and A/C switch OFF.
2)Measure the resistance between air mix door
CHECK POOR CONTACT.
Check poor contact in auto A/C control module
and air mix door actuator.
Check
Yes
No
Replace the auto
A/C control module.
Repair the open

circuit in harness
between auto A/C
control module
and air mix door
cutuator.
Go to step 4.
Replace the auto

A/C control module.
Go to step 5.

?
Go to step 6.
Repair the open

circuit in harness
between auto A/C
control module
and air mix door
actuator.
Repair the open
circuit in harness
between air mix
door actuator and
chassis ground.
Repair the poor

contact.
AC-37
Contact with your

Subaru distributor
service.
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
F78
F45
1 : LHD MODEL: 2
B9
B17
B62
RHD MODEL: 1
2 : LHD MODEL: 1
RHD MODEL: 2
A: B282
B: B283
3 : LHD MODEL: 4
AUTO A/C
CONTROL MODULE
RHD MODEL: 14
4 : LHD MODEL: 5
RHD MODEL: 13
F78
1 2
B: B283
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
F45
RHD
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
F45
LHD
7 8 9 10 11
1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
HV0041
AC-38

Step
CHECK AMBIENT SENSOR.
2)Disconnect the connector from ambient sensor.
terminals of ambient sensor.
Terminals:
No. 1 No. 2
CHECK INPUT SIGNALS FOR AMBIENT
SENSOR.
1)Turn the ignition ON.
2)Measure the voltage between (F78) connector terminals.
(F78) No. 1 No. 2
CHECK OUTPUT SIGNALS FROM A/C CONTROL MODULE.
2)Pull out the A/C control panel.
5)Measure the voltage between connector terminals of A/C control module.
(B283) No. 9 (+) No. 17 ()
A/C CONTROL MODULE AND AMBIENT
SENSOR.
2)Disconnect the connectors from A/C control
module.
A/C control module and ambient sensor.
LHD model:
(F78) No. 1 (B283) No. 9
RHD model:
(F78) No. 2 (B283) No. 9
A/C CONTROL MODULE AND AMBIENT
SENSOR.
A/C control module and ambient sensor.
LHD model:
(F78) No. 2 (B283) No. 17
RHD model:
(F78) No. 1 (B283) No. 17
CHECK POOR CONTACT.
Check
Is the resistance approx. 2.2
k at 25C (77F)?
Yes
Go to step 2.
No
Replace the ambient sensor.
Is the voltage approx. 4.5 V?
Go to step 6.
Go to step 3.
Go to step 6.
Go to step 4.

?
Go to step 5.
Repair the open

circuit in harness
ambient sensor.

?
Go to step 6.
Repair the open

circuit in harness
ambient sensor.

control module?
Contact with your

Repair the poor
trol module.
service.
AC-39

B: IN-VEHICLE SENSOR
TROUBLE SYMPTOM:
When turning the AUTO switch to ON, blower fan speed, outlet port and inlet port is not changed.
If the switch LED indicates that the sensor is malfunctioning, replace the A/C control module. The in-vehicle
sensor is built into the A/C control module and cannot be replaced as a single unit.
AC-40

AC-41

C: EVAPORATOR SENSOR
WIRING DIAGRAM:
EVAPORATION
THERMO
SWITCH
B7
A: B282
B256
1 2
B: B283
B17
B256
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
HV0042
AC-42

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 SIGNALS FOR EVAPORATOR SENSOR.
2)Measure the voltage between (B88) connector terminal and chassis ground.
CHECK OUTPUT SIGNALS FROM A/C CONTROL MODULE.
2)Pull out the A/C control module.
module connector terminals.
(B283) No. 7 (+) No. 17 ()
A/C CONTROL MODULE AND EVAPORATOR SENSOR.
module.
A/C control module and evaporator sensor.
(B256) No. 2 (B283) No. 7
A/C CONTROL MODULE AND EVAPORATOR SENSOR.
A/C control module and evaporator sensor.
(B256) No. 1 (B283) No. 17
CHECK POOR CONTACT.
Check
Is the resistance approx. 3.3
k at 20C (68F)?
Yes
Go to step 2.
No
Replace the evaporator sensor.
Go to step 3.
Replace the evaporator sensor.
Go to step 4.
Go to step 6.

?
Go to step 5.
Repair the open

circuit in harness
evaporator sensor.

?
Go to step 6.
Repair the open

circuit in harness
evaporator sensor.

control module?
Repair the poor

Contact with your
trol module.
service.
AC-43

D: SUNLOAD SENSOR
TROUBLE SYMPTOM:
Sensor identified that sunlight is at maximum. Then, A/C system is controlled to COOL side.
Sensor identified that sunlight is at minimum. Then, A/C system is controlled to HOT side.
NOTE:
When the sunload sensor is checked indoors or in the shade, open circuit might be indicated. Always check
the sunload sensor at a place where sun shines directly on it.
WIRING DIAGRAM:
SUNLOAD
SENSOR
A: B282
i51
1 2
B: B283
B16
B17
i51
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
HV0043
AC-44

Step
CHECK SUNLOAD SENSOR.
2)Remove the sunload sensor. <Ref. to AC-41,
INSTALLATION, Sun-load Sensor (Auto A/C
Model).>
3)Measure the resistance between sunload
sensor terminals.
Terminals:
No. 2 No. 1
CHECK SUNLOAD SENSOR.
Make sure that there is no resistance in the
reverse side terminals.
Terminals:
No. 1 No. 2
CHECK INPUT VOLTAGE TO SUNLOAD
SENSOR.
2)Measure the input voltage to sunload sensor.
(i51) No. 2 (+) No. 1 ()
A/C CONTROL MODULE AND SUNLOAD
SENSOR.
module.
A/C control module and sunload sensor.
(i51) No. 2 (B283) No. 16
A/C CONTROL MODULE AND SUNLOAD
SENSOR.
A/C control module and sunload sensor.
(i51) No. 1 (B283) No. 17
CHECK POOR CONTACT.
Check
?
Yes
Go to step 2.
No
Replace the sunload sensor.

M?
Go to step 3.
Replace the sunload sensor.
Go to step 6.
Go to step 4.

?
Go to step 5.
Repair the open

circuit in harness
sunload sensor.

?
Go to step 6.
Repair the open

circuit in harness
sunload sensor.

control module?
Repair the poor

Contact with your
trol module.
service.
AC-45

9. Symptom Related Diagnostic
Condenser fan does not operate

during A/C operation.
Compartment temperature does not quickly

respond to the set value.
Compartment temperature is higher than

or lower than the set value.
Compartment temperature does not decrease

(No cool air is discharged).
Air outlet cannot be switched.
A/C does not change from

"Fresh" to "Recirc" or vise versa.
Blower motor does not rotate or

rotates erroneously.
Illumination does not dim at night.
Burned-out fuse.
Component parts
A/C system fails to operate when

IG SW is turned "ON" .
Symptom
Compartment temperature does not increase

(No hot air is discharged).
A: GENERAL DIAGNOSTICS TABLE
Fuses (M/B No. 5, F/B No. 17)

Poor connector contacts
Ground
A/C control module
Air mix door actuator and potentiometer (including
links)
Mode door actuator and potentiometer (including
links)
Intake door actuator and potentiometer (including
links)
Blower fan motor
Blower fan relay
A/C relay
Magnet clutch
Radiator fan motors (Main and sub)
Radiator fan relays (Main and sub)
Sensors (In-vehicle, ambient, water temperature,
evaporator, sunload, etc.)
In-vehicle sensor aspirator duct
HV0044
AC-46
AIRBAG SYSTEM
AB
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Page
Airbag Connector ........................................................................................8
Inspection Locations After a Collision .......................................................10
Driver's Airbag Module ..............................................................................12
Passenger's Airbag Module ......................................................................13
Side Airbag Module...................................................................................14
Airbag Control Module ..............................................................................15
Side Airbag Sensor ...................................................................................16
Roll Connector ..........................................................................................17
Front Sub Sensor ......................................................................................18
Disposal of Airbag Module (Deploying While Installed in Vehicle)............19
Disposal of Airbag Module (Deploying After Removal from Vehicle) ........23
GENERAL DESCRIPTION
AIRBAG SYSTEM
A: COMPONENT
1. SRS AIRBAG
(1)
(4)
T2
(2)
(3)
T2
(11)
(2)
(12)
T1
(11)
(10)
(6)
(5)
T3
T4
(13)
(9)
(7)
T2
(8)
RE0031
(1)
Combination switch ASSY with roll

connector
(2)
TORX bolt T30

Airbag module ASSY (Driver)
Airbag module ASSY (Passenger)
Airbag control module
(3)
(4)
(5)
(6)
TORX bolt T40
(7)
(8)
(9)
Side airbag sensor

Side airbag harness
Side airbag module
(10)
(11)
(12)
(13)
Airbag main harness

Front sub sensor harness
Front sub sensor
TORX bolt T30
AB-2

T1: 7.4 (0.75, 5.4)
T2: 10 (1.0, 7.2)
T3: 20 (2.0, 14.5)
T4: 25 (2.5, 18.1)
GENERAL DESCRIPTION
AIRBAG SYSTEM
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.
When checking, use a test harness. Do not directly apply the tester probe to any connector terminal of the airbag.
G5M0293
G5M0292
If sensors, airbag module, airbag control module,

pretensioner, and harness are deformed or damaged, replace them with new genuine parts.
G5M0291
When checking the system, be sure to use a digital circuit tester.

Use of an analog circuit tester may cause the airbag to activate erroneously.
G5M0294
Do not check continuity of either of the airbag

modules for driver, passenger or side, or pretensioner.
G5M0302
AB-3
GENERAL DESCRIPTION
AIRBAG SYSTEM
Do not drop the airbag modulator parts, subject

them to high temperature over 93C (199F), or let
water, oil, or grease get on them; otherwise, the internal parts may be damaged and reliability greatly
lowered.
Install the wire harness securely with the specified clips to avoid interference or tangled up with
other parts.
G5M0297
Do not allow water or oil to come in contact with

the connector terminals. Do not touch the connector terminals.
G5M0295
If any damage, opening, or rust is found on the

airbag system wire harness, do not attempt to repair using soldering equipment. Be sure to replace
the faulty harness with a new genuine part.
G5M0298
Either of the airbag modules for driver, passenger or side, or pretensioner must not be disassembled.
G5M0299
G5M0296
AB-4
GENERAL DESCRIPTION
AIRBAG SYSTEM
The removed front seat with the airbag module

must be kept at least 200 mm (8 in) away from walls
and other objects.
When painting or performing sheet metal work

on the side of the vehicle, including the side sill,
center pillar, and front and rear doors, remove the
side airbag sensors and wire harness of the airbag
system.
B5M1072A
Do not use the airbag or pretensioner parts from

other vehicles. Always replace defective parts with
new parts.
Never re-use a deployed airbag or 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 the
airbag system.
G5M0310
When storing a removed airbag module, do not

place any objects on it or pile airbag modules on
top of each other. If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object, a serious accident may
result.
AB-5
GENERAL DESCRIPTION
AIRBAG SYSTEM
G5M0604
AB-6
GENERAL DESCRIPTION
AIRBAG SYSTEM
C: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME
REMARKS
Used for removal/installation of drivers airbag module.
Used for removal/installation of airbag control module.
Used for removal of side airbag sensor.
TORX T30
TORX T40 (Tamper resistant type)
TORX T30 (Tamper resistant type)
AB-7
AIRBAG CONNECTOR
AIRBAG SYSTEM
2. Airbag Connector
2. DRIVER'S AIRBAG, PASSENGER'S AIRBAG AND SIDE AIRBAG
A: OPERATION
1. POWER SUPPLY
1) How to disconnect:
(1) Move the slide lock (A) in the direction of the
arrow.
(2) Pull the female connector in the direction of
the arrow with slide lock (A) moved.
(1) Push the lock arm (A).
(2) With the lock arm (A) pushed in, move the
slide lock (B) in the direction of the arrow.
B5M1153A
(3) With the slide lock (B) pulled, remove the

lock arm (A) to its original position, and then pull
in the direction of the arrow and separate the
connector.
RE0012
CAUTION:
When pulling, 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.
CAUTION:
B5M1154
RE0013
CAUTION:
Be sure to insert the connector in until it locks.
Then pull on it gently to make sure that it is
locked.
2) How to connect:
Holding the connector, and push it in carefully until
a connecting sound is heard.
CAUTION:
locked.
B5M1155
AB-8
AIRBAG CONNECTOR
AIRBAG SYSTEM
3. FRONT SUB-SENSOR AND SIDE AIRBAG SENSOR
4. PRETENSIONER
(1) Holding outer part (A), pull it in the direction
of the arrow.
CAUTION:
arrow.
(2) Pull the connector (B) in the direction of the
arrow with slide lock (A) moved.
RE0016
RE0014
2) How to connect:
CAUTION:
Outer (A) moves back, and so do not put your
hand on the outer part.
Be sure to insert the connector in until it
locks. Then pull on it gently to make sure that it
is locked.
CAUTION:
2) How to connect:
RE0017
RE0015
CAUTION:
locks.
locked.
AB-9
INSPECTION LOCATIONS AFTER A COLLISION

AIRBAG SYSTEM
3. Inspection Locations After a

Collision
3. AIRBAG MODULE (SIDE)
If the vehicle is involved in a collision on any side,

even if it is a slight collision, be sure to check the
following system parts.
Check for the following, and replace damaged

parts with new parts.
Front seat is damaged or deformed.
Harness and/or connector is cracked, deformed
or open.
Lead wire is exposed.
1. AIRBAG MODULE (DRIVER)
4. AIRBAG CONTROL MODULE
1) Check for the following, and replace damaged

Airbag module is cracked or deformed.
or open. Lead wire is exposed.
The module surface is fouled with grease, oil,
water or cleaning solvent.
2) When installing a new driver's airbag module,
check the following. If necessary, install a new airbag module and steering wheel.
The steering wheel is in the way, making it difficult to install the airbag module.
The clearance between the driver's airbag module and steering wheel is not constant.
The steering wheel deformation in axial and radial directions exceed limits.

Control module is cracked or deformed.
Mounting bracket is cracked or deformed.
Connector is scratched or deformed.
Airbag is deployed.
Side airbag is deployed.
A: INSPECTION
5. FRONT SUB SENSOR

If the front section of vehicle as shown in the figure
is damaged:
Specifications:
Height deflection A
Less than 6 mm (0.24 in)
O.D. deflection L
Less than 17 mm (0.67 in)
G5M0311

Front sub sensor is cracked or deformed.
Connector is scratched or cracked.
Airbag is deployed.
6. FRONT SUB SENSOR HARNESS

B5M0096A
2. AIRBAG MODULE (PASSENGER)

Airbag module is cracked or deformed.
or open. Lead wire is exposed.

Harness is open, lead wire is exposed, and corrugated tube is noticeably cracked.
AB-10

AIRBAG SYSTEM
7. SIDE AIRBAG SENSOR
8. SIDE AIRBAG SENSOR HARNESS
If the side section of vehicle as shown in the figure

is damaged:

9. MAIN HARNESS
B5M0514
10.ROLL CONNECTOR

Side airbag sensor is cracked or deformed.
Side airbag is deployed. (operating side)

Combination switch or steering roll connector is
cracked or deformed.
11.STEERING SHAFT
Check for the following, and replace damaged parts with new parts.
Overall length of steering column should be within specifications.
Specifications:
Overall length L
825.71.5 mm (32.50.06 in)
RE0032
If necessary, replace it with a new part.
AB-11
DRIVER'S AIRBAG MODULE

AIRBAG SYSTEM
4. Driver's Airbag Module
C: INSPECTION
A: REMOVAL
CAUTION:
Refer to CAUTION in General Description before handing the airbag module. <Ref. to AB-3,
Airbag module, harness, connector, and mounting bracket are damaged.
CAUTION:
1) Position the front wheels straight ahead. (After
moving the vehicle more than 5 m (16 ft) with front
wheels positioned straight ahead, make sure that
the vehicle moves straight ahead).
3) Disconnect the ground cable from battery, and
wait for at least 20 seconds before starting work.
4) Using the TORX BIT T30, remove the two
TORX bolts on side of steering wheel.
H5M0662A
5) Disconnect the airbag connector on the back of

airbag module, and then remove the airbag module.
H5M0664
6) Refer to CAUTION for handling of a removed

airbag module. <Ref. to AB-3, CAUTION, General
Description.>
B: INSTALLATION
CAUTION:
Do not allow harness and connectors to interfere or get tangled up with other parts.
AB-12
PASSENGER'S AIRBAG MODULE

AIRBAG SYSTEM
5. Passenger's Airbag Module

A: REMOVAL
CAUTION:
4) Detach the airbag connector from support beam
bracket, and then disconnect the airbag connector.
5) Remove the three bolts, and then carefully remove the airbag module.
RE0002
6) Refer to CAUTION for handling of a removed

airbag module. <Ref. to AB-3, CAUTION, General
Description.>
B: INSTALLATION
CAUTION:
Do not allow harness and connectors to interfere or get tangled up with other parts.
C: INSPECTION
CAUTION:
Airbag module, harness, connector, and mounting bracket are damaged.
AB-13
SIDE AIRBAG MODULE

AIRBAG SYSTEM
6. Side Airbag Module

A: REMOVAL
CAUTION:
Refer to CAUTION in General Description
before handing the airbag module. <Ref. to AB3, CAUTION, General Description.>
The side airbag module cannot be detached
from the front seat assembly.
When replacing the side airbag module, replace the front seat assembly.
<Ref. to SE-6, REMOVAL, Front Seat.>
B: INSTALLATION
<Ref. to SE-6, INSTALLATION, Front Seat.>
C: INSPECTION
CAUTION:
Front seat is deformed or damaged.
or open.
Lead wire is exposed.
AB-14
AIRBAG CONTROL MODULE

AIRBAG SYSTEM
7. Airbag Control Module

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 genuine part.
Do not drop the airbag control module.
After removal, keep the airbag control module on a dry, clean surface away from moisture,
heat, and dust.
4) Disconnect the connector from airbag control
module.
5) Using the T40 TORX bit (Tamper resistant
type), remove the four TORX bolts in the order
RE0001
RE0001
B: INSTALLATION
CAUTION:
Use new TORX bolts during re-assembly.
C: INSPECTION
Control module, connector, and mounting bracket are damaged.
Airbag is deployed.
Side airbag is deployed.
AB-15
SIDE AIRBAG SENSOR

AIRBAG SYSTEM
8. Side Airbag Sensor

A: REMOVAL
3) Remove the outer belt (FRONT). <Ref. to SB-8,
OUTER BELT (FRONT), REMOVAL, Front Seat
Belt.>
4) Using the T30 TORX bit (Tamper resistant
type), remove the two TORX bolts.
5) Detach the side airbag sensor, and then disconnect the airbag connector.
RE0018
B: INSTALLATION
CAUTION:
Use new TORX bolts during re-assembly.
C: INSPECTION
Bracket connector for side airbag sensor is damaged.
AB-16
ROLL CONNECTOR
AIRBAG SYSTEM
9. Roll Connector
A: REMOVAL
3) Remove the driver's airbag module. <Ref. to AB12, Driver's Airbag Module.>
5) Remove the steering column cover.
6) Remove the screws, and then remove the roll
connector.
B5M1074
B: INSTALLATION
2) Before installing the steering wheel, be sure the
direction of roll connector is adjusted with steering.
<Ref. to AB-17, ADJUSTMENT, Roll Connector.>
C: INSPECTION
Combination switch and roll connector is cracked
or deformed.
D: ADJUSTMENT
1) Check that the front wheels are positioned in
2) Turn the roll connector pin (A) clockwise until it
stops.
3) Turn the roll connector pin (A) counterclockwise
approx. 2.65 turns until marks are aligned.
H5M0663B
AB-17
FRONT SUB SENSOR

AIRBAG SYSTEM
10.Front Sub Sensor

A: REMOVAL
3) Remove the front bumper. <Ref. to EI-22, REMOVAL, Front Bumper.>
4) Loosen the two bolts to remove the sensor cover.
RE0019
5) Remove the bolt, and then detach the front sub

sensor.
6) Disconnect the connector from front sub sensor.
RE0020
B: INSTALLATION
C: INSPECTION
Front sub sensor, mounting bracket, and connector are damaged.
AB-18
DISPOSAL OF AIRBAG MODULE (DEPLOYING WHILE INSTALLED IN VEHICLE)

AIRBAG SYSTEM
11.Disposal of Airbag Module

(Deploying While Installed in
Vehicle)
5) Short the terminal to alligator clip furnished as

deployment tool (A).
6) Connect the deployment tool and adapter A (deployment) (B).
A: OPERATION
CAUTION:
The deployment tool should be kept shorted
until just before deployment of the airbag module.
CAUTION:
Do not discard an undeployed airbag module
because it may cause serious personal injury
when accidentally deployed.
As a rule, the airbag module should be deployed while still installed in the vehicle. Do not
remove it unless necessary.
Deployment of the airbag module should be
done on a flat place free from any possible danger. Avoid deploying outdoors during rainy or
windy weather.
Deploying the airbag module causes a high
explosive noise, be sure to warn people in the
area, and do not allow anyone within a 5 m (16
ft) radius of the disposal site.
Some smoke will be emitted from deployment
of the airbag module. Therefore, it must be deployed in a well-ventilated place with no fire
alarms nearby.
Wear gloves, goggles, and earplugs during
this operation. Wash your hands afterwards.
After deployment, the airbag module will be
especially hot. Leave it unattended for 40 minutes, and then discard it.
Do not let water get on the deployed airbag
module.
Wrap the deployed airbag module in an airtight vinyl bag, and discard it.
If circumstances do not permit airbag module
deployment, contact a SUBARU dealer.
S5M0309B
(A) Deployment tool: (Part No. 98299PA030)

(B) Adapter A (deployment): (Part No.
98299FC030)
7) Connect the adapter A (deployment) connector

(2D) to airbag connector (AB3).
S5M0310A

3) Remove the lower cover.
4) Disconnect the airbag connector (AB3) and
(AB8) below steering column.
8) Extend the deployment tool to the limit, and

make sure that the vehicle is empty. Close all windows, sunroof, and rear gate completely.
B5M1068
G5M0312
9) Move the battery at least 5 m (16 ft) from vehicle,

and secure the nearby area. Connect the deployment tool alligator clip to the battery negative ()
terminal.
AB-19

AIRBAG SYSTEM
10) Connect the other cable of the deployment tool

to the battery positive (+) terminal. Then, deploy the
airbag module.

CAUTION:
G5M0531
CAUTION:
module.
11) Remove the airbag module. <Ref. to AB-12,
Driver's Airbag Module.>
12) Wrap the deployed airbag module in an airtight
vinyl bag, and discard it.
S5M0309B

98299FC030)

(2D) to airbag connector (AB10).
S5M0311A
G5M0532

3) Remove the glove box.
4) Disconnect the airbag connectors (AB9) and
(AB10).

B5M1068

terminal.
AB-20

AIRBAG SYSTEM

airbag module.

CAUTION:
G5M0531
CAUTION:
module.
Passenger's Airbag Module.>
S5M0309B

98299FC030)

(2D) to side airbag module connector (yellow).
CAUTION:
Do not put any objects on the front seat.
G5M0532
S5M0313A

3) Disconnect the side airbag module connector
(yellow) under the front seat cushion.
4) Adjust both the front seat and front seat backrest
to center positions.

B5M1068

terminal.
AB-21

AIRBAG SYSTEM

airbag module.
G5M0531
CAUTION:
module.
11) Remove the side airbag module.
G5M0532
AB-22
DISPOSAL OF AIRBAG MODULE (DEPLOYING AFTER REMOVAL FROM VEHICLE)

AIRBAG SYSTEM
12.Disposal of Airbag Module

(Deploying After Removal
from Vehicle)
5) Bundle three wire automotive harnesses [each

with a sectional area of 1.25 mm2 (0.00194 sq in) or
more], and bind them twofold around the airbag
module stay.
A: OPERATION
CAUTION:
Do not discard an undeployed airbag module
because it may cause serious personal injury
As a rule, the airbag module should be deployed while still installed in the vehicle. Do not
remove it unless necessary.
Deployment of the airbag module should be
done on a flat place free from any possible danger. Avoid deploying outdoors during rainy or
windy weather.
Do not damage the airbag module or drop it.
Deploying the airbag module causes a high
explosive noise, be sure to warn people in the
area, and do not allow anyone within a 5 m (16
Some smoke will be emitted from deployment
of the airbag module. Therefore, it must be deployed in a well-ventilated place with no fire
alarms nearby.
Wear gloves, goggles, and earplugs during
this operation. Wash your hands afterwards.
module.
Wrap the deployed airbag module in an airtight vinyl bag, and discard it.
If circumstances do not permit airbag module
deployment, contact a SUBARU dealer.
H5M0736

CAUTION:
S5M0309B

98299FC030)

Driver's Airbag Module.>
4) Install the removed bolts to airbag module.

(2D) to airbag module.
9) Install the airbag module with pad side facing upward on a wheel with tire.
G5M0535
H5M0735
AB-23

AIRBAG SYSTEM
10) Put three tires without a wheel on the tire installed with the airbag module. Put on an additional
tire with a wheel, and then fasten them tight with a
rope.

G5M0532
G5M0536
11) 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.

Passenger's Airbag Module.>
more], and route them through the airbag module
bracket (A). Then, twist them for added strength.
G5M0537

airbag module.
S5M0312A

G5M0531
CAUTION:
module.
AB-24

AIRBAG SYSTEM

CAUTION:
10) 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.
G5M0537

airbag module.
S5M0309B

98299FC030)

8) Install the airbag module with pad side facing upward on 14 inch or greater size wheel with tire.
G5M0531
G5M0613
9) Put three tires without a wheel 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.
CAUTION:
module.
G5M0532
G5M0536
AB-25

AIRBAG SYSTEM

3) Remove the front seat. <Ref. to SE-6, REMOVAL, Front Seat.>
4) Remove the side airbag module. <Ref. to SE-6,
DISASSEMBLY, Front Seat.>
5) Install the nuts to side airbag module.
more], and bind them twofold around the airbag
module stay.
10) Install the side airbag module on 14 inch or

greater size tire without disk wheel.
S5M0317
11) Put two tires without a wheel (A) under the tire
installed with the side airbag module (B). Put on an
additional tire without disk wheel (C), and then put
a tire with a wheel (D) on top. Fasten them tight with
a rope.
S5M0316

CAUTION:
B5M0768A
12) Move the battery at least 5 m (16 ft) from the

vehicle, and secure the nearby area. Connect the
deployment tool alligator clip to the battery negative
() terminal.
S5M0309B
G5M0537

98299FC030)

AB-26

AIRBAG SYSTEM

airbag module.
G5M0531
CAUTION:
module.
G5M0532
AB-27

AIRBAG SYSTEM
AB-28
AB
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Page
A/B Control Module I/O Signal ..................................................................19
Airbag Connector ......................................................................................26
Airbag Warning Light Illumination Pattern.................................................28
Inspection Mode........................................................................................30
Airbag Warning Light Failure.....................................................................33
Diagnostic Chart with Trouble Code .........................................................40


A: PROCEDURE
1
Step
Check
READ DIAGNOSTIC TROUBLE CODE (DTC). Is the normal code being
<Ref. to AB-29, Read Diagnostic Trouble Code detected?
(DTC).>
READ DIAGNOSTIC TROUBLE CODE (DTC). Is the DTC being detected?
<Ref. to AB-29, Read Diagnostic Trouble Code
(DTC).>

Is the DTC being detected?
1)Judge the possible cause from List of Diagnostic Trouble Code <Ref. to AB-38, List of
Diagnostic Trouble Code (DTC).> .
2)Inspect using Diagnostic Chart with Trouble
Code. (DTC)
3)Repair the cause of the trouble.
AB-31, Clear Memory Mode.>
5)Perform the inspection mode. <Ref. to AB30, Inspection Mode.>
6)Read any DTC again.
AB-2
Yes
No
Finish the diagno- Go to step 2.
sis.
Go to step 3.
Go to Airbag
Warning Light Failure.<Ref. to AB33, Airbag Warning Light Failure.>
Perform the proce- Finish the diagnodure 1) to 5) in
sis.
step 3.


A: CHECK
Customer's Name
Date Vehicle Brought In
Inspector's Name
Registration No.
Km
Vin No.
Miles
Odometer Reading
Date Problem Occurred
Weather
Registration Year
Fine
Cloudy
Vehicle Operation
Snowy
Other:
Level road
Uphill
Downhill
Rough road
Starting
Idling
Driving ( Constant Speed
Acceleration
Steering wheel turn
Other:
Others:
Deceleration
)
Details of Problem
Check Airbag Warning Light
Check DTC
C (F)
Temperature
Road Condition
Rainy
Remains ON
Normal Code
AB-3
Remains OFF
Trouble Code: (Code:
GENERAL DESCRIPTION
When checking, use a test harness. 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 fitted with a backup power
source. If the airbag system is serviced within 20
seconds after the ground cable is disconnected, it
may inflate.
G5M0293
G5M0292
If sensors, airbag module, airbag control module

pretensioner, and harness are deformed or damaged, replace them with new genuine parts.
Do not use the airbag system and pretensioners
on other vehicles. When replacing parts, be sure to
replace them with new parts.
G5M0294
G5M0291
When checking the system, be sure to use a digital circuit tester.

Use of an analog circuit tester may cause the airbag to activate erroneously.
AB-4
GENERAL DESCRIPTION
Do not drop the airbag modulator parts, subject

them to high temperature over 93C (199F), or let
water, oil, or grease get on them; otherwise, the internal parts may be damaged and reliability greatly
lowered.
Install the wire harness securely with the specified clips to avoid interference or tangled up with
other parts.
G5M0297
Do not allow water or oil to come in contact with

the connector terminals. Do not touch the connector terminals.
G5M0295
If any damage, opening or rust is found on the

airbag system wire harness, do not attempt to repair using soldering equipment. Be sure to replace
the faulty harness with a new genuine part.
G5M0298
The airbag module (driver, passenger, and side,

pretensioner) must not be disassembled.
The airbag module cannot be used again once
inflated.
G5M0296
G5M0299
AB-5
GENERAL DESCRIPTION
After removal, keep the airbag module with the

pad facing upward on a dry, clean, and flat surface
away from heat and light sources, and moisture
and dust.

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.
G5M0301
Do not check continuity of the airbag module

(driver, passenger, and side, pretensioner).
G5M0310
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.
G5M0302
The removed front seat with the airbag module

must be kept at least 200 mm (8 in) away from walls
and other objects.
B5M1072A

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.
AB-6
GENERAL DESCRIPTION
G5M0604
AB-7
GENERAL DESCRIPTION
Do not discard undeployed airbag modules.

They could easily cause a serious accident if accidentally deployed.
Do not damage the airbag module or drop it.
B: INSPECTION
Before diagnosing, check the following items that
might be related to the engine problem:
1. BATTERY
electrolyte.
AB-8
GENERAL DESCRIPTION
C: PREPARATION TOOL
CAUTION:
Be sure to use specified test harness M, F, G, H, L and I or I2 when measuring the voltage, resistance,
etc. of AIRBAG system component parts.
1. TEST HARNESS M
PN 98299FE020
4M
3M
1M
2M
5M
2 1
1
2
3
4
5
6
1
2
4M
1M
L
Y
1
2
Lg
Lg
3M
2
1
6 5 4 3
1 2
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 15 16
100
GW
Y
5M
8
18
5
16
7
6
9
1
11
10
4
2
1
2
3
4
5
6
2M
1
2
3 4 5 6
RE0021
AB-9
GENERAL DESCRIPTION
2. TEST HARNESS F
S5M0247A
AB-10
GENERAL DESCRIPTION
3. TEST HARNESS G
S5M0248A
AB-11
GENERAL DESCRIPTION
4. TEST HARNESS H
B5M0553B
AB-12
GENERAL DESCRIPTION
5. TEST HARNESS L
PN 98299FE000
2L
3L
1 2
1
2
1L
2L
3L
5
6
3
4
1L
1
2
1
2
3 4 5 6
2 1
RE0063
AB-13
GENERAL DESCRIPTION
6. TEST HARNESS I
S5M0340A
AB-14
GENERAL DESCRIPTION
7. TEST HARNESS I2
B5M0927A
AB-15
GENERAL DESCRIPTION
8. AIRBAG RESISTOR
The airbag resistor is used during diagnostics. The airbag resistor has the same resistance as the airbag
module and thus provides safety when used instead of the airbag module. It also makes it possible to finish,
diagnostics in less time.
B5M0114A
AB-16


A: LOCATION
1. LHD MODEL
B5M1162A
Connector
No.
Pole
Color
Male/Female
(AB1)
(AB2)
(AB3)
6
Yellow
Male
2
Yellow
Male
2
Yellow
Male
(AB6)
(AB7)
(AB8)
(AB9)
28
2
2
2
Yellow Yellow Yellow Yellow
Female Female Female Female
Connector
(AB15) (AB16) (AB17) (AB18) (AB19)
No.
Pole
2
2
12
12
2
Color
Blue
Male/Female Female Female Female Female Female
(AB10)
(AB11)
2
Yellow
Male
2
Blue
Male
(AB23)
(AB12)
(AB13)
2
2
Blue
Yellow
Female Female
(AB14)
2
Blue
Male
(AB20)
(AB21)
(AB24)
(AB25)
(AB26)
2
Yellow
Male
2
4
2
Yellow Yellow Yellow
Female Female Female
2
Yellow
Male
2
4
Yellow Yellow
Female Female
AB-17
(AB28)

2. RHD MODEL
Front sub sensor (LH)
Front sub sensor (RH)
AB13
AB16
Front sub sensor harness(RH)

Front sub sensor harness(LH)
B31
Airbag control
module with
safety sensor
and electric sensor
Inflator
(Passenger)
Airbag main
harness
AB17
To body
harness
AB15
AB14
AB1
AB8
Roll connector
AB9
AB7
AB10
AB3
AB6
AB2
AB18
Inflator(Driver)
Side airbag
harness(RH)
Side airbag
harness(LH)
AB26
AB21
AB19 AB20
AB25 AB24
To seat belt
pretensioner(RH)
To seat belt
pretensioner(LH)
AB23
AB28
Inflator LH
(Side)
Side airbag
sensor(LH)
Inflator RH
(Side)
Side airbag
sensor(RH)
RE0023
Connector
No.
Pole
Color
Male/Female
Connector
No.
Pole
Color
Male/Female
(AB1)
(AB2)
(AB3)
6
Yellow
Male
2
Yellow
Male
2
Yellow
Male
(AB15)
(AB16)
(AB17)
2
Blue
Male
(AB6)
(AB7)
(AB8)
(AB9)
(AB10)
(AB13)
(AB14)
28
2
2
2
2
Yellow
Male
2
2
Yellow
Blue
Female Female
(AB18)
(AB23)
(AB19)
(AB20)
(AB21)
(AB24)
(AB25)
(AB26)
2
12
12
2
2
Yellow
Male
2
4
2
Yellow Yellow Yellow
Female Female Female
2
Yellow
Male
2
4
Yellow Yellow
Female Female
AB-18
(AB28)
A/B CONTROL MODULE I/O SIGNAL

5. A/B Control Module I/O Signal

A: SCHEMATIC
AB-19

1. AIRBAG LHD MODEL
A:
A/B(L)-01
A/B(L)-01
i10
B:
i11
GB
GY
RW
FB-23
FB-22
FB-17
FB-36
F/B FUSE NO. 13 F/B FUSE NO. 11 F/B FUSE NO. 6 F/B FUSE NO. 18
(IG)
(IG)
(IG)
(IG)
COMBINATION
METER
AIRBAG
INDICATOR
LIGHT
A7 GOr
GOr
B18 GR
GR
i1
AIRBAG
CIRCUIT
A6
CHECK
CONNECTOR
GB 7
23 RW
B36
8
GR
24
i2
GR
B79
B37
DIAGNOSIS
CONNECTOR
L
1
TB :TURBO ENGINE MODEL
W
B82
DIAGNOSIS
TERMINAL
BR
BR
NA
TB
N2
BR
B81
B209
SMJ
GR
GY
BR
B31
5
AB1
E3
NA
E3
B22
2
F60
16
16
BR
F76
A:
B31 (YELLOW)
B82 (BLACK)
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
1
2
3 4 5 6
B36 (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
B22 (BROWN)
F60
2 3
9 10
REF. TO GND-02
B79 (GRAY)
1
8
AB6
GE
19
GR
GY
6
BR
TB
4 5
11 12
6 7
13 14
1
5
9
13
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
2
6
10
14
3
7
11
15
B:
(BROWN)
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
4
8
12
16
i11
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
GL86-21A
GL86-21A
AB-20
1
2
A/B(L)-02
FRONT SUB SENSOR RH
A/B(L)-02
FRONT SUB SENSOR LH
2
1
W
G
G
WR
AB13
AB16
1
2
AB12
26
15
LY
Br
20 G
9 WR
LY
Br
AB11
BW 27
28
B
YL
YB
YL
YB
YR
YG
10
11
14
13
AB6
YL
YB
1
2
AB8
AB3
AB7 (YELLOW)
AB13 (YELLOW)
(YELLOW)
AB16 (YELLOW)
1 2
BW
1
2
INFLATOR (DRIVER SIDE)
AB9 (YELLOW)
GB-4
AB10
AB2
AB8
GB-5
AB9
2
1
AB7
YL
YB
YR
YG
STEERING
ROLL CONNECTOR
INFLATOR (PASSENGER SIDE)

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
AB11 (YELLOW)
1 2
GL86-21B
AB-21
INFLATOR
(SIDE LH)
AB19 (YELLOW)
AB23 (YELLOW)
AB21 (YELLOW)
AB28 (YELLOW)
AB24 (YELLOW)
AB26 (YELLOW)
2
3
5
6
YG
YB
2
1
YG
YB
YR
YL
AB20
ELR WITH
PRETENSIONER LH
AB26
AB24
1
2
1
2
3
4
AB28
AB18
1
2
AB23
1
2
3
4
1
2
AB19
1
2
YR
YL
Gr
Y
Lg
Br
Gr
Y
Lg
Br
W
L
G
B
W
L
G
B
YG
YB
YR
YL
YR
YL
AB21
12
10
9
7
AB17
YG
YB
2
1
5
6
7
9
10
12
A/B(L)-03
A/B(L)-03
AB25
SIDE AIRBAG
SENSOR LH
AB17 (YELLOW)
SIDE AIRBAG
SENSOR RH
ELR WITH
PRETENSIONER RH
INFLATOR
(SIDE RH)
AB18 (YELLOW)
1 2 3 4 5 6
1 2 3 4 5 6
7 8 9 10 11 12
7 8 9 10 11 12
1 2
GL86-21C
AB-22

2. AIRBAG RHD MODEL
FB-17
F/B FUSE NO. 18
(IG)
GW
Or
GB
GW
MT
B36
B:
4
i3
COMBINATION
METER
i11
GW
GW 22
B38
i10
A/B(R)-01
FB-23
F/B FUSE NO. 6
(IG)
GW
AT
AT
i1
MT
A7 GW
AIRBAG
INDICATOR
LIGHT
CHECK
CONNECTOR
GB 7
AIRBAG
CIRCUIT
B18 LgR
A6
LgR 10
LgR
21
i2
LgR
B79
B37
DIAGNOSIS
CONNECTOR
L
1
V
2
B82
DIAGNOSIS
TERMINAL
B
B
B31
3
Or
LgR
R
6
B81
Lg
RY
Or
19
AB6
LR
AB1
A:
FB-22
F/B FUSE NO. 11
(IG)
R
A/B(R)-01

FB-36
F/B FUSE NO. 13
(IG)
REF. TO GND-07
A:
B31 (YELLOW)
B82 (BLACK)
i10
(GREEN)
B79 (GRAY)
1 2 3 4 5 6 7 8 9 10
1
8
1
2
3 4 5 6
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
B:
i11
2 3
9 10
4 5
11 12
i1
(BLACK)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
6 7
13 14
(GREEN)
i3
(BLACK)
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
i2
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
GR86-21A
AB-23
1
2
A/B(R)-02
FRONT SUB SENSOR RH
A/B(R)-02
FRONT SUB SENSOR LH
1
2
AB13
G
W
G
W
L
Br
AB16
2
1
AB15
20
9
26
15
G
W
L
Br
G
W
AB14
27
BY
28
B
YL
YB
YL
YB
YR
YG
10
11
14
13
AB6
YL
YB
1
2
AB8
AB3
AB7 (YELLOW)
AB13 (YELLOW)
AB8 (YELLOW)
AB16 (YELLOW)
AB14 (YELLOW)
BY
1
2
1 2
GB-4
AB10
AB2
AB9 (YELLOW)
GB-5
AB9
2
1
AB7
YL
YB
YR
YG
STEERING
ROLL CONNECTOR

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
1 2
GR86-21B
AB-24
INFLATOR
(SIDE LH)
AB19 (YELLOW)
AB23 (YELLOW)
AB21 (YELLOW)
AB28 (YELLOW)
AB24 (YELLOW)
AB26 (YELLOW)
2
3
YR
YL
A/B(R)-03
YR
YL
AB18
AB26
1
2
AB24
1
2
1
2
3
4
AB28
AB20
ELR WITH
PRETENSIONER LH
5
6
2
1
YG
YB
W
L
G
B
AB23
1
2
3
4
1
2
AB19
1
2
YG
YB
W
L
G
B
W
L
G
B
W
L
G
B
YG
YB
YR
YL
AB21
12
10
9
7
AB17
YG
YB
2
1
5
6
7
9
10
12
YR
YL
A/B(R)-03
AB25
SIDE AIRBAG
SENSOR LH
AB17 (YELLOW)
ELR WITH
PRETENSIONER RH
SIDE AIRBAG
SENSOR RH
INFLATOR
(SIDE RH)
AB18 (YELLOW)
1 2 3 4 5 6
1 2 3 4 5 6
7 8 9 10 11 12
7 8 9 10 11 12
1 2
GR86-21C
AB-25
AIRBAG CONNECTOR
6. Airbag Connector
2. DRIVER'S AIRBAG, PASSENGER'S AIRBAG, AND SIDE AIRBAG
A: OPERATION
1. POWER SUPPLY
arrow.
(2) Pull the female connector in the direction of
the arrow with slide lock (A) moved.
(1) Push the lock arm (A).
(2) With lock arm (A) pushed in, move the slide
lock (B) in the direction of the arrow.
B5M1153A
(3) With slide lock (B) pulled, remove the lock

arm (A) to its original position, and then pull in
the direction of the arrow and separate the connector.
RE0012
CAUTION:
2) How to connect:
CAUTION:
B5M1154
RE0013
CAUTION:
locked.
2) How to connect:
CAUTION:
locked.
B5M1155
AB-26
AIRBAG CONNECTOR
3. FRONT SUB-SENSOR, SIDE AIRBAG

SENSOR
4. PRETENSIONER
(1) Holding the outer part (A), pull it in the direction of the arrow.
CAUTION:
arrow.
(2) Pull the connector (B) in the direction of the
arrow with slide lock (A) moved.
RE0016
RE0014
2) How to connect:
CAUTION:
Outer (A) moves back, and so do not put your
hand on the outer part.
locks. Then pull on it gently to make sure that it
is locked.
CAUTION:
2) How to connect:
Holding connector (A), and push it in carefully until
RE0017
CAUTION:
locked.
RE0015
AB-27
AIRBAG WARNING LIGHT ILLUMINATION PATTERN

7. Airbag Warning Light Illumination Pattern

A: INSPECTION
Keep the ignition switch to ON, and confirm that the
airbag warning light remains off approx. 6 seconds
after being turned on.
B5M1096A
AB-28

8. Read Diagnostic Trouble

Code (DTC)
A: OPERATION
2) Connect the diagnosis terminal to diagnosis connector terminal No. 1 in the driver's seat lower cover area.
3) Read the DTC by identifying the way airbag

warning light flashes.
The airbag warning light flashes a code corresponding to the faulty parts.
The long segment (1.2 sec on) indicates a ten,
and the short segment (0.3 sec on) indicates a
one.
NOTE:
List of Diagnostic Trouble Code <Ref. to AB-38,
List of Diagnostic Trouble Code (DTC).>
Airbag Warning Light Failure <Ref. to AB-33,
Airbag Warning Light Failure.>
B5M0115D
B5M0117A
4) Turn the ignition switch to OFF, and disconnect

the diagnosis terminal from the diagnosis connector terminal No 1.
5) Wind tape around the diagnosis terminal and return it to its original position.
AB-29
INSPECTION MODE
9. Inspection Mode
A: OPERATION
Recreate the circumstance by referring to the conditions described in the checklist.
AB-30
CLEAR MEMORY MODE


A: OPERATION
2) Connect the diagnosis terminal (DIAG, terminal
A) to diagnosis connector terminal No. 1 in the
driver's seat lower cover area.
B5M0116D
3) While the warning light flashes, connect another

diagnosis terminal (DIAG, terminal B) to diagnosis connector terminal No.2.
4) Once the memory is erased, the warning light returns to the normal flash rate (0.6 sec on). The failure to recover the normal flash rate indicates that
trouble parts still remain. Having repaired such
parts, erase the memory again and confirm that the
normal flash rate has returned.
5) When the memory has been cleared, disconnect
the diagnosis terminal from the diagnosis connector.
6) Wind tape around the diagnosis terminal and return it to its original position.
AB-31
CLEAR MEMORY MODE

AB-32
AIRBAG WARNING LIGHT FAILURE

11.Airbag Warning Light Failure

A: AIRBAG WARNING LIGHT REMAINS ON.
DIAGNOSIS:
Airbag warning light unit is faulty.
Airbag control module to airbag warning light circuit is shorted or open.
Grounding circuit is faulty.
Airbag control module is faulty.
(AB1) and (B31) are not connected properly.
(AB6) is not connected properly to the airbag control module.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the
ground cable from battery, and wait 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 driver
and passenger seats for safety reasons.
AB-33

WIRING DIAGRAM:
IG SW
NO.13
A7
1 : LHD MODEL: 3
RHD MODEL: 1
A:
I10
B:
I12
BATTERY
A6
AIRBAG
AIRBAG
CIRCUIT INDICATOR
LIGHT
B31
AB1
AB6
B31
I12
AB6
I10
1
2
3 4 5 6
1 2 3
4 5 6
7 8 9 10 11 12 13 14
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
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
RE0024
Step
Check
CHECK POOR CONTACT IN CONNECTORS Is the poor contact in connec(AB1) AND (B31).
tors (AB1) and (B31)?
1)Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2)Remove the side sill cover. (Driver's side)
3)Confirm that firm contact is secured between
connectors (AB1) and (B31).
AB-34
Yes
No
Repair the body
Go to step 2.
harness or replace
the body harness
with airbag main
harness.

Step
CHECK AIRBAG WARNING LIGHT.
20 seconds.
2)Connect the connector (1M) in test harness
M to the body harness connector (B31).
3)Connect the battery ground cable and turn
the ignition switch to ON.
4)Connect two connectors, (3M) and (4M) in
test harness M.
CHECK BODY HARNESS.
Check the body harness.
Check
Is the airbag warning light
turned off?
Is the anything unusual to body Repair the body

harness?
harness.
NOTE:
After problem has been eliminated, disconnect
the connectors (3M) and (4M).
4
CHECK POOR CONTACT.

Confirm that firm contact is secured between
the airbag control module and the connector
(AB6). <Ref. to AB-15, Airbag Control Module.>

CHECK AIRBAG MAIN HARNESS.
1)Turn the ignition switch to OFF, disconnect turned off?
20 seconds.
2)Connect the connector (AB1) to (B31).
3)Disconnect the connectors (AB3) and (AB8).
4)Remove the glove box and disconnect the
connectors (AB10) and (AB9).
5)Disconnect the connector (AB6) from the airbag control module, and connect the connector
(1I) in test harness I or I2. <Ref. to AB-15, Airbag Control Module.>
7)Connect the connectors (4I) and (5I) in test
harness I or I2.
Yes
Go to step 4.
Is the poor contact in connector (AB6)?
NOTE:
After problem has been eliminated, disconnect
the connectors (4I) and (5I).
CHECK GROUNDING CIRCUIT.
1)Turn the ignition switch to OFF, disconnect ?
20 seconds.
2)Disconnect the connector (AB6) from the airbag control module.
3)Connect the connector (1I) in test harness I
or I2 to body harness connector (AB6).
(2I) in test harness I or I2 and the chassis
ground.
(2I) No. 9 Chassis ground:
AB-35
No
Go to step 3.
Replace the combination meter

printed circuit.
<Ref. to IDI-15,
Combination
Meter Assembly.>
Go to step 5.
Replace the body

harness with airbag main harness
or Replace the airbag control module. <Ref. to AB15, Airbag Control
Module.>
Go to step 6.
Replace the body
harness with airbag main harness.
Replace the airbag Repair the bodycontrol module.

grounding circuit.
<Ref. to AB-15,
Airbag Control
Module.>

B: AIRBAG WARNING LIGHT REMAINS OFF.

DIAGNOSIS:
Fuse No. 13 (in fuse box) is blown.
Body harness circuit is open.
Airbag warning light is faulty.
Airbag main harness is faulty.
CAUTION:
WIRING DIAGRAM:
IG SW
NO.13
A7
1 : LHD MODEL: 3
RHD MODEL: 1
I10
B:
I12
BATTERY
A6
A:
AIRBAG
AIRBAG
CIRCUIT INDICATOR
LIGHT
B31
AB1
AB6
B31
I12
AB6
I10
1
2
3 4 5 6
1 2 3
4 5 6
7 8 9 10 11 12 13 14
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
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
RE0024
AB-36

Step
Check
Do the warning lights not for
Turn the ignition switch to ON, and confirm that airbag turn on?
warning lights equipped in the combination
meter are turned on.
Yes
Go to step 2.
CHECK FUSE NO. 13 (IN MAIN FUSE BOX). Is the fuse No. 13 (in main fuse Replace the fuse
Remove the fuse No. 13 and perform visual
box) blown?
No. 13. If fuse No.
inspection.
13 blows again, go
to step 3.
CHECK AIRBAG WARNING LIGHT CIRCUIT Is the airbag warning light
Go to step 4.
(IN COMBINATION METER).
turned on?
20 seconds.
2)Disconnect the connector (AB1) from (B31).
Replace the airbag
1)Turn the ignition switch to OFF, disconnect turned on?
control module.
<Ref. to AB-15,
20 seconds.
Airbag Control
2)Connect the connector (AB1) to (B31).
Module.>
3)Disconnect the connector (AB6) from the airbag control module. <Ref. to AB-15, Airbag
Control Module.>
AB-37
No
Repair the combination meter
power supply.
<Ref. to IDI-4,
Combination
Meter System.>
Go to step 3.
Replace the airbag

warning light bulb
or combination
meter printed circuit. <Ref. to IDI15, Combination
Meter Assembly.>
Replace the body


A: LIST
DTC
Memory function
Airbag main harness circuit is open, shorted or
shorted to ground.
Airbag module harness (driver) circuit is open,
shorted or shorted to ground.
Roll connector circuit is open, shorted or shorted to
ground.
Driver's airbag module is faulty.
Airbag main harness circuit is open, shorted or
shorted to ground.
Airbag module harness (passenger) circuit is open,
shorted or shorted to ground.
Passenger's airbag module is faulty.
Airbag main harness circuit (driver) is shorted to
power supply.
Airbag module harness (driver) is shorted to power
supply.
Roll connector is shorted to power supply.
Airbag main harness circuit (passenger) is shorted
to power supply.
Airbag module harness (passenger) is shorted to
power supply.
11
Provided.
12
Provided.
15
Provided.
16
Provided.
21
Provided.
22
Provided.
Front airbag module and seat belt pretensioner (LH/

RH) are inflated.
23
Not provided.
(AB6), (AB17) and (AB18) are not connected properly to airbag control module.
24
Not provided.
25
Provided.
31
Provided.
32
Provided.

Airbag main harness circuit is open.
Fuse No. 11 (in joint box) is blown.
Front sub-sensor harness (RH) circuit is shorted.
Front sub-sensor harness (RH) circuit is open.
Front sub-sensor (RH) is faulty.
Front sub-sensor harness (LH) circuit is shorted.
Front sub-sensor harness (LH) circuit is open.
Front sub-sensor (LH) is faulty.
AB-38
Index No.
<Ref. to AB-40, DTC 11,

Diagnostic Chart with
Trouble Code.>

Trouble Code.>

Trouble Code.>

Trouble Code.>
Trouble Code.>
Trouble Code.>
Trouble Code.>
Trouble Code.>
Trouble Code.>
Trouble Code.>
Trouble Code.>

DTC
Memory function
41
Provided.
42
Provided.
45
Provided.
46
Provided.
51
Provided.
52
Provided.
53
Provided.
Side airbag sensor (RH) is faulty.
54
Provided.
Side airbag sensor (LH) is faulty.
55
Provided.
Side airbag module is inflated.
61
Provided.
62
Provided.
65
Provided.
66
Provided.
Index No.
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.

Trouble Code.>
Trouble Code.>
Trouble Code.>
Trouble Code.>
Trouble Code.>
Trouble Code.>
Trouble Code.>
Trouble Code.>
Trouble Code.>
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.
AB-39

Trouble Code.>

Trouble Code.>

Trouble Code.>

Trouble Code.>
DIAGNOSTIC CHART WITH TROUBLE CODE

13.Diagnostic Chart with Trouble Code

A: DTC 11
DIAGNOSIS:
Airbag main harness circuit is open, shorted or shorted to ground.
Airbag module harness (Driver) circuit is open, shorted or shorted to ground.
Roll connector circuit is open, shorted or shorted to ground.
CAUTION:
When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's
airbag module connectors for safety reasons.
WIRING DIAGRAM:
B5M1098
AB-40

Step
CHECK DRIVER'S AIRBAG MODULE.
20 seconds.
2)Remove the driver's airbag module. <Ref. to
AB-12, Driver's Airbag Module.>
3)Connect the connector (1F) in test harness F
to connector (AB7).
4)Connect the airbag resistor to connector (3F)
in test harness F.
CHECK ROLL CONNECTOR.
20 second.
2)Disconnect the test harness F from the connector (AB7).
3)Remove the lower cover panel, disconnect
the connector (AB3) from (AB8) and connect
the connector (1F) in test harness F to connector (AB8).
in test harness F.
the ground cable, and wait more than 20 seconds.
2)Disconnect the airbag resistor from the connector (3F) in test harness F.
3)Remove the glove box, <Ref. to AB-13, Passenger's Airbag Module.> and disconnect connectors (AB10) and (AB9).
(2I) in test harness I or I2 and the connector
(3F) in test harness F.
(2I) No. 1 (3F) No. 4:
(2I) No. 4 (3F) No. 3:
Measure the resistance of the connector (2I) in
test harness I or I2.
(2I) No. 1 No. 4:
Check
Does the airbag warning light
operate properly?
Yes
Replace the
driver's airbag
module. <Ref. to
AB-12, Driver's
Airbag Module.>
No
Go to step 2.

operate properly?
Replace the roll

connector. <Ref.
to AB-17, Roll
Connector.>
Go to step 3.

?
Go to step 4.
Replace the body


M?
Replace the airbag Replace the body

harness with aircontrol module.
bag main harness.
<Ref. to AB-15,
Airbag Control
Module.>
AB-41

B: DTC 12
DIAGNOSIS:
Airbag main harness circuit is open, shorted or shorted to ground.
Airbag module harness (Passenger) circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:
RE0064
AB-42

Step
CHECK PASSENGER'S AIRBAG MODULE.
20 seconds.
3)Disconnect the connector (AB10) from
(AB9).
to connector (AB9).
in test harness F.
20 seconds.
3)Remove the lower cover and disconnect the
connector (AB3) from (AB8).
(2I) No. 2 (3F) No. 3:
(2I) No. 5 (3F) No. 4:
(2I) No. 2 No. 5:
Check
operate properly?
Yes
No
Replace the pas- Go to step 2.
senger airbag
module. <Ref. to
AB-13, Passenger's Airbag Module.>

?
Go to step 3.

M?

harness with aircontrol module.
bag main harness.
<Ref. to AB-15,
Airbag Control
Module.>
AB-43
Replace the body


C: DTC 15
DIAGNOSIS:
Airbag main harness circuit (Driver) is shorted to the power supply.
Airbag module harness (Driver) is shorted to the power supply.
Roll connector is shorted to the power supply.
CAUTION:
WIRING DIAGRAM:
B5M1098
AB-44

Step
CHECK DRIVER'S AIRBAG MODULE.
20 seconds.
2)Remove the driver's airbag module. <Ref. to
AB-12, Driver's Airbag Module.>
3)Connect the connector (AB7) to connector
in test harness F.
CHECK ROLL CONNECTOR.
20 seconds.
2)Disconnect the test harness F from the connector (AB7).
3)Remove the lower cover panel and disconnect the connector (AB3) from (AB8).
to connector (AB8).
in test harness F.
20 seconds.
3)Remove the glove box, and disconnect the
connectors (AB10) and (AB9).
the ignition switch to ON. (engine OFF)
6)Measure the voltage between connector (2I)
in test harness I or I2 and the chassis ground.
(2I) No. 4 (+) Chassis ground ():
Check
operate properly?
Yes
Replace the
driver's airbag
module. <Ref. to
AB-12, Driver's
Airbag Module.>
No
Go to step 2.

operate properly?
Replace the roll

connector. <Ref.
to AB-17, Roll
Connector.>
Go to step 3.

control module.
harness with air<Ref. to AB-15,
bag main harness.
Airbag Control
Module.>
AB-45

D: DTC 16
DIAGNOSIS:
Airbag main harness circuit (Passenger) is shorted to the power supply.
Airbag module harness (Passenger) is shorted to the power supply.
CAUTION:
WIRING DIAGRAM:
RE0064
AB-46

Step
Check
CHECK PASSENGER'S AIRBAG MODULE. Does the airbag warning light
1)Turn the ignition switch to OFF, disconnect operate properly?
20 seconds.
3)Disconnect the connector (AB10) from (AB9)
to connector (AB9).
in test harness F.
20 seconds.
3)Remove the lower cover and disconnect the
connector (AB3) from (AB8).
Yes
No
Replace the pas- Go to step 2.
senger airbag
module. <Ref. to

control module.
harness with air<Ref. to AB-15,
bag main harness.
Airbag Control
Module.>
E: DTC 21
DIAGNOSIS:
CAUTION:
Step
Check
CHECK IF TROUBLE CODE 21 IS INDICAT- Is the airbag warning light DTC
ED.
21 indicated?
Read the DTC. <Ref. to AB-29, Read Diagnostic Trouble Code (DTC).>
AB-47
Yes
Replace the airbag
control module.
<Ref. to AB-15,
Airbag Control
Module.>
No
Perform clear
memory. <Ref. to
AB-31, Clear
Memory Mode.>

F: DTC 22
WIRING DIAGRAM:
RE0065
This code is indicated when the front airbag and the pretensioner are in operation.
Once this code is indicated, memory is not erasable; therefore replace the following parts.
Airbag control module. <Ref. to AB-15, Airbag Control Module.>
Driver's airbag module. <Ref. to AB-12, Driver's Airbag Module.>
Passenger's airbag module. <Ref. to AB-13, Passenger's Airbag Module.>
Front sub-sensor of both sides. <Ref. to AB-18, Front Sub Sensor.>
Front seat belt outer with pretensioner of both sides. <Ref. to SB-8, Front Seat Belt.>
AB-48

G: DTC 23
DIAGNOSIS:
(AB6), (AB17) and (AB18) are not connected properly to airbag control module.
CAUTION:
Step
CHECK POOR CONTACT IN CONECTORS
(AB6), (AB17) and (AB18).
20 seconds.
2)Disconnect the connectors (AB6), (AB17)
and (AB18) from the airbag control module.
<Ref. to AB-15, Airbag Control Module.>
Check
Check if rust or damage
appear on the harness connector and the control module connector.
CHECK POOR CONTACT IN CONECTORS

(AB6), (AB17) and (AB18).
1)Ensure that connectors are firmly reconnected.

operate properly?
AB-49
Yes
No
Replace the airbag Go to step 2.
control module.
<Ref. to AB-15,
Airbag Control
Module.> Replace
the body harness
with airbag main
harness.
Replace the body
harness with side
airbag harness.
Finish the diagno- Replace the airbag
sis.
control module.
<Ref. to AB-15,
Airbag Control
Module.>

H: DTC 24
DIAGNOSIS:
Fuse No, 11 (in joint box) is blown.
CAUTION:
WIRING DIAGRAM:
IG SW
B31
BATTERY
NO.11
AB1
1 : LHD MODEL: 1
RHD MODEL: 6
AB6
B31
AB1
AB6
1
2
3 4 5 6
2
1
6 5 4 3
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
RE0027
AB-50

Step
CHECK AIRBAG CONTROL MODULE.
20 seconds.
2)Disconnect the connector (AB6) from the airbag control module. <Ref. to AB-15, Airbag
Control Module.>
or I2 to connector (AB6).
in test harness I or I2 and chassis ground.
1)While checking control module, turn the ignition switch to OFF and disconnect the battery
ground cable. Wait more than 20 seconds
before operation.
2)Disconnect the airbag connector (AB1) from
the body harness (B31).
M to connector (AB1).
(5M) in test harness M and the connector (2I)
in test harness I or I2.
LHD MODEL:
(5M) No. 2 (2I) No. 3:
RHD MODEL:
(5M) No. 9 (2I) No. 3:
Measure the following resistance with the
above-mentioned condition maintained.
LHD MODEL:
(5M) No. 2 Chassis ground:
RHD MODEL:
CHECK FUSE No. 11 (IN JOINT BOX).
1)Confirm that the ignition switch is turned
OFF.
2)Remove the fuse No. 11 (in joint box) and
perform visual inspection.
Check
Yes
No
Is the voltage more than 10 V? Replace the airbag Go to step 2.
control module.
<Ref. to AB-15,
Airbag Control
Module.>

?
Go to step 3.
Replace the body


M?
Go to step 4.
Replace the body

Is the fuse No. 11 blown?
Replace the fuse Repair the body

No. 11. If fuse No. harness.
11 blows again,
repair the body
harness.
AB-51

I:
DTC 25
DIAGNOSIS:
CAUTION:
WIRING DIAGRAM:
IG SW
B31
BATTERY
NO.6
AB1
1 : LHD MODEL: 2
RHD MODEL: 5
AB6
B31
AB1
AB6
1
2
3 4 5 6
2
1
6 5 4 3
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
RE0028
AB-52

Step
CHECK AIRBAG CONTROL MODULE.
20 seconds.
2)Disconnect the connector (AB6) from airbag
control module. <Ref. to AB-15, Airbag Control
Module.>
4)Connect the battery ground cable, and turn
5)Measure the voltage between the connector
ground.
1) While checking control module, turn the ignition switch to OFF and disconnect the battery
ground cable. Wait more than 20 seconds
before operation.
2)Disconnect the airbag connector (AB1) from
the body harness (B31).
M to the airbag connector (AB1).
4)Measure the resistance between the connector (5M) in test harness M and the connector (2I) in test harness I or I2.
LHD MODEL:
(5M) No. 2 (2I) No. 6:
RHD MODEL:
(5M) No. 1 (2I) No. 6:
Measure the following resistance with the
above-metioned condition maintained.
LHD MODEL:
RHD MODEL:
CHECK FUSE NO. 6 (IN JOINT BOX).
1)Confirm that the ignition switch is turned
OFF.
2)Remove the No. 6 fuse (in joint box) and perform visual inspection.
Check
Yes
No
Is the voltage more than 10 V? Replace the airbag Go to step 2.
control module.
<Ref. to AB-15,
Airbag Control
Module.>

?
Go to step 3.
Replace the body


M?
Go to step 4.
Replace the body

Is the fuse No. 6 blown?
Replace the fuse Repair the body

No. 6. If fuse No. 6 harness.
is blown again,
repair the body
harness.
AB-53

J: DTC 31
DIAGNOSIS:
Front sub-sensor harness (RH) circuit is shorted.
Front sub-sensor harness (RH) circuit is open.
Front sub-sensor (RH) is faulty.
CAUTION:
WIRING DIAGRAM:
9
20
AB6
1
2
AB14
AB15
2
1
AB16
FRONT SUB SENSOR RH
AB14
AB16
AB6
1 2
1 2
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
RE0029
AB-54

Step
CHECK FRONT SUB-SENSOR (RH) AND
FRONT SUB-SENSOR HARNESS (RH).
20 seconds.
3)Measure the resistance of the connector (3I)
in test harness I or I2.
(3I) No. 2 No. 4:
CHECK FRONT SUB-SENSOR (RH) AND
ground.
CHECK AIRBAG MAIN HARNESS AND
1)Disconnect the connector (AB16) from the
front sub-sensor. <Ref. to AB-18, Front Sub
Sensor.>
2)Connect the connector (IH) in test harness H
to connector (AB16).
(3I) in test harness I or I2 and connector (3H)
in test harness H.
(3I) No. 2 (3H) No. 5:
(3I) No. 4 (3H) No. 6:
ground.
CHECK AIRBAG MAIN HARNESS
(AB14), and connect the connector (1F) in test
harness F to connector (AB14).
(3I) in test harness I or I2 and connector (3F) in
test harness F.
(3I) No. 2 (3F) No. 4:
(3I) No. 4 (3F) No. 3:
CHECK AIRBAG MAIN HARNESS
ground.
Check
Yes
No
Is the resistance between 750 Replace the airbag Go to step 2.
and 1 K?
control module.
<Ref. to AB-15,
Airbag Control
Module.>

M?

control module.
<Ref. to AB-15,
Airbag Control
Module.>

?
Go to step 4.
Go to step 5.

M?
Go to step 9.
Go to step 5.

?
Go to step 6.
Replace the body


M?
Go to step 7.
Replace the body

AB-55

10
Step
CHECK FRONT SUB-SENSOR HARNESS
(RH).
to the connector (AB15).
(3H) in test harness H and connector (3F) in
the test harness F.
(3F) No. 5 (3H) No. 5:
(3F) No. 6 (3H) No. 6:
(RH).
(3F) in test harness F and the chassis ground.
(3F) No. 5 Chassis ground:
CHECK FRONT SUB-SENSOR (RH).
1)Connect the connector (2H) in test harness
H to front sub-sensor (RH).
2)Measure the resistance of the connector
(3H) in test harness H.
(3H) No. 3 No. 4:
CHECK FRONT SUB-SENSOR (RH).
(3H) in test harness H and the chassis ground.
(3H) No. 3 Chassis ground:
Check
?
Yes
Go to step 8.
No
Replace the body
harness with front
sub-sensor harness (RH).

M?
Go to step 9.
Replace the body

harness with front
sub-sensor harness (RH).

and 1 K?

M?
AB-56
Replace the front

sub-sensor (RH).
<Ref. to AB-18,
Front Sub Sensor.>
Finish the diagno- Replace the front

sis.
sub-sensor (RH).
<Ref. to AB-18,
Front Sub Sensor.>

AB-57

K: DTC 32
DIAGNOSIS:
Front sub-sensor harness (LH) circuit is shorted.
Front sub-sensor harness (LH) circuit is open.
Front sub-sensor (LH) is faulty.
CAUTION:
WIRING DIAGRAM:
15
26
AB6
LHD
RHD
LHD
RHD
2
1
AB11
LHD
AB12
LHD
RHD
1
2
RHD
AB13
1 : LHD MODEL: 1
RHD MODEL: 2
2 : LHD MODEL: 2
RHD MODEL: 1
FRONT SUB SENSOR LH
AB11
AB13
AB6
1 2
1 2
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
RE0030
AB-58

Step
CHECK FRONT SUB-SENSOR (LH) AND
20 seconds.
2)Disconnect the connector (AB6) from the airbag control module, and connect connector
(1I) in the test harness I or I2 to connector
(AB6). <Ref. to AB-15, Airbag Control Module.>
3)Measure the resistance of the connector (3I)
in the test harness I or I2.
(3I) No. 1 No. 3:
CHECK FRONT SUB-SENSOR (LH) AND
ground.
FRONT SUB-SENSOR HARNESS (LH).
front sub-sensor. <Ref. to AB-18, Front Sub
Sensor.>
H to connector (AB13).
(3I) in test harness I or I2 and connector (3H)
in test harness H.
LHD MODEL:
(3I) No. 3 (3H) No. 6:
(3I) No. 1 (3H) No. 5:
RHD MODEL:
(3I) No. 3 (3H) No. 5:
(3I) No. 1 (3H) No. 6:
FRONT SUB-SENSOR HARNESS (LH).
ground.
harness F to (AB11).
test harness F.
(3I) No. 3 (3F) No. 3:
(3I) No. 1 (3F) No. 4:
Check
Yes
No
Is the resistance between 750 Replace the airbag Go to step 2.
and 1 K?
control module.
<Ref. to AB-15,
Airbag Control
Module.>

M?

control module.
<Ref. to AB-15,
Airbag Control
Module.>

?
Go to step 4.
Go to step 5.

M?
LHD MODEL:
Go to step 9.
RHD MODEL:
Finish the diagnosis.

?
Go to step 6.
LHD MODEL:
Go to step 5.
RHD MODEL:
Replace the front
sub-sensor (LH).
<Ref. to AB-18,
Front Sub Sensor.>
Replace the body
AB-59

10
Step
(3I) in the test harness I or I2 and the chassis
ground.
(LH).
to connector (AB12).
(3H) in test harness H and connector (3F) in
test harness F.
(3F) No. 5 (3H) No. 5:
(3F) No. 6 (3H) No. 6:
(LH).
CHECK FRONT SUB-SENSOR (LH).
H to front sub-sensor (LH).
2)Measure the resistance of the connector
(3H) in test harness H.
(3H) No. 3 No. 4:
CHECK FRONT SUB-SENSOR (LH).
(3H) in test harness H and the chassis ground.
Check
M?
Yes
Go to step 7.
No
Replace the body

?
Go to step 8.
Replace the body

harness with front
sub-sensor harness (LH).

M?
Go to step 9.
Replace the body

harness with front
sub-sensor harness (LH).

and 1 K?

M?
AB-60
Replace the front

sub-sensor (LH).
<Ref. to AB-18,
Front Sub Sensor.>
Finish the diagno- Replace the front

sis.
sub-sensor (LH).
<Ref. to AB-18,
Front Sub Sensor.>

AB-61

L: DTC 41
DIAGNOSIS:
Side airbag module (RH) is faulty.
CAUTION:
When inspecting the side airbag harness, disconnect the side airbag module connector and seat
belt pretensioner connector for the safety reasons.
WIRING DIAGRAM:
B5M1105
AB-62

Step
CHECK SIDE AIRBAG MODULE.
20 seconds.
seat belt pretensioner (RH). <Ref. to SB-8,
Front Seat Belt.>
in test harness F.
CHECK SIDE AIRBAG HARNESS (RH).
20 seconds.
2)Disconnect the airbag resistor from test harness F.
3)Disconnect the connector (AB18) from air
bag control module. <Ref. to AB-15, Airbag
Control Module.>
test harness F.
(3I) No. 7 (3F) No. 4:
(3I) No. 9 (3F) No. 3:
(3I) No. 7 No. 9:
Measure the resistance of the connector (3F)
in test harness F.
(3F) No. 3 No. 4:
ground.
Check
operate properly?
Yes
No
Replace the front Go to step 2.
seat with side
airbag module
(RH). <Ref. to SE6, Front Seat.>

?
Go to step 3.
Replace the body

harness with side
airbag harness.

M?
Go to step 4.
Replace the body

harness with side
airbag harness.
Is the resistance more 1 M?
Go to step 5.
Replace the body

harness with side
airbag harness.

M?
Go to step 6.
Replace the body

harness with side
airbag harness.

M?

control module.
harness with side
<Ref. to AB-15,
airbag harness.
Airbag Control
Module.>
AB-63

M: DTC 42
DIAGNOSIS:
Side airbag module (LH) is faulty.
CAUTION:
WIRING DIAGRAM:
B5M1106
AB-64

Step
20 seconds.
seat belt pretensioner (LH). <Ref. to SB-8,
Front Seat Belt.>
in test harness F.
CHECK SIDE AIRBAG HARNESS (LH).
1)Turn ignition switch to OFF, disconnect the
battery ground cable, and wait more than 20
seconds.
2)Disconnect the airbag resistor from the test
harness.
airbag control module. <Ref. to AB-15, Airbag
Control Module.>
test harness F.
(3I) No. 10 (3F) No. 3:
(3I) No. 12 (3F) No. 4:
(3I) No. 10 No. 12:
Measure the resistance of the connector (3F)
in test harness F.
(3F) No. 3 No. 4:
ground.
Check
operate properly?
Yes
No
seat with side
airbag module
(LH). <Ref. to SE6, Front Seat.>

?
Go to step 3.
Replace the body

harness with side
airbag harness.

M?
Go to step 4.
Replace the body

harness with side
airbag harness.

M?
Go to step 5.
Replace the body

harness with side
airbag harness.

M?
Go to step 6.
Replace the body

harness with side
airbag harness.

M?

control module.
harness with side
<Ref. to AB-15,
airbag harness.
Airbag Control
Module.>
AB-65

N: DTC 45
DIAGNOSIS:
Side airbag harness (RH) is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
B5M1105
AB-66

Step
Check
20 seconds.
Front Seat Belt.>
in test harness F.
20 seconds.
harness.
Control Module.>
AB-67
Yes
No
seat with side
airbag module
(RH). <Ref. to SE6, Front Seat.>

control module.
harness with side
<Ref. to AB-15,
airbag harness.
Airbag Control
Module.>

O: DTC 46
DIAGNOSIS:
Side airbag harness (LH) is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
B5M1106
AB-68

Step
Check
20 seconds.
Front Seat Belt.>
in test harness F.
20 seconds.
harness.
Control Module.>
AB-69
Yes
No
seat with side
airbag module
(LH). <Ref. to SE6, Front Seat.>

control module.
harness with side
<Ref. to AB-15,
airbag harness.
Airbag Control
Module.>

P: DTC 51
DIAGNOSIS:
CAUTION:
WIRING DIAGRAM:
B5M1105
AB-70

Step
20 seconds.
Front Seat Belt.>
(AB24).
Control Module.>
or I2 to the connector (AB18).
side airbag sensor (RH), and connect the connector (1G) in test harness G to connector
(AB28).
(3I) in test harness I or I2 and connector (3G)
in test harness G.
(3I) No. 17 (3G) No. 2:
(3I) No. 18 (3G) No. 1:
(3I) No. 19 (3G) No. 5:
(3I) No. 20 (3G) No. 4:
ground.
Check
?
Yes
Go to step 2.

M?
Replace the side Replace the body

airbag sensor
harness with side
(RH). <Ref. to AB- airbag harness.
16, Side Airbag
Sensor.> When
sensor replacement is not OK,
replace the airbag
control module.
<Ref. to AB-15,
Airbag Control
Module.>
AB-71
No
Replace the body
harness with side
airbag harness.

Q: DTC 52
DIAGNOSIS:
CAUTION:
WIRING DIAGRAM:
B5M1106
AB-72

Step
20 seconds.
Front Seat Belt.>
(AB19).
Control Module.>
side airbag sensor (LH), and connect the connector (1G) in test harness G to connector
(AB23).
(3I) in test harness I or I2 and connector (3G)
in test harness G.
(3I) No. 5 (3G) No. 4:
(3I) No. 14 (3G) No. 5:
(3I) No. 15 (3G) No. 1:
(3I) No. 16 (3G) No. 2:
ground.
Check
?
Yes
Go to step 2.
No
Replace the body
harness with side
airbag harness.

M?
Replace the side Replace the body

airbag sensor
harness with side
(LH). <Ref. to AB- airbag harness.
16, Side Airbag
Sensor.> When
sensor replacement is not OK,
replace the airbag
control module.
<Ref. to AB-15,
Airbag Control
Module.>
R: DTC 53
DIAGNOSIS:
When Code 53 is displayed, the circuit within the side airbag sensor (RH) is faulty. Replace the side airbag
sensor (RH).
<Ref. to AB-16, Side Airbag Sensor.>
S: DTC 54
DIAGNOSIS:
When Code 53 is displayed, the circuit within the side airbag sensor (LH) is faulty. Replace the side airbag
sensor (LH).
<Ref. to AB-16, Side Airbag Sensor.>
T: DTC 55
This code is displayed when the side airbag is deployed.
When this code is displayed, the memory cannot be erased. Replace the following parts.
Airbag control module. <Ref. to AB-15, Airbag Control Module.>
Front seat with side airbag module. (Operating side) <Ref. to SE-6, Front Seat.>
Side airbag sensor. (Operating side) <Ref. to AB-16, Side Airbag Sensor.>
AB-73

U: DTC 61
DIAGNOSIS:
Seat belt pretensioner (RH) circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:
B5M1109
AB-74

Step
CHECK SEAT BELT PRETENSIONER.
20 seconds.
Front Seat Belt.>
3)Connect the connector (1L) in test harness L
to (AB26).
4)Connect the airbag resistor to connector (3L)
in test harness L.
20 seconds.
harness.
(AB24).
4)Disconnect the connectors (AB17) and
(AB18) from the airbag control module. <Ref.
to AB-15, Airbag Control Module.>
(3I) in test harness I or I2 and connector (3L) in
test harness L.
(3I) No. 8 (3L) No. 6:
(3I) No. 6 (3L) No. 5:
(3I) No. 6 No. 8:
ground.
Check
operate properly?
Yes
No
Replace the seat Go to step 2.
belt pretensioner
(RH). <Ref. to SB8, Front Seat
Belt.>

?
Go to step 3.
Replace the body

harness with side
airbag harness.

M?
Go to step 4.
Replace the body

harness with side
airbag harness.

M?

control module.
harness with side
<Ref. to AB-15,
airbag harness.
Airbag Control
Module.>
AB-75

V: DTC 62
DIAGNOSIS:
Seat belt pretensioner (LH) circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:
B5M1108
AB-76

Step
20 seconds.
Front Seat Belt.>
to (AB21).
4)Connect the airbag resistor to the connector
(3L) in test harness L.
20 seconds.
harness.
(AB19).
(3I) No. 11 (3L) No. 6:
(3I) No. 13 (3L) No. 5:
(3I) No. 11 No. 13:
Measure the resistance between the connector
ground.
Check
operate properly?
Yes
No
belt pretensioner
(LH). <Ref. to SB8, Front Seat
Belt.>

?
Go to step 3.
Replace the body

harness with side
airbag harness.

M?
Go to step 4.
Replace the body

harness with side
airbag harness.

M?

control module.
harness with side
<Ref. to AB-15,
airbag harness.
Airbag Control
Module.>
AB-77

W: DTC 65
DIAGNOSIS:
Seat belt pretensioner (RH) circuit is shorted to the power supply.
CAUTION:
WIRING DIAGRAM:
B5M1109
AB-78

Step
Check
20 seconds.
Front Seat Belt.>
to (AB26).
4)Connect the airbag resistor to connector (3L)
in test harness L.
20 seconds.
harness.
(AB24).
AB-79
Yes
No
belt pretensioner
(RH). <Ref. to SB8, Front Seat
Belt.>

control module.
harness with side
<Ref. to AB-15,
airbag harness.
Airbag Control
Module.>

X: DTC 66
DIAGNOSIS:
Seat belt pretensioner (LH) circuit is shorted to the power supply.
CAUTION:
Before replacing the airbag module, seat belt pretensioner roll connector, control module and the
WIRING DIAGRAM:
B5M1108
AB-80

Step
Check
20 seconds.
Front Seat Belt.>
to (AB21).
4)Connect the airbag resistor to the connector
20 seconds.
harness.
(AB19).
AB-81
Yes
No
belt pretensioner
(LH). <Ref. to SB8, Front Seat
Belt.>

control module.
harness with side
<Ref. to AB-15,
airbag harness.
Airbag Control
Module.>

AB-82
SEAT BELT SYSTEM
SB
1.
2.
3.
4.
5.
Page
Inspection Locations After a Collision .........................................................7
Front Seat Belt ............................................................................................8
Rear Seat Belt...........................................................................................10
Disposal of Pretensioner ...........................................................................13
GENERAL DESCRIPTION
SEAT BELT SYSTEM
A: COMPONENT
1. FRONT SEAT BELT
T2
(1)
(2)
T3
(3)
T1
T2
(4)
T2
BO0239
(1)
(2)
(3)
(4)
Adjuster anchor ASSY

Anchor cover
Outer belt ASSY
Inner belt ASSY

T1: 7.5 (0.76, 5.5)
T2: 30 (3.1, 22)
T3: 53 (5.4, 39)
SB-2
GENERAL DESCRIPTION
SEAT BELT SYSTEM
2. REAR SEAT BELT (SEDAN)
(1)
(7)
(2)
(4)
(5)
(6)
(3)
BO0240
(1)
(2)
(3)
(4)
Outer seat belt RH

Outer seat belt CENTER
Outer seat belt LH
Inner seat belt RH
(5)
(6)
(7)
Inner seat belt CENTER

Inner seat belt LH
Case center ELR
SB-3

T: 30 (3.1, 22)
GENERAL DESCRIPTION
SEAT BELT SYSTEM
3. REAR SEAT BELT (WAGON)
T1
(2)
(1)
T2
T1
T2
(3)
(4)
(5)
T1
T1
BO0241
(1)
(2)
(3)
(4)
Outer seat belt RH

Outer seat belt CENTER
Outer seat belt LH
Inner seat belt RH
(5)
Inner seat belt LH
SB-4

T1: 30 (3.1, 22)
T2: 53 (5.4, 39)
GENERAL DESCRIPTION
SEAT BELT SYSTEM
B: CAUTION
Before starting, turn the ignition switch to OFF,
disconnect the battery ground cable and wait for 20
seconds or more.
The pretension 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 parts with new
parts.
When handling a seat belt with a deployed pretensioner, wear gloves and goggles. Wash your
hands afterwards.
Do not re-use a seat belt with a deployed pretensioner again.
Be sure to deploy pretensioner before disposal.
<Ref. to SB-13, OPERATION, Disposal of Pretensioner.>
If the material gets in your eyes or on your skin
during deployment, wash it away with clean water,
and then consult a doctor.
SB-5
GENERAL DESCRIPTION
SEAT BELT SYSTEM
C: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
98299FE010
DESCRIPTION
ADAPTER C
(DEPLOYMENT)
REMARKS
Used for deploying the pretensioner.
Used with DEPLOYMENT TOOL
(98299PA030).
DEPLOYMENT
TOOL
Used for deploying the pretensioner.

Used with ADAPTER C (DEPLOYMENT)
(98299FE010).
B5M1114
98299PA030
B5M1115
SB-6

SEAT BELT SYSTEM
2. Inspection Locations After a

Collision
A: INSPECTION
Check for the following, and then replace with new
parts if necessary.
Center pillar lower garnish is discolored or
cracked.
Wire harness and/or connector is damaged.
SB-7
FRONT SEAT BELT

SEAT BELT SYSTEM
3. Front Seat Belt
2. INNER BELT (FRONT)
A: REMOVAL
1) Disconnect the connector.

2) Remove the anchor bolt, and then detach the inner belt.
1. OUTER BELT (FRONT)

1) Fold backrest all the way forward, and then
move front seat all the way forward.
2) Turn the ignition switch to OFF, disconnect the
ground cable from battery, and wait for more than
20 seconds before starting work.
3) Remove the center pillar lower trim. <Ref. to EI45, REMOVAL, Lower Inner Trim.>
4) Remove the anchor cover. Loosen the shoulder
anchor bolt, and then detach the shoulder anchor
from center pillar.
B5M1070
5) Turn over the floor mat to remove the bolts.
RE0003
6) Disconnect the yellow connector of pretensioner

harness, and remove the outer belt (front).
CAUTION:
Do not drop or apply any impact to the pretensioner.
Pretensioner and bracket should be treated
as an assembly. Do not attempt to disassemble
it.
SB-8
S5M0234
FRONT SEAT BELT

SEAT BELT SYSTEM
B: INSTALLATION
C: INSPECTION
Check for the following, and replace with new parts

if necessary.
Pretensioner is cracked or deformed.
Seat belt is slackened, bent, or frayed. Seat belt
is abnormally wound or extended.
CAUTION:
The parts on right and left are not identical.
Before installation, make sure that the correct
part is used.
Be careful not to twist the belts during installation.


if necessary.
Inner belt is deformed or damaged.
Seat belt buckle is engaged improperly.
SB-9
REAR SEAT BELT

SEAT BELT SYSTEM
4. Rear Seat Belt
5) Remove the bolts, and then detach the seat belt.
A: REMOVAL
1. OUTER BELT SIDE (SEDAN)
1) Remove the rear seat. <Ref. to SE-11, REMOVAL, Rear Seat.>
2) Remove the side sill rear lower cover. <Ref. to
EI-45, REMOVAL, Lower Inner Trim.>
3) Remove the seat belt lower anchor bolt.
RE0005
3. INNER BELT (SEDAN)

1) Remove the rear cushion. <Ref. to SE-11, REMOVAL, Rear Seat.>
2) Remove the bolts, and then detach the inner
belt.
RE0010
4) Remove the quarter pillar trim. <Ref. to EI-46,

5) Remove the bolts, and then detach the seat belt.
B5M0814
4. OUTER BELT SIDE (WAGON)
RE0004
2. OUTER BELT CENTER (SEDAN)

1) Remove the luggage floor mat. <Ref. to EI-54,

REMOVAL, Luggage Floor Mat.>
3) Remove the side sill rear lower cover. <Ref. to
EI-45, REMOVAL, Lower Inner Trim.>
RE0006
5) Remove the rear quarter trim. <Ref. to EI-46,

RE0011
3) Remove the quarter pillar trim. <Ref. to EI-46,

Removal, Rear Quarter Trim.>
4) Remove the rear shelf trim. <Ref. to EI-51, REMOVAL, Rear Shelf Trim.>
SB-10
REAR SEAT BELT

SEAT BELT SYSTEM
6) Remove the bolts, and then detach the outer belt

side.
6. INNER BELT (WAGON)

2) Remove the bolt, and then detach the inner belt.
RE0007
B5M0919
5. OUTER BELT CENTER (WAGON)

1) Remove the shoulder anchor bolt, and then detach the shoulder anchor from quarter pillar.
RE0008
2) Remove the quarter trim. <Ref. to EI-46, REMOVAL, Rear Quarter Trim.>
3) Remove the three bolts, and then detach the
outer belt center.
RE0009
SB-11
REAR SEAT BELT

SEAT BELT SYSTEM
B: INSTALLATION
C: INSPECTION

if necessary.
CAUTION:
During installation, make sure that the seat
belts are not twisted.
After installation, make sure that the seat
belts can be smoothly extended and wound.

CAUTION:

if necessary.

if necessary.
CAUTION:

if necessary.

CAUTION:

if necessary.

if necessary.

CAUTION:
belts are smoothly extended and wound.

CAUTION:
SB-12
DISPOSAL OF PRETENSIONER
SEAT BELT SYSTEM
5. Disposal of Pretensioner
6) Connect the deployment tool and adapter C (deployment) (B).
A: CAUTION
Do not discard undeployed pretensioners, because they may cause serious personal injury
Deployment of the pretensioners should be done
on a flat place free from any possible danger. Avoid
deploying outdoors during rainy or windy weather.
Do not drop or damage the pretensioner.
Because deploying the pretensioners causes a
high-explosive noise, be sure to warn people in the
area, and do not allow anyone within a 5-meter (16
Some smoke will be emitted after deployment of
the pretensioners. Therefore, it must be deployed
in a well-ventilated area with no smoke alarms
nearby.
Wear gloves, goggles, and earplugs during this
operation. Wash your hands afterwards.
After deployment, the pretensioner is especially
hot. Leave it unattended for 40 minutes, and then
discard it.
Do not let water get on the deployed pretensioner.
Wrap the deployed pretensioner in an airtight vinyl bag, and then discard it.
If circumstances do not permit pretensioner deployment, contact a SUBARU dealer.
CAUTION:
until just before deployment of the pretensioner.
S5M0309B

(B) Adapter C (deployment): (Part No.
98299FE010)

and pretensioner yellow connector.
B: OPERATION
1. DEPLOYING WHILE INSTALLED IN VEHICLE
1) Fold backrest all the way forward, and then
move front seat all the way forward.
4) Disconnect the yellow connector from pretensioner (a).
B5M1068
9) Move the battery at least 5 m (16 ft) from the vehicle, and secure the nearby area. Connect the deployment tool alligator clip to the battery negative ()
terminal.
B5M0918A

SB-13
SEAT BELT SYSTEM
10) Connect the other cable of deployment tool to

the battery positive (+) terminal. Then deploy the
pretensioner.
4) Cut off the seat belt as close to retractor as possible.
B5M0494
G5M0531
CAUTION:
After deployment, pretensioner is especially
hot. Leave it unattended for 40 minutes.
11) Remove the outer belt (front). <Ref. to SB-8,
Removal.>
12) Wrap the deployed pretensioner in an airtight
vinyl bag, and then discard it.
5) Short the terminal to alligator clip furnished as a

6) Connect the deployment tool and adapter C (deployment) (B).
CAUTION:
until just before deployment of the pretensioner.
S5M0309B
B5M0500

(B) Adapter C (deployment): (Part No.
98299FE010)
2. DEPLOYING AFTER REMOVAL FROM

VEHICLE
1) Fold backrest all the way forward, then move
front seat all the way forward.
3) Remove the outer belt (front). <Ref. to SB-8, Removal.>

and pretensioner yellow connector.
8) Install the pretensioner on a wheel with tire.
Then, bundle three wire automotive harness [each
more], and bind them twofold around the pretensioner bracket and wheel.
B5M0669
SB-14
SEAT BELT SYSTEM
9) Put three tires without a wheel 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 an airtight

B5M0500
G5M0536
10) Move the battery at least 5 m (16 ft) from the vehicle, and secure the nearby area. Connect the deployment tool alligator clip to the battery negative
() terminal.
G5M0537
11) Connect the other cable of deployment tool to

the battery positive (+) terminal. Then deploy the
pretensioner.
G5M0531
CAUTION:
After deployment, pretensioner is especially
hot. Leave it unattended for 40 minutes.
SB-15
SEAT BELT SYSTEM
SB-16
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.
Page
Headlight and Tail Light System .................................................................3
Front Fog Light System...............................................................................4
Rear Fog Light System ...............................................................................5
Turn Signal and Hazard Light System ........................................................6
Back-up Light System .................................................................................7
Stop Light System .......................................................................................8
Interior Light System ...................................................................................9
Headlight Beam Leveler System...............................................................10
Combination Switch (Light) .......................................................................11
Headlight Assembly ..................................................................................13
Headlight Bulb...........................................................................................15
Front Turn Signal Light Bulb .....................................................................16
Clearance/Parking Light Bulb....................................................................17
Front Fog Light Assembly .........................................................................18
Front Fog Light Bulb..................................................................................19
Rear Combination Light Assembly............................................................20
Brake/Tail Light Bulb .................................................................................21
Back-up Light Bulb ....................................................................................22
Rear Turn Signal Light Bulb ......................................................................23
Rear Fog Light Bulb ..................................................................................24
License Plate Light....................................................................................25
High-mounted Stop Light ..........................................................................26
Side Turn Signal Light...............................................................................27
Spot Light ..................................................................................................28
Room Light................................................................................................29
Luggage Room Light.................................................................................30
Trunk Room Light......................................................................................31
Glove Box Light.........................................................................................32
GENERAL DESCRIPTION
LIGHTING SYSTEM
A: SPECIFICATIONS
Headlight
Front turn signal light
Side turn signal light
Parking light
Front fog light
Rear fog light
Rear combination light
12 V 55 W/60 W (Halogen)
12 V 21 W
12 V 5 W
12 V 5 W
12 V 55 W
12 V 21 W
12 V 5/21 W
12 V 21 W
12 V 21 W
12 V 5 W
12 V 21 W
12 V 1.2 W
12 V 10 W
12 V 8 W
12 V 8 W
12 V 13 W
12 V 5 W
12 V 1.4 W
Tail/Stop light
Turn signal light
Back-up light
License plate light

High-mounted stop light
Sedan
Standard type
Rear spoiler built-in type
Wagon
Room light
Spot light
Luggage room light
Trunk room light
Glove box light
B: PRECAUTIONS
After reassembly, make sure functional parts operate smoothly.
Before disassembling or reassembling parts, always disconnect the battery ground cable. When
replacing radio, control module, and other parts
provided with memory functions, record memory
contents before disconnecting the battery ground
cable. Otherwise, the memory will be erased.
Reassemble in reverse order of disassembly, unless otherwise indicated.
Adjust parts to the given specifications.
Connect the connectors and hoses securely during reassembly.
WARNING:
Airbag system wiring harness is routed near
electrical parts and switches. All airbag system
wiring harnesses and connectors are yellow.
Do not use electric test equipment on these circuits.
wiring harness when servicing electrical parts
and switches.
C: PREPARATION TOOL
1. GENERAL TOOLS
TOOL NAME
Circuit Tester
REMARKS
Used for measuring resistance and voltage.
LI-2
HEADLIGHT AND TAIL LIGHT SYSTEM

LIGHTING SYSTEM
2. Headlight and Tail Light System
2. TAIL AND ILLUMINATION RELAY

Measure the tail and illumination relay resistance
between terminals when connecting terminal No. 4
to battery positive terminal and terminal No. 3 to
battery ground terminal.
A: SCHEMATIC
1. HEADLIGHT LHD MODEL
<Ref. to WI-209, LHD MODEL, SCHEMATIC,
Headlight System.>
(1)
2. HEADLIGHT RHD MODEL

<Ref. to WI-210, RHD MODEL, SCHEMATIC,
Headlight System.>
(2)
3. CLEARANCE LIGHT AND ILLUMINATION LIGHT LHD MODEL
(3)
(2)
(1)
(3)
(4)
(4)

Clearance Light and Illumination Light System.>
BO0308
Current
Flow
No flow
4. CLEARANCE LIGHT AND ILLUMINATION LIGHT RHD WITHOUT ILLUMINATION

CONTROL MODEL
<Ref. to WI-198, RHD WITHOUT ILLUMINATION
CONTROL MODEL, SCHEMATIC, Clearance
Light and Illumination Light System.>
5. CLEARANCE LIGHT AND ILLUMINATION LIGHT RHD WITH ILLUMINATION

CONTROL MODEL
<Ref. to WI-201, RHD WITH ILLUMINATION CONTROL MODEL, SCHEMATIC, Clearance Light and
Illumination Light System.>
B: INSPECTION
1. HEADLIGHT RELAY
Measure the headlight relay resistance between
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)
BO0308
Current
Flow
No flow
Terminal No.
1 and 2
Standard
Less than 1
More than 1M
LI-3
Terminal No.
1 and 2
Standard
Less than 1
More than 1M
FRONT FOG LIGHT SYSTEM

LIGHTING SYSTEM
3. Front Fog Light System
2. FRONT FOG LIGHT RELAY
A: SCHEMATIC
Measure the front fog light relay resistance between terminals when connecting terminal No. 4 to
battery positive terminal and terminal No. 3 to battery ground terminal.
1. FRONT FOG LIGHT LHD MODEL

Front Fog Light System.>
2. FRONT FOG LIGHT RHD FOR EUROPE

MODEL
(1)
<Ref. to WI-206, RHD FOR EUROPE MODEL,

SCHEMATIC, Front Fog Light System.>
(2)
(1)
(3)
(4)
(2)
3. FRONT FOG LIGHT RHD EXCEPT FOR

EUROPE MODEL
(3)
(4)
<Ref. to WI-207, RHD EXCEPT FOR EUROPE

MODEL, SCHEMATIC, Front Fog Light System.>
BO0308
B: INSPECTION
Current
Flow
No flow
1. FRONT FOG LIGHT SWITCH

Measure the front fog light switch resistance.
B6M1482
Switch position
OFF
ON
Terminal No.
3 and 5
Standard
More than 1M
Less than 1
LI-4
Terminal No.
1 and 2
Standard
Less than 1
More than 1M
REAR FOG LIGHT SYSTEM

LIGHTING SYSTEM
4. Rear Fog Light System

A: SCHEMATIC
1. REAR FOG LIGHT LHD MODEL
<Ref. to WI-244, LHD MODEL, SCHEMATIC, Rear
Fog Light System.>
2. REAR FOG LIGHT RHD FOR EUROPE

MODEL
<Ref. to WI-245, RHD FOR EUROPE MODEL,
SCHEMATIC, Rear Fog Light System.>
3. REAR FOG LIGHT RHD EXCEPT FOR

EUROPE MODEL
<Ref. to WI-246, RHD EXCEPT FOR EUROPE
MODEL, SCHEMATIC, Rear Fog Light System.>
B: INSPECTION
1. REAR FOG LIGHT SWITCH
2) Turn on the headlight or front fog light.
3) Push the rear fog light switch and check if the
rear fog light turns on.
2. REAR FOG LIGHT RELAY

Measure the rear fog light relay resistance between
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)
BO0308
Current
Flow
No flow
Terminal No.
1 and 2
Standard
Less than 1
More than 1M
LI-5
TURN SIGNAL AND HAZARD LIGHT SYSTEM

LIGHTING SYSTEM
5. Turn Signal and Hazard Light

System
A: SCHEMATIC
1. TURN SIGNAL LIGHT AND HAZARD
LIGHT LHD MODEL
<Ref. to WI-218, LHD MODEL, SCHEMATIC, Turn
Signal Light and Hazard Light System.>
2. TURN SIGNAL LIGHT AND HAZARD

LIGHT RHD MODEL
<Ref. to WI-220, RHD MODEL, SCHEMATIC, Turn
Signal Light and Hazard Light System.>
B: INSPECTION
1. TURN SIGNAL SWITCH
<Ref. to LI-11, INSPECTION, Combination Switch
(Light).>
2. HAZARD SWITCH
Measure the hazard switch resistance.
B6M1483
Switch position
OFF
ON
Terminal No.
6 and 7
1, 3 and 4
7 and 8
Standard
Less than 1
Less than 1
Less than 1
3. TURN SIGNAL & HAZARD MODULE

Connect the battery and turn signal light bulb to the
module, as shown in the figure. The module is
properly functioning if it blinks when power is supplied to the circuit.
B6M1584
LI-6
BACK-UP LIGHT SYSTEM

LIGHTING SYSTEM
6. Back-up Light System
2. INHIBITOR SWITCH (A/T)
A: SCHEMATIC
Measure the inhibitor switch resistance.
1. BACK-UP LIGHT
<Ref. to WI-193, SCHEMATIC, Back-up Light System.>
B: INSPECTION
1. BACK-UP LIGHT SWITCH (M/T)
Measure the back-up light switch resistance.
B6M1485
(A)
Switch position
When select lever
is set in R position
Other positions
2 1
(B)
2 1
4 3
BO0344
(A) Non-turbo model

(B) Turbo model
Switch position
When shift lever is
set in reverse
position
Other positions
Terminal No.
Turbo model:
2 and 4
Non-turbo model:
1 and 2
Standard
Less than 1
More than 1M
LI-7
Terminal No.
1 and 2
Standard
Less than 1
More than 1M
STOP LIGHT SYSTEM

LIGHTING SYSTEM
7. Stop Light System

A: SCHEMATIC
1. STOP LIGHT
<Ref. to WI-216, SCHEMATIC, Stop Light System.>
B: INSPECTION
1. STOP LIGHT SWITCH
Measure the stop light switch resistance.
B6M1486A
Switch position
When brake pedal
is depressed
When brake pedal
is released
Terminal No.
Standard
1 and 2: Without
cruise control
2 and 3: With
cruise control
Less than 1
More than 1M
LI-8
INTERIOR LIGHT SYSTEM

LIGHTING SYSTEM
8. Interior Light System

A: SCHEMATIC
1. INTERIOR LIGHT LHD MODEL
<Ref. to WI-212, LHD MODEL, SCHEMATIC, In
Compartment Light System.>
2. INTERIOR LIGHT RHD MODEL

<Ref. to WI-214, RHD MODEL, SCHEMATIC, In
Compartment Light System.>
B: INSPECTION
1. DOOR SWITCH
Measure the door switch resistance.
1
2
3
BO0157
Switch position
When door is
opened
When door is
closed
Terminal No.
Standard
Less than 1
1 and 3
More than 1M
2. REAR GATE LATCH SWITCH

Measure the rear gate latch switch resistance.
Switch position
When rear gate is
opened
When rear gate is
closed
Terminal No.
Standard
Less than 1
1 and 2
More than 1
3. TRUNK ROOM LIGHT SWITCH

Measure the trunk room light switch resistance.
Switch position
When trunk lid is
opened
When trunk lid is
closed
Terminal No.
Standard
Less than 1
1 and 2
More than 1M
LI-9
HEADLIGHT BEAM LEVELER SYSTEM

LIGHTING SYSTEM
9. Headlight Beam Leveler System

A: SCHEMATIC
1. HEADLIGHT BEAM LEVELER
<Ref. to WI-179, SCHEMATIC, 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.
2. HEADLIGHT BEAM LEVELER SWITCH

Connect the battery, headlight beam leveler switch
connector, circuit tester and resistor (470 ) as
shown in the figure. Measure the current at each
switch position.
4 3 2 1
470
BO0212
Switch position
0
1
2
3
Current (mA)
3.8
9.8
15
21
LI-10
COMBINATION SWITCH (LIGHT)

LIGHTING SYSTEM
10.Combination Switch (Light)
C: INSPECTION
A: REMOVAL
Measure the combination switch resistance.

2) Remove the instrument panel lower cover. <Ref.
to EI-41, REMOVAL, Instrument Panel Assembly.>
3) Remove the screws which secure upper column
cover to lower column cover.
LHD model and RHD for europe model

8
17
7 6 5 4 3
2
16 1514131211 10
1
9
RHD except for europe model

8
17
B6M1184
4) Disconnect the connector from combination

switch.
5) Remove the screws which secure switch, and
then remove the switch.
7
6 5 4 3 2
16 1514 131211 10
1
9
Lighting and turn signal switch connector

2 1
4 3
Parking switch connector
BO0158
1. LIGHTING SWITCH
LHD model and RHD for europe model:
Switch position
OFF
Tail
Head
S6M0046
Terminal No.
14 and 16
13, 14 and 16
Standard
More than 1M
Less than 1
Less than 1
RHD except for europe model:
B: INSTALLATION
Switch position
OFF
Tail
Head
Terminal No.
9 and 15
9, 14 and 15
Standard
More than 1M
Less than 1
Less than 1
2. DIMMER AND PASSING SWITCH

Switch position
Passing
Low beam
High beam
Terminal No.
7, 8 and 16
16 and 17
7 and 16
Standard
Less than 1
Less than 1
Less than 1

Switch position
Passing
Low beam
High beam
LI-11
Terminal No.
1, 2 and 9
9 and 10
2 and 9
Standard
Less than 1
Less than 1
Less than 1
COMBINATION SWITCH (LIGHT)

LIGHTING SYSTEM
3. TURN SIGNAL SWITCH

Switch position
Left
Neutral
Right
Terminal No.
1 and 2
2 and 3
Standard
Less than 1
More than 1M
Less than 1

Switch position
Left
Neutral
Right
Terminal No.
6 and 7
7 and 8
Standard
Less than 1
More than 1M
Less than 1
4. PARKING SWITCH
Switch position
OFF
ON
Terminal No.
2 and 4
1 and 4
Standard
Less than 1
Less than 1
LI-12
HEADLIGHT ASSEMBLY
LIGHTING SYSTEM
11.Headlight Assembly
B: INSTALLATION
A: REMOVAL

2) Remove the duct (A) (when right side headlight
is removed).
C: ADJUSTMENT
1. HEADLIGHT AIMING
CAUTION:
Turn off the light before adjusting headlight
aiming. If the light is necessary to check aiming, do not turn on for more than 2 minutes.
BO0024
3) Remove the front grille and headlight side cover.

<Ref. to EI-17, REMOVAL, Front Grille.> and <Ref.
to EI-22, REMOVAL, Front Bumper.>
4) Disconnect the headlight bulb connector.
NOTE:
Before checking the headlight aiming, be sure of
the following:
The area around the headlight has not sustained
any accident, damage or other type of deformation.
Vehicle is parked on level ground.
The inflation pressure of tires is correct.
Vehicles gas tank is fully charged.
Bounce the vehicle several times to normalize
the suspension.
Make certain that someone is seated in the drivers seat.
Turn the headlights on and then adjust the low
beam pattern to the following positions on the
screen.
NOTE:
Set the headlight leveler switch to 0 position.
Adjust the vertical aim (A) first, then horizontal
aim (B).
BO0025
5) Remove the three bolts and disconnect connectors, and then detach the headlight assembly.
BO0027
BO0026
LI-13
HEADLIGHT ASSEMBLY
LIGHTING SYSTEM
Vehicle
center
W1
W2
W2
W
W1
H
Vehicle center
h
h
Bulb center marking
H
3 m (10 ft)
BO0211
This illustration is for LHD model.

The pattern for RHD model is symmetrically opposite.
H mm (in)
W mm (in)
1,170 (46.06)
Sedan
GX, RS, WRX
TS
STi
625 (24.60)
620 (24.41)
Wagon
h mm (in) at 3 m (10 ft)
TS
GX, WRX
Outback
625 (24.60)
620 (24.41)
630 (24.80)
LI-14
30 (1.18)
HEADLIGHT BULB
LIGHTING SYSTEM
12.Headlight Bulb
B: INSTALLATION
A: REMOVAL
CAUTION:
Because the tungsten halogen bulb operates
at a high temperature, dirt and oil on the bulb
surface reduces the bulb's 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.
2) Remove the duct (A) (when right side headlight
is removed).
CAUTION:
Attach the rubber cap with letters TOP on the
top so the drain hole will be on the lower side.
C: INSPECTION
1) Visually check the bulb for blow out.
2) Check the bulb specification. <Ref. to LI-2,
SPECIFICATIONS, General Description.>
3) If NG, replace the bulb with a new one.
BO0024
3) Disconnect the harness connector.

4) Remove the rubber cap (A).
BO0029
5) Remove the light bulb retaining spring to remove

the bulb.
BO0030
LI-15
FRONT TURN SIGNAL LIGHT BULB

LIGHTING SYSTEM
13.Front Turn Signal Light Bulb

A: REMOVAL
1) Remove the headlight assembly. <Ref. to LI-13,
REMOVAL, Headlight Assembly.>
2) Turn the socket (A) and remove the bulb.
BO0031
B: INSTALLATION
C: INSPECTION
LI-16
CLEARANCE/PARKING LIGHT BULB

LIGHTING SYSTEM
14.Clearance/Parking Light Bulb

A: REMOVAL
1) Remove the headlight assembly. <Ref. to LI-13,
REMOVAL, Headlight Assembly.>
2) Turn the socket (A) and remove the bulb.
BO0032
B: INSTALLATION
C: INSPECTION
LI-17
FRONT FOG LIGHT ASSEMBLY

LIGHTING SYSTEM
15.Front Fog Light Assembly
2. NON-TURBO ENGINE MODEL
A: REMOVAL

2) Remove the two clips and lower mudguard.
1. TURBO ENGINE MODEL

BO0049
3) Disconnect the harness connector (A).

4) Remove the bolts (B), and then detach the fog
light assembly.
BO0049
BO0052
B: INSTALLATION
BO0050
4) Remove the mounting bolts, and then detach the

fog light assembly.
BO0051
LI-18
FRONT FOG LIGHT BULB

LIGHTING SYSTEM
16.Front Fog Light Bulb
A: REMOVAL

BO0049
2) Remove the back cover.

BO0049
2) Remove the back cover.
BO0054
3) Remove the spring retainer, and then detach the

fog light bulb.
BO0053
B: INSTALLATION
3) Remove the spring retainer, and then detach the

fog light bulb.
C: INSPECTION
LI-19
REAR COMBINATION LIGHT ASSEMBLY

LIGHTING SYSTEM
17.Rear Combination Light Assembly
2. WAGON
2) Remove the clips, and then detach the rear combination light covers.
A: REMOVAL
1. SEDAN
2) Remove the clips, and then detach the trunk rear
trim.
BO0035
3) Remove the two bolts, and then remove the rear

combination light while disconnecting connector.
BO0033
3) Remove the trunk side trim of rear portion.

4) Remove the four nuts, and then detach the rear
combination light while disconnecting connector.
BO0036
BO0034
BO0037
B: INSTALLATION
LI-20
BRAKE/TAIL LIGHT BULB

LIGHTING SYSTEM
18.Brake/Tail Light Bulb

A: REMOVAL
1. SEDAN
2) Turn the socket and remove the bulb.
BO0038
2. WAGON
1) Remove the rear combination light assembly.
<Ref. to LI-20, WAGON, REMOVAL, Rear Combination Light Assembly.>
BO0039
B: INSTALLATION
C: INSPECTION
LI-21
BACK-UP LIGHT BULB

LIGHTING SYSTEM
19.Back-up Light Bulb

A: REMOVAL
1. SEDAN
BO0040
2. WAGON
BO0041
B: INSTALLATION
C: INSPECTION
LI-22
REAR TURN SIGNAL LIGHT BULB

LIGHTING SYSTEM
20.Rear Turn Signal Light Bulb

A: REMOVAL
1. SEDAN
BO0042
2. WAGON
BO0043
B: INSTALLATION
C: INSPECTION
LI-23
REAR FOG LIGHT BULB

LIGHTING SYSTEM
21.Rear Fog Light Bulb

A: REMOVAL
1. SEDAN
BO0044
2. WAGON
BO0041
B: INSTALLATION
C: INSPECTION
LI-24
LICENSE PLATE LIGHT

LIGHTING SYSTEM
22.License Plate Light

A: REMOVAL
1) Remove the license plate light mounting screw
(A), and then remove the lens (B).
BO0122
2) Remove the bulb.
B: INSTALLATION
C: INSPECTION
LI-25
HIGH-MOUNTED STOP LIGHT

LIGHTING SYSTEM
23.High-mounted Stop Light
3. WAGON
A: REMOVAL

2) Remove the cap (a) by prying on the edge with
screwdriver.
3) Remove the screws (b), and then the detach
cover (c).
4) Remove screws (d), and then detach the highmounted stop light while disconnecting connector.
1. SEDAN (STANDARD TYPE)

2) Disconnect the connector of high-mounted stop
light from body harness.
3) Remove the bolts, then detach the high-mounted stop light assembly.
B6M1343A
B: INSTALLATION
B5M0816
2. SEDAN (REAR SPOILER BUILT-IN

TYPE)

2) Remove the bolts, then detach the high-mounted stop light assembly.
3) Disconnect the connector of high-mounted stop
light from body harness.

C: INSPECTION
BO0028
LI-26
SIDE TURN SIGNAL LIGHT

LIGHTING SYSTEM
24.Side Turn Signal Light

A: REMOVAL
2) Pull out the light from body while pushing it in direction of vehicle front.
3) Disconnect the harness connector and remove
the light.
B6M1543
B: INSTALLATION
C: INSPECTION
LI-27
SPOT LIGHT
LIGHTING SYSTEM
25.Spot Light
A: REMOVAL
2) Remove the lens (A) and spot light mounting
screw (B).
BO0045
BO0046
3) Disconnect the harness connectors and remove

the spot light.
B: INSTALLATION
C: INSPECTION
1. SPOT LIGHT BULB
2. SPOT LIGHT SWITCH

Measure the spot light resistance.
Switch position
OFF
ON
Terminal No.
1 and 2
Standard
More than 1M
18 5.4
LI-28
ROOM LIGHT
LIGHTING SYSTEM
26.Room Light
A: REMOVAL
2) Remove the lens (A) and room light mounting
screws (B).
B6M1479A

the light.
B: INSTALLATION
C: INSPECTION
1. ROOM LIGHT BULB
2. ROOM LIGHT SWITCH

Measure the room light resistance.
B6M1489A
Switch position
OFF
ON
DOOR
Terminal No.
1 and 3
1 and 2
Standard
More than 1M
1.5 0.5
1.5 0.5
LI-29
LUGGAGE ROOM LIGHT

LIGHTING SYSTEM
27.Luggage Room Light
C: INSPECTION
A: REMOVAL
1. LUGGAGE ROOM LIGHT BULB

2) Remove the lens (A) And luggage room light
mounting screws (B).

2. LUGGAGE ROOM LIGHT SWITCH

Measure the luggage room light resistance.
BO0352
Switch position
OFF
ON
DOOR
B6M1480A

the luggage room light.
B: INSTALLATION
LI-30
Terminal No.
1 and 3
1 and 2
Standard
More than 1M
1.5 0.5
1.5 0.5
TRUNK ROOM LIGHT

LIGHTING SYSTEM
28.Trunk Room Light

A: REMOVAL
the trunk room light.
BO0047
B: INSTALLATION
C: INSPECTION
LI-31
GLOVE BOX LIGHT

LIGHTING SYSTEM
29.Glove Box Light

A: REMOVAL
4) Remove the glove box light.
BO0048
B: INSTALLATION
C: INSPECTION
LI-32
WW
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Page
Wiper and Washer System .........................................................................5
Combination Switch (Wiper)........................................................................7
Wiper Blade...............................................................................................10
Washer Tank and Motor............................................................................12
Front Wiper Arm........................................................................................13
Front Wiper Motor and Link.......................................................................14
Front Washer Nozzle ................................................................................16
Rear Wiper Arm ........................................................................................17
Rear Wiper Motor......................................................................................18
Rear Washer .............................................................................................19
Wiper Control Relay ..................................................................................20
GENERAL DESCRIPTION
A: SPECIFICATIONS
Front wiper motor
Rear wiper motor
Front washer motor
Rear washer motor
Input
Input
Pump type
Input
Pump type
Input
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
BO0272
(1)
(2)
(3)
Wiper rubber
Wiper blade ASSY
Wiper arm
(4)
(5)
Wiper rink
Wiper motor
WW-2

T1: 6.0 (0.61, 4.4)
T2: 20 (2.0, 14.5)
GENERAL DESCRIPTION
2. REAR WIPER
B6M1463B
(1)
(2)
(3)
(4)
(5)
(6)
Wiper rubber
Wiper blade ASSY
Wiper arm
Wiper motor
Spacer A
Cushion
(7)
(8)
(9)
(10)
Spacer B
Nut
Cap
Wiper arm cover
WW-3

T1: 6.0 (0.61, 4.4)
T2: 7.5 (0.76, 5.5)
T3: 8.0 (0.82, 5.9)
GENERAL DESCRIPTION
3. WASHER TANK
BO0295
(1)
(2)
(3)
(4)
Washer nozzle
Washer hose
Washer tank
Washer tank cap
(5)
(6)
(7)
Front washer motor

Rear washer motor
Grommet

T: 6.0 (0.61, 4.4)
C: CAUTION
Reconnect the connectors and hoses securely.
After reconnecting, confirm that each function operates normally.
Be careful that wire harnesses of airbag system pass near electrical parts and switches.
Wire harnesses and connectors of all airbag system are yellow color. Do not use a tester on these circuits.
Care must be taken when installing the piping hose so that no bending, jamming, etc. are caused.
If even a little oil or grease such as silicon oil gets in the tank and washer passages, an oil film easily forms
on the glass, causing the wiper to chatter and judder. Therefore, be careful not to let this happen.
WW-4
WIPER AND WASHER SYSTEM

2. Wiper and Washer System

A: SCHEMATIC
1. WIPER AND WASHER (FRONT) LHD
MODEL
<Ref. to WI-261, LHD MODEL, SCHEMATIC, Wiper and Washer System (Front).>
2. WIPER AND WASHER (FRONT) RHD

MODEL
<Ref. to WI-262, RHD MODEL, SCHEMATIC, Wiper and Washer System (Front).>
3. WIPER AND WASHER (REAR) LHD

MODEL
<Ref. to WI-264, LHD MODEL, SCHEMATIC, Wiper and Washer System (Rear).>
4. WIPER AND WASHER (REAR) RHD

MODEL
<Ref. to WI-265, RHD MODEL, SCHEMATIC, Wiper and Washer System (Rear).>
WW-5
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.
Repair order
(1) Wiper fuse (F/B No. 14, 15)
(2) Combination switch
(3) Wiper motor
(4) Wire harness
(2) Wiper motor
(3) Wire harness
(2) Wiper motor
(3) Wire harness
(1) Washer switch
(2) Washer motor
(3) Wire harness
(1) Washer motor
(2) Wire harness
(1) Washer hose and nozzle
WW-6
COMBINATION SWITCH (WIPER)

3. Combination Switch (Wiper)
C: INSPECTION
A: REMOVAL
Inspect the continuity between each connector

terminal.
1) Loosen the screw to remove the steering column

cover.
B6M1184
2) Disconnect the connectors from combination

switches.
3) Loosen the screw to remove combination switch.
S6M0137
LHD model and RHD model (Europe model):
B6M1499
B: INSTALLATION
Switch position
OFF
INT
FRONT
LO
HI
Washer ON
Washer ON
REAR
OFF
ON
Washer ON
Terminal No.
7 and 16
7 and 16
7 and 17
8 and 17
2 and 11
2 and 10
10 and 12
2 and 12
2 and 10
2 and 10
10 and 12
2 and 12
Standard
Less than 1
Less than 1
Less than 1
Less than 1
Less than 1
Less than 1
More than 1M
Less than 1
Less than 1
If continuity is not as specified, replace the switch.
WW-7

RHD model (Except Europe model):

Switch position
OFF
INT
FRONT
LO
HI
Washer ON
Washer ON
REAR
OFF
ON
Washer ON
Terminal No.
3 and 12
3 and 12
3 and 11
2 and 11
8 and 17
8 and 16
16 and 18
8 and 18
8 and 18
8 and 16
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 1M
Less than 1
Less than 1
If continuity is not as specified, replace the switch.
WW-8

Intermittent operation inspection

1) Turn the wiper switch to INT.
2) Adjust the intermittent control switch to MAX.
3) Apply battery voltage to switch terminals 16 and 2, and inspect the voltage of terminals 7 and 2. (Measure
the voltage from after the second time the wiper stops.)
B6M1465A
If operation is not as specified, replace the switch.
WW-9
WIPER BLADE
4. Wiper Blade
D: ASSEMBLY
A: REMOVAL
1. METAL TYPE
While pushing the locking clip (A) up, pull out the
blade from arm to arrow direction.
1) Insert the wiper rubber onto the blade so that the

stopper is in the position shown.
B6M1536A
B6M1497
B: INSTALLATION
2) Make sure the wiper rubber is securely fastened

to the pull stopper (A).

2) Confirm that the clip is locked securely.
C: DISASSEMBLY
1. METAL TYPE
Pull on side (A) of the wiper rubber stopper and remove the rubber from the blade assembly.
B6M1498A
B6M1496A
2. RESIN TYPE
Pull the wiper rubber top slightly from the stopper
and pull out fully.
Stopper
BO0196
WW-10
WIPER BLADE
2. RESIN TYPE
BO0197
1) Insert the wiper rubber through the claw (B).
3) Insert the wiper rubber into the claw (A).
A
A
B
BO0198
BO0200
2) Insert the wiper rubber top until it protrudes

about 20 mm (0.79 in) from the stopper (D).
20mm ( 0.79 in. )
E: INSPECTION
1) When the wiper does not perform well, inspect
the following:
Make sure the movable part of the blade assembly moves smoothly.
Make sure the wiper rubber is not deformed or
damaged.
2) Replace with a new part if damage is found.
BO0199
WW-11
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 two bolts, hose and connector, and
then remove the tank.
E: INSPECTION
Apply battery voltage to the connector terminal of
the washer motor and make sure the motor operates.
B5M1464
B: INSTALLATION
B6M1567

Tightening torque:
6.0 Nm (0.61 kgf-m, 4.4 ft-lb)
C: DISASSEMBLY
Pull out the washer motor from tank.
B5M1465
WW-12
FRONT WIPER ARM

6. Front Wiper Arm
C: ADJUSTMENT
A: REMOVAL
NOTE:
The positions for RHD model are symmetrically opposite.
Operate the wiper once. Align the wiper blade to
ceramic print point mark (A) of front window pane.
NOTE:
1) Open the hood.
2) Remove the cap.
3) Loosen the nut to remove arm.
B6M1193A
S6M0050
B: INSTALLATION
NOTE:
2) Operate the wiper once.
3) Align the wiper blade to ceramic print point mark
(A) of front window pane.
B6M1193A
Tightening torque:
Refer to COMPONENT in General Description.
<Ref. to WW-2, FRONT WIPER,
WW-13
FRONT WIPER MOTOR AND LINK

7. Front Wiper Motor and Link
A: REMOVAL
Tightening torque:
<Ref. to WW-2, FRONT WIPER,
NOTE:
2) Remove the cowl panel. <Ref. to EI-32, REMOVAL, Cowl Panel.>
3) Disconnect the connector of motor.
4) Loosen the bolts and nuts to remove wiper link.
C: INSPECTION
1) When the battery is connected to the terminal of
connectors, confirm that motor operates at low
speed.
3 2 1
5 4
BO0201
B5M1466
2) When the battery is connected to the terminal of

connectors, confirm that motor operates at high
speed.
5) Loosen the bolts and nuts to remove motor.
3 2 1
5 4
B5M1467
B: INSTALLATION
BO0202

2) To confirm that the motor is at auto stop position,
connect the harness to motor and turn the wiper
switch ON/OFF once.
4) Tighten the nut where rod (A) and link plate (B) is
aligned in a straight line.
3) Connect the battery to terminals of connector,

and remove the terminal connection with motor rotated at low speed, and stop the wiper motor
through operation.
3 2 1
5 4
BO0203
BO0274
WW-14
FRONT WIPER MOTOR AND LINK

4) Connect the battery and confirm that the motor

stops at automatic stop position after the motor operates at low speed again.
3 2 1
5 4
BO0204
WW-15
FRONT WASHER NOZZLE

8. Front Washer Nozzle

A: REMOVAL
1) Remove the washer hose from the washer nozzle.
2) Open the clips on the underside of the hood with
a thin screwdriver or other tool, and remove the
washer nozzle.
B6M1505
B: INSTALLATION
2) Adjust the position of the washer liquid sprayer.
<Ref. to WW-16, ADJUSTMENT, Front Washer
Nozzle.>
C: INSPECTION
Make sure the nozzle and hose are not clogged.
Make sure the hose is not bent.
D: ADJUSTMENT
NOTE:
This adjustment position is for left-handed vehicle.
Carry out left-right symmetry for adjustment positions for right-handed vehicle.
1) Turn the wiper switch to OFF position.
2) When the vehicle stops, adjust the washer injection position as shown in the figure.
Injection position:
A: 350 mm (13.78 in)
B: 162 mm (6.38 in)
C: 300 mm (11.81 in)
D: 500 mm (19.69 in)
S6M0165A
WW-16
REAR WIPER ARM

9. Rear Wiper Arm

A: REMOVAL
1) Raise the wiper arm cover (A).
2) Loosen the nut to remove wiper arm.
B6M1201A
B: INSTALLATION
2) Operate the rear wiper once.
3) Align the blade to rear defogger heat wire (A).
BO0206
Tightening torque:
<Ref. to WW-3, REAR WIPER, COMPONENT,
C: ADJUSTMENT
1) Operate the rear wiper once.
2) Align the blade to rear defogger heat wire (A).
BO0206
WW-17
REAR WIPER MOTOR

10.Rear Wiper Motor
C: INSPECTION
A: REMOVAL
1) Connect the battery to wiper motor connector

and confirm that the wiper motor operates.

2) Remove the rear wiper arm.
3) Remove the cap (A), nut (B), and spacer (C)
from rear wiper shaft.
S6M0072
2) Connect the battery to terminal of connector and

remove the terminal connections with motor rotated, and stop the wiper motor through operation.
B6M1202A
4) Remove the rear gate lower trim. <Ref. to EI-50,

REMOVAL, Rear Gate Trim.>
5) Unclip the clip of harness and disconnect the
connector of wiper motor.
6) Loosen the bolts to remove the wiper motor assembly (A).
S6M0073
3) Connect the battery and confirm that the motor

stops at automatic stop position after the motor operates at low speed again.
BO0207
B: INSTALLATION
2) Install the rear wiper cushion with the arrow
mark facing up, as shown in the figure.
S6M0074
B5M1463
Tightening torque:
<Ref. to WW-3, REAR WIPER, COMPONENT,
WW-18
REAR WASHER
11.Rear Washer
A: REMOVAL
1) Remove the high-mount stop light. <Ref. to LI26, REMOVAL, High-mounted Stop Light.>
2) Remove the washer hose from the washer nozzle.
3) Open the clips on the underside of the hood with
a thin screwdriver or other tool, and remove the
washer nozzle.
B6M1505
B: INSTALLATION
2) Adjust the position of the washer liquid sprayer.
<Ref. to WW-19, ADJUSTMENT, Rear Washer.>
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) When the vehicle stops, adjust the washer injection position as shown in the figure.
Injection position:
A: 39 mm (1.54 in)
B: 72
B6M1200C
WW-19
WIPER CONTROL RELAY

12.Wiper Control Relay
3) Measure the voltage when the wiper relay is operated.
A: REMOVAL
1. WAGON
2) Remove the right quarter lower trim. <Ref. to EI46, REMOVAL, Rear Quarter Trim.>
3) Loosen the nut to remove control unit.
B6M1523A
If operation is not as specified, replace the switch.
BO0209
B: INSTALLATION
1. WAGON
C: INSPECTION
1. WAGON
1) Disconnect the connector from the wiper control
relay.
2) Connect the positive (+) lead from the battery to
terminal 8 and the negative () lead to terminal 6.
Connect the positive (+) lead from the voltmeter to
terminal 3 and the negative () lead to ground.
BO0276
WW-20
ENTERTAINMENT
ET
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Page
Radio System..............................................................................................3
Cigarette Lighter System.............................................................................4
Radio Body..................................................................................................5
Front Speaker .............................................................................................6
Tweeter .......................................................................................................7
Rear Speaker ..............................................................................................8
Antenna.......................................................................................................9
Antenna Amplifier......................................................................................10
Noise Suppressor......................................................................................11
Cigarette Lighter........................................................................................12
GENERAL DESCRIPTION
ENTERTAINMENT
A: CAUTION
replacing radio, control module, and other parts
B: PREPARATION TOOL
1. GENERAL TOOLS
TOOL NAME
Circuit Tester
Conductive Silver Composition
(DUPONT NO. 4817 or
equivalent)
REMARKS
Used for repairing antenna
wire.
ET-2
RADIO SYSTEM
ENTERTAINMENT
2. Radio System
A: SCHEMATIC
1. RADIO LHD MODEL
<Ref. to WI-91, LHD MODEL, SCHEMATIC, Audio System.>
2. RADIO RHD MODEL

<Ref. to WI-93, RHD MODEL, SCHEMATIC, Audio System.>
B: INSPECTION
Symptom
No power coming in. (No display and no sound from speakers)
A specific speaker does not operate.

Radio generates noise with engine running.
AM and FM modes are weak or noisy.
Repair order
(1) Check the fuse and power supply for radio.
(2) Check the radio ground.
(3) Remove the radio for repair.
(1) Check the speaker.
(2) Check the output circuit between radio 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
CIGARETTE LIGHTER SYSTEM

ENTERTAINMENT
3. Cigarette Lighter System

A: SCHEMATIC
1. CIGARETTE LIGHTER
<Ref. to WI-178, SCHEMATIC, Front Accessory
Power Supply System.>
ET-4
RADIO BODY
ENTERTAINMENT
4. Radio Body
A: REMOVAL
2) Remove the center panel while disconnecting
connector.
: Hook pawl
BO0017
3) Remove the fitting screws, and slightly pull out

the radio from center console.
BO0018
4) Disconnect the electric connectors and antenna

feeder cord.
B: INSTALLATION
ET-5
FRONT SPEAKER
ENTERTAINMENT
5. Front Speaker
A: REMOVAL
2) Remove the front door trim. <Ref. to EI-36, REMOVAL, Front Door Trim.>
3) Remove the front speaker mounting screws.
BO0019

front speaker.
B: INSTALLATION
ET-6
TWEETER
ENTERTAINMENT
6. Tweeter
A: REMOVAL
3) Remove the tweeter mounting screws.
BO0020

tweeter.
B: INSTALLATION
ET-7
REAR SPEAKER
ENTERTAINMENT
7. Rear Speaker
A: REMOVAL
2) Remove the rear door trim. <Ref. to EI-37, REMOVAL, Rear Door Trim.>
3) Remove the rear speaker mounting screws.
B6M1211

rear speaker.
B: INSTALLATION
ET-8
ANTENNA
ENTERTAINMENT
8. Antenna
B: REPAIR
A: INSPECTION
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.
3) Deposit conductive silver composition (DUPONT NO. 4817) on the broken portion with a
drawing pen.
Measure the resistance between antenna terminal

and each antenna wire.
If an antenna wire is OK, resistance will be less
than 1 W. If an antenna wire is broken, the resistance will be more than 1 MW.
NOTE:
When checking the continuity, wind a piece of tin
foil around the tip of tester probe and press foil
against wire with your finger.
G6M0138
4) Dry out the deposited portion.

5) After repair has been completed, measure the
resistance in repaired wire.
B6M1494A
To locate the broken point, move the probe along

antenna wire.
B6M1495
ET-9
ANTENNA AMPLIFIER
ENTERTAINMENT
9. Antenna Amplifier
C: INSPECTION
A: REMOVAL
Measure the antenna amplifier resistance.

SEDAN
1. SEDAN
2) Remove the rear pillar upper trim. <Ref. to EI-46,
SEDAN, REMOVAL, Rear Quarter Trim.>
3) Disconnect the harness connector and terminal.
4) Remove the mounting screws and detach antenna amplifier.
(3)
(1)
(2)-b
(2)-a
(1)-a
(1)-b
(2)
BO0504
WAGON (Specification for Europe)

(1)
(1)-a
(1)-b
BO0021
(4)-a
(3)
2. WAGON
(2)-b

2) Remove the rear quarter upper trim and roof
trim. <Ref. to EI-48, WAGON, REMOVAL, Roof
Trim.>
3) Disconnect the harness connector and terminal.
4) Remove the mounting screws and detach antenna amplifier.
(2)-a
(4)-b
(2)
(4)
BO0505
WAGON (Specification except for Europe)

(1)
(1)-a
(1)-b
(2)-b
(2)-a
(4)-a
(2)
(4)-b
(4)
Terminal No.
1-a and Amplifier body
1-b and Amplifier body
3 and Amplifier body
BO0503
B: INSTALLATION
ET-10
BO0506
Standard
More than 100 k
Less than 1
More than 100 k
More than 100 k
More than 100 k
More than 100 k
Less than 1
NOISE SUPPRESSOR
ENTERTAINMENT
10.Noise Suppressor
A: REMOVAL
1. SEDAN
2) Remove the rear pillar upper trim. <Ref. to EI-46,
3) Remove the rear shelf trim. <Ref. to EI-51, REMOVAL, Rear Shelf Trim.>
4) Disconnect the feeder cord connector from antenna amplifier.
5) Disconnect the harness connector of noise suppressor from terminal on glass antenna.
6) Remove the harness clip.
7) Remove the mounting nut and detach noise suppressor.
BO0507
2. WAGON
2) Remove the rear gate trim. <Ref. to EI-50, REMOVAL, Rear Gate Trim.>
3) Disconnect the connector from noise suppressor.
4) Remove the mounting nut and detach noise suppressor.
B: INSTALLATION
ET-11
CIGARETTE LIGHTER
ENTERTAINMENT
11.Cigarette Lighter
A: REMOVAL
2) Remove the center panel. <Ref. to ET-5, REMOVAL, Radio Body.>
cigarette lighter.
BO0023
B: INSTALLATION
ET-12
COM
1.
2.
3.
4.
Page
Horn System ...............................................................................................3
Horn ............................................................................................................4
Horn Switch.................................................................................................5
GENERAL DESCRIPTION
A: PREPARATION TOOL
1. GENERAL TOOLS
TOOL
NAME
Circuit
Tester
REMARKS
COM-2
HORN SYSTEM
2. Horn System
A: SCHEMATIC
1. HORN
<Ref. to WI-180, SCHEMATIC, Horn System.>
B: INSPECTION
1. HORN RELAY
Measure the horn relay resistance between terminals (indicated in table below) when connecting terminal No. 4 to battery positive terminal and terminal
No. 3 to battery ground cable.
(1)
(2)
(1)
(3)
(4)
(2)
(3)
(4)
BO0308
Current
Flow
No Flow
Terminal No.
1 and 2
Standard
Less than 1
More than 1M
COM-3
HORN
3. Horn
A: REMOVAL
2) Remove the horn bracket mounting bolt (A).
the horn assembly (B).
BO0001
B: INSTALLATION
C: INSPECTION
With 12 V direct current supplied between horn terminal and case ground, check that the horn sounds
properly.
BO0353
COM-4
HORN SWITCH
4. Horn Switch
C: INSPECTION
A: REMOVAL
Measure the horn switch resistance.
WARNING:
Before servicing, be sure to read the notes in
the AB section for proper handling of the driver
airbag module. <Ref. to AB-3, CAUTION, General Description.>
2) Remove the driver's airbag module. <Ref. to AB12, Driver's Airbag Module.>
3) Remove the horn switch from the steering wheel
as shown.
B6M1493
Switch position
When horn switch
is pushed.
When horn switch
is not pushed.
S6M0095
B: INSTALLATION
COM-5
Terminal No.
1 and Body
ground
Resistance
Less than 1
More than 1M
HORN SWITCH
COM-6
GW
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Page
Power Window System ...............................................................................8
Power Window Control Switch ....................................................................9
Front Door Glass.......................................................................................12
Front Regulator and Motor Assembly .......................................................16
Remote Control Mirror System..................................................................17
Outer Mirror Assembly ..............................................................................18
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 ...................................................................................33
Roof Window Glass...................................................................................34
Inner Rearview Mirror................................................................................35
GENERAL DESCRIPTION
A: COMPONENT
1. FIXED GLASS (SEDAN)
BO0494
(1)
(2)
(3)
Windshield glass
Dam rubber
Molding
(4)
(5)
(6)
Rearview mirror mount

Locate pin
Rear window glass
GW-2
(7)
(8)
Spring
Fastener
GENERAL DESCRIPTION
2. FIXED GLASS (WAGON)
BO0495
(1)
(2)
(3)
(4)
Windshield glass
Dam rubber
Molding
Rearview mirror mount
(5)
(6)
(7)
(8)
Locate pin
Fastener
Rear quarter glass
Locate pin
GW-3
(9)
(10)
Glass
Spring
GENERAL DESCRIPTION
3. FRONT DOOR GLASS
BO0236
(1)
(2)
(3)
(4)
Glass
Door sash (Front)
Door sash (Rear)
Regulator ASSY
(5)
Motor ASSY
GW-4

T1: 7.4 (0.75, 5.5)
T2: 13.7 (1.4, 10.1)
GENERAL DESCRIPTION
4. REAR DOOR GLASS
BO0237
(1)
(2)
(3)
(4)
Glass
Door sash (Front)
Door sash (Rear)
Regulator ASSY
(5)
Motor ASSY
GW-5

T1: 7.4 (0.75, 5.5)
T2: 13.7 (1.4, 10.1)
GENERAL DESCRIPTION
5. MIRRORS
BO0238
(1)
(2)
Outer mirror
Inner rearview mirror
(3)
(4)
Mount
Spring
(5)
GW-6
Mirror
GENERAL DESCRIPTION
B: CAUTION
When the electrical connectors are disconnected, always conduct an operational check after connecting them again.
Avoid impact and damage to the glass.
C: PREPARATION TOOL
TOOL NAME
Circuit Tester
Piano Wire
Windshield Knife
REMARKS
Used for checking voltage and continuity.
Used for window glass removal.
Used for window glass removal.
GW-7
POWER WINDOW SYSTEM

2. Power Window System

A: SCHEMATIC
1. POWER WINDOW LHD MODEL
<Ref. to WI-232, LHD MODEL, SCHEMATIC, Power Window System.>
2. POWER WINDOW RHD MODEL

<Ref. to WI-236, RHD MODEL, SCHEMATIC, Power Window System.>
B: INSPECTION
Symptom
All power windows does not operate.
One window does not operate.

Window Lock does not operate.
Repair order
(1) Fuse (SBF-6) (F/B No. 18: RHD model)
(2) Power window circuit breaker
(3) Power window relay
(4) Wire harness
(1) Power window main switch
(2) Power window sub switch
(3) Power window motor
(4) Wire harness
(1) Power window main switch
GW-8
POWER WINDOW CONTROL SWITCH

3. Power Window Control

Switch
A: REMOVAL
1. MAIN SWITCH
2) Loosen the screw to remove the power window
main switch.
BO0101
2. SUB-SWITCH
2) Remove the switch panel.
BO0102
B: INSTALLATION
1. MAIN SWITCH
2. SUB-SWITCH
GW-9

C: INSPECTION
1. MAIN SWITCH LHD MODEL
Measure the switch resistance.
Driver's switch:
Switch position
AUTO UP
UP
OFF
DOWN
AUTO DOWN
Terminal No.
13 and 2, 1 and 5
13 and 2, 1 and 5
1 and 2
1 and 5
2 and 5
13 and 1, 2 and 5
13 and 1, 2 and 5
Standard
Less than 1
Less than 1
Less than 1
Less than 1
Less than 1
Front passenger's switch:

Switch position
UP
OFF
DOWN
Terminal No.
13 and 6, 7 and 5
5 and 6
5 and 7
6 and 7
13 and 7, 6 and 5
Standard
Less than 1
Less than 1
Less than 1
Rear left switch:

Switch position
UP
OFF
DOWN
Terminal No.
10 and 13, 9 and 5
5 and 9
5 and 10
9 and 10
13 and 9, 10 and 5
Standard
Less than 1
Less than 1
Less than 1
Rear right switch:

Switch position
UP
OFF
DOWN
Terminal No.
13 and 16, 15 and 5
5 and 15
5 and 16
15 and 16
13 and 15, 16 and 5
If NG, replace the main switch.
GW-10
Standard
Less than 1
Less than 1
Less than 1

2. MAIN SWITCH RHD MODEL

Drivers switch:
Switch position
AUTO UP
UP
OFF
DOWN
AUTO DOWN
Terminal No.
12 and 6, 7 and 1
12 and 6, 7 and 1
1 and 6
1 and 7
6 and 7
12 and 7, 6 and 1
12 and 7, 6 and 1
Standard
Less than 1
Less than 1
Less than 1
Less than 1
Less than 1
Front passengers switch:

Switch position
UP
OFF
DOWN
Terminal No.
12 and 3, 2 and 1
1 and 2
1 and 3
2 and 3
12 and 2, 3 and 1
Standard
Less than 1
Less than 1
Less than 1
Rear left switch:

Switch position
UP
OFF
DOWN
Terminal No.
12 and 10, 9 and 1
1 and 9
1 and 10
9 and 10
12 and 9, 10 and 1
Standard
Less than 1
Less than 1
Less than 1
Rear right switch:

Switch position
UP
OFF
DOWN
Terminal No.
12 and 14, 1 and 13
1 and 13
1 and 14
13 and 14
12 and 13, 14 and 1
Standard
Less than 1
Less than 1
Less than 1
If NG, replace the main switch.
3. SUB-SWITCH
Front passenger's door switch and rear door switch:
Switch position
UP
OFF
DOWN
Terminal No.
8 and 5, 6 and 7
4 and 5, 6 and 7
8 and 7, 4 and 5
If NG, replace the sub-switch.
GW-11
Standard
Less than 1
Less than 1
Less than 1
FRONT DOOR GLASS

4. Front Door Glass
6) Remove the rear end of door weather strip and

weather strip outer.
A: REMOVAL
2) Remove the sealing cover. <Ref. to EB-14, REMOVAL, Front Sealing Cover.>
3) Remove the outer mirror assembly. <Ref. to
GW-18, REMOVAL, Outer Mirror Assembly.>
4) Remove the gusset.
BO0087
7) Operate the power window switch to move the

glass to position shown in the figure, and then remove the two nuts from service holes.
BO0085
8) Take out the door glass.
BO0492
5) Remove the stabilizers and trim hooks.
B5M1047
BO0086
CAUTION:
Do not turn the regulator in closing direction
after removal of the glass. Otherwise gear may
be disengaged.
GW-12
FRONT DOOR GLASS

B: INSTALLATION
CAUTION:
Make sure that the glass stay is placed securely
in sash.
2) Adjust the front door glass. <Ref. to GW-13, ADJUSTMENT, Front Door Glass.>
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 in General Description. <Ref. to GW-4, FRONT DOOR GLASS,
<Ref. to GW-3, FIXED GLASS (WAGON),
BO0265
C: ADJUSTMENT
NOTE:
Before adjustment, ensure that all adjusting bolts of
stabilizer, upper stopper, and sash are loose and
door glass is raised so that it is in contact with
weatherstrip.
1) Temporarily tighten one adjusting bolt on one
side of rear sash at the midpoint of slotted hole in
the inner panel.
2) Temporarily tighten the regulator B-channel in a
position at the top of slotted hole.
3) Lower the door glass 10 to 15 mm (0.39 to 0.59
in) from fully closed position. While applying outward pressure of 45.04.9 N (4.60.5 kg, 11.01.1
lb) (F) to upper edge of glass above midpoint of two
outer stabilizers, press the inner stabilizer at pressure of 105 N (1.00.5 kg, 0.20.1 lb) to the glass,
then secure it.
12 (0.472)
12 (0.472)
A A
A-A
Unit: mm (in)
BO0388
5) For adjustment of upper and lower ends of center pillar, loosen the adjusting nut (A) of B-channel
(B).
B5M0729A
G5M0421
GW-13
FRONT DOOR GLASS

6) Adjust so that the upper and lower ends of center pillar are the same size.
8) After stabilizer adjustment, carry out the glass

crimp adjustment. First, visually ensure positional
relationship between retainer & molding and glass
of the roof side, and then begin with rear sash adjustment. Adjust two adjusting bolts alternately step
by step to obtain dimensions shown below (crosssection A).
NOTE:
If two nuts are loosened at the same time, sash
moves back and forth. Therefore, when one nut is
adjusted, secure the other.
9) Make the same adjustment of two adjusting bolts
of rear sash.
2-3
(0.079-0.118)
6 (0.236)
Unit: mm (in)
BO0389
7) For glass stroke adjustment, close the door,

raise glass until positional relationship between
glass and weatherstrip becomes as shown. And
secure the glass so that the upper stopper lightly
touches the glass holder.
BO0267
CAUTION:
Do not tilt the sash bracket to inner panel during adjustment. Otherwise smooth regulator
operation cannot be achieved.
2-3
(0.079-0.118)
6 (0.236)
Unit: mm (in)
S5M0201A
BO0267
For preventing wind noise, adjust the glass at the

position where tip of gusset is raised up a little.
10) Make adjustment of front sash in the same

manner as that of rear sash.
CAUTION:
Although front and rear sashes must, as a rule,
be adjusted in the same manner, in some door
installation, the adjustment in a different manner may be required. However, adjustment of
one sash to the maximum amount and the other
to the minimum amount is not permitted. Such
adjustment may result in application of excessive load to regulator.
BO0390
(A) 0-1.5 mm (0-0.059 in)
GW-14
FRONT DOOR GLASS

11) After adjustments, tighten the nuts.

12) After adjustment to 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 the gusset to prevent generation
of wind noise.
13) During adjustments, loosen the other three
clamping bolts.
BO0492
14) After adjustment, tighten the bolts and nuts.
GW-15
FRONT REGULATOR AND MOTOR ASSEMBLY

5. Front Regulator and Motor

Assembly
B: INSTALLATION
2) Adjust the front door glass. <Ref. to GW-13, ADJUSTMENT, Front Door Glass.>
A: REMOVAL
1) Remove the door glass. <Ref. to GW-12, REMOVAL, Front Door Glass.>
2) Loosen the nuts to remove rear sash.
Tightening torque:
Refer to COMPONENT in General Description. <Ref. to GW-4, FRONT DOOR GLASS,
C: INSPECTION
1) Make sure that the power window motor rotates
properly when battery voltage is applied to the terminals of motor connector.
2) Change polarity of battery connections to terminals to ensure that the motor rotates in reverse direction.
BO0089
3) Disconnect the motor connector.

4) Loosen the four bolts and two nuts to remove
regulator assembly.
BO0090
5) Loosen the screw to remove motor assembly.
BO0091
GW-16
REMOTE CONTROL MIRROR SYSTEM

6. Remote Control Mirror System

A: SCHEMATIC
1. REMOTE CONTROL MIRROR LHD MODEL
<Ref. to WI-251, LHD MODEL, SCHEMATIC, Remote Controlled Rearview Mirror System.>
2. REMOTE CONTROL MIRROR RHD MODEL

<Ref. to WI-252, RHD MODEL, SCHEMATIC, Remote Controlled Rearview 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. 1) (F/B No. 4) (F/B No. 19)
(2) Mirror switch
(3) Wire harness
(1) Mirror switch
(2) Mirror motor
(3) Wire harness
(1) Mirror switch
(2) Mirror heater
(3) Wire harness
GW-17
OUTER MIRROR ASSEMBLY

7. Outer Mirror Assembly
B: INSTALLATION
A: REMOVAL
1) Remove the door trim. <Ref. to EI-36, REMOVAL, Front Door Trim.>
2) Remove the mirror gusset cover.
: Hook
BO0099
3) Disconnect the mirror connector.

4) Loosen the screws to remove mirror assembly.
BO0100
GW-18
OUTER MIRROR ASSEMBLY

C: INSPECTION
Check to ensure that the rearview mirror moves properly when battery voltage is applied to terminals.
Mirror heater not-equipped model:
Switch position
OFF
UP
DOWN
LEFT
RIGHT
Terminal No.
4 (+) and 6 ()
6 (+) and 4 ()
5 (+) and 6 ()
6 (+) and 5 ()
If NG, replace the mirror.

Mirror heater equipped model:
Switch position
OFF
UP
DOWN
LEFT
RIGHT
Terminal No.
6 (+) and 8 ()
8 (+) and 6 ()
7 (+) and 8 ()
8 (+) and 7 ()
If NG, replace the mirror.
GW-19
OUTER MIRROR
8. Outer Mirror
A: REPLACEMENT
1) Remove the door mirror assembly. <Ref. to GW18, REMOVAL, Outer Mirror Assembly.>
2) Warm the area around the mirror holder with a
hair drier until the edges of the mirror holder become soft (about 2 or 3 minutes with a 1,000 W drier.)
3) Use a flat-bladed screwdriver without sharp edges to lift the mirror out of the mirror holder. (Also remove the connector from the back of mirrors with
heaters.)
B5M1144A
4) Warm the area around the mirror holder with a

hair drier until the edges of the mirror holder become soft (about 2 or 3 minutes with a 1,000 W drier.)
5) Remove the backing of the new double-stick
tape, and push the mirror in to install it.
CAUTION:
Unless the mirror holder is warmed sufficiently,
the mirror holder edges may be damaged or the
mirror cracked.
GW-20
REMOTE CONTROL MIRROR SWITCH

9. Remote Control Mirror

Switch
B: INSTALLATION
A: REMOVAL
BO0103
GW-21
REMOTE CONTROL MIRROR SWITCH

C: INSPECTION
Move the rearview mirror switch to each position
and check continuity between terminals.
B5M1132
Change over switch right position:

Switch position
OFF
UP
DOWN
LEFT
RIGHT
Terminal No.
4 and 6, 2 and 1
6 and 2, 4 and 1
4 and 8, 2 and 1
8 and 2, 4 and 1
Standard
More than 1M
Less than 1
Less than 1
Less than 1
Less than 1
Terminal No.
4 and 7, 2 and 1
7 and 2, 4 and 1
4 and 9, 2 and 1
9 and 2, 4 and 1
Standard
More than 1M
Less than 1
Less than 1
Less than 1
Less than 1
Change over switch left position:

Switch position
OFF
UP
DOWN
LEFT
RIGHT
If NG, replace the switch.
GW-22
REAR DOOR GLASS

10.Rear Door Glass
5) Loosen the two screws to remove the weather

strip outer.
A: REMOVAL
2) Remove the sealing cover. <Ref. to EB-17, REMOVAL, Rear Sealing Cover.>
3) Remove the stabilizer.
B5M1044
4) Remove the door weather strip.
BO0093
6) Operate the power window switch to remove

glass as shown in the figure, and then remove two
nuts.
BO0094
BO0092
7) Loosen the two rear sash installation nuts, and

then move the rear sash backward.
8) Remove the glass.
CAUTION:
GW-23
REAR DOOR GLASS

B: INSTALLATION
2) Adjust the crimp of glass using the following dimensions as a guide line.

CAUTION:
Make sure that the glass stay is placed securely
in sash.
2) Adjust the rear door glass. <Ref. to GW-24, ADJUSTMENT, Rear Door Glass.>
Tightening torque:
Refer to COMPONENT in General Description. <Ref. to GW-5, REAR DOOR GLASS,
<Ref. to GW-4, FRONT DOOR GLASS,
6 (0.236)
NOTE:
The rear door glass, as a rule, should be adjusted
in the same manner as front glass, although they
are different in dimension. Special notes for the
rear glass are given below.
1) Adjust the glass position using the following dimensions as a guide line.
Unit: mm (in)
C: ADJUSTMENT
12 (0.472)
2-3
(0.079-0.118)
BO0269
CAUTION:
If the crimp of rear glass is higher than necessary, glass may get caught in weatherstrip of
center pillar corner, resulting in early wear of
weatherstrip. Be careful when adjusting.
After adjustment, move the glass up and
down to check whether it is caught.
12 (0.472)
A-A
Unit: mm (in)
BO0394
CAUTION:
If the dimensions are smaller than the given
dimensions, glass may get caught in weatherstrip during lifting/lowering operation. In the
worst case, it may cause the glass not to be
opened fully.
After adjustment, move the glass up and
down to check whether it is caught.
GW-24
REAR REGULATOR AND MOTOR ASSEMBLY

11.Rear Regulator and Motor Assembly

A: REMOVAL
1) Remove the door glass. <Ref. to GW-23, REMOVAL, Rear Door Glass.>
2) Remove the front sash.
3) Disconnect the motor connector.
4) Loosen the four bolts and two nuts to remove
regulator assembly.
BO0097
5) Loosen the screws to remove motor assembly.
BO0098
B: INSTALLATION
2) Adjust the rear door glass. <Ref. to GW-24, ADJUSTMENT, Rear Door Glass.>
Tightening torque:
Refer to COMPONENT in General Description. <Ref. to GW-5, REAR DOOR GLASS,
C: INSPECTION
1) Make sure that the power window motor rotates
properly when battery voltage is applied to the terminals of motor connector.
2) Change polarity of battery connections to the terminals to ensure that the motor rotates in reverse
direction.
GW-25
WINDSHIELD GLASS
12.Windshield Glass
NOTE:
Because the matching pins are bonded to the corners of glass, use piano wire to cut the pin.
A: REMOVAL
1. USING WINDSHIELD KNIFE
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 layer.
5) Insert the windshield knife into the adhesive layer.
6) While holding the knife edge and windshield
glass edge at a right angle, move the windshield
knife in parallel to the windshield glass edge along
face and edge of windshield glass to cut the adhesive layer.
CAUTION:
Do not twist the windshield knife.
Cutting of adhesive layer shall be started with
wider gap between windshield glass and body.
G5M0412
2. USING PIANO WIRE

2) Remove the roof molding and upper front molding.
3) Tape the body side of the circumference of windshield glass for protection.
4) Make a hole in the adhesive layer using a drill or
knife.
5) Pass the piano wire through the hole, and attach
securely both the wire ends to pieces of wood.
G5M0494
6) Pull the wire ends alternately to cut off the adhesive layer.
G5M0418
CAUTION:
Do not tightly pull the piano wire against the
windshield glass edge.
Be careful not to damage the 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
8) Fit the molding mark (B) to notch (A).
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 2 mm (0.08 in)
thick.
CAUTION:
Be careful not to damage the body and paint
surface.
G5M0553
3) Clean the body with alcohol or white gasoline to

remove thoroughly chips, dusts, and dirts from
body face.
4) Place the glass on body.
5) Adjust the glass position to make uniform clearance between body and glass in four corners.
6) Place the matching pins and body on glass.
11 (0.433)
Matching pin
BO0270
9) Apply primer to the adhesive layer of glass using

sponge.
10) Apply primer to the adhesive layer of body.
CAUTION:
Primer once attached to the painted surface
of the body and internal trim is hard to wipe off.
Mask the circumference of such areas.
Let the primer dry for about ten minutes before installing the glass.
Do not touch the surface coated with primer.
Fastener
Dam rubber
11 (0.433)
15 (0.591)
G5M0495
Unit: mm (in)
BO0395
7) Remove the glass from body.
GW-27
WINDSHIELD GLASS
11) Cut off the cartridge nozzle tip and set it in sealant gun as shown.
G5M0408
12) Apply adhesive to the glass end surface as

shown.
13) Fit the matching pins using suction rubber cup
to install the windshield glass.
G5M0409
14) Lightly press the windshield glass for tight fit.

15) Make the adhesive surface flush using spatula.
CAUTION:
When the door is opened/closed after glass is
bonded, always lower the door glass and then
open/close it carefully.
Move the vehicle slowly.
16) After completion of all work, allow the vehicle to
stand for about 24 hours.
NOTE:
For minimum drying time and time the vehicle must
be left standing before driving after bonding, follow
instructions or instruction manual from the adhesive manufacturer.
17) After curing of adhesive, pour water on external
surface of vehicle to check that there are no water
leaks.
CAUTION:
When a vehicle is returned to the user, tell him
or her that the vehicle should not be subjected
to heavy impact for at least three days.
18) Install the cowl panel. <Ref. to EI-32, INSTALLATION, Cowl Panel.>
GW-28
REAR GATE GLASS

13.Rear Gate Glass

A: REMOVAL
1) Remove the rear wiper motor. <Ref. to WW-18,
REMOVAL, Rear Wiper Motor.>
2) Remove the electrical connector 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 evenly to the glass attachment
area.
2) Insert the glass clip pin into the 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:
CAUTION:
5) Connect the rear defogger terminals.
6) Install the rear wiper. <Ref. to WW-18, INSTALLATION, Rear Wiper Motor.>
Upper side
Molding
Glass
Adhesive
Lower side
Glass
Adhesive
Molding
BO0396
CAUTION:
GW-29
REAR WINDOW GLASS

14.Rear Window Glass

leaks.
A: REMOVAL
1) Disconnect the electrical connectors from rear
defogger terminals.
2) Remove the glass in the same procedure as for
windshield glass. <Ref. to GW-26, REMOVAL,
Windshield Glass.>
CAUTION:
B: INSTALLATION
1) Bond the dam rubber and matching pin.
14.5 (0.571)
Matching pin
Fastener
Dam rubber
8 (0.315)
R20
22 (0.866)
Unit: mm (in)
BO0271
2) Install the glass in the same procedure as for

windshield glass. <Ref. to GW-27, INSTALLATION, Windshield Glass.>
3) Connect the rear defogger terminals.
CAUTION:
open/close door carefully.
NOTE:
GW-30
REAR WINDOW DEFOGGER SYSTEM

15.Rear Window Defogger System

A: SCHEMATIC
1. REAR WINDOW DEFOGGER LHD MODEL
<Ref. to WI-248, LHD MODEL, SCHEMATIC, Rear Window Defogger System.>
2. REAR WINDOW DEFOGGER RHD MODEL

<Ref. to WI-249, RHD MODEL, SCHEMATIC, Rear Window Defogger System.>
B: INSPECTION
Symptom
Rear window defogger does not operate.
Repair order
(1) Fuse (M/B No. 1) (F/B No. 17)
(2) Rear defogger relay
(3) Rear defogger timer
(4) Defogger switch
(5) Rear defogger condenser
(6) Defogger wire
(7) Wire harness
GW-31
REAR WINDOW DEFOGGER

16.Rear Window Defogger
B: REPAIR
A: INSPECTION
1) Clean the broken portion with alcohol or white

gasoline.
2) Mask both side of wire with thin film.
3) Apply conductive silver composition (DUPONT
No. 4817) to broken portion.
CAUTION:
When wiping stain on glass off with cloth, use a
dry and soft cloth and move it in the direction of
the heat wire extension to avoid damage to the
heat wire.
2) Turn the defogger switch to ON.
3) Wrap the tips of tester pins with aluminum foil to
avoid damage to heat wire.
G6M0138
4) After repair, check the wire.
G6M0136
4) Measure the voltage at wire center with DC voltmeter.

Standard voltage:
Approx. 6 volts
B5M1053A
Voltage
Approx. 6 V
Approx. 12 V or 0 V
Criteria
OK
Broken
NOTE:
If the measured value is 12 volts, heat wire is
open between wire center and positive (+) end.
If zero volt, heat wire is open between wire center and ground.
5) Apply positive lead of voltmeter to positive terminal of voltmeter, and then move the negative lead
along the wire up to negative terminal end. If voltage changes from zero to several volts during
movement of lead, heat wire is open at the voltage
change point.
GW-32
REAR QUARTER GLASS

17.Rear Quarter Glass

A: REMOVAL
Remove the glass in the same procedure as for windshield glass. <Ref. to GW-26, REMOVAL, Windshield
Glass.>
Matching pin
C-C
Rear gate glass
Matching pin
A
Molding
Adhesive
C
Rear quarter glass
C
Molding
B-B
A-A
Adhesive
Dam rubber
Matching pin
Rear quarter glass

Molding
Adhesive
Molding
Rear quarter glass

BO0210
B: INSTALLATION

1) Cut off the nozzle tip as shown in the figure.
NOTE:
leaks.
G5M0414
2) Install the glass in the same procedure as for

windshield glass. <Ref. to GW-27, INSTALLATION, Windshield Glass.>
CAUTION:
CAUTION:
GW-33
ROOF WINDOW GLASS

18.Roof Window Glass

A: REMOVAL
<Ref. to SR-5, REMOVAL, Sunroof Lid.>
B: INSTALLATION
<Ref. to SR-5, INSTALLATION, Sunroof Lid.>
C: ADJUSTMENT
<Ref. to SR-5, ADJUSTMENT, Sunroof Lid.>
GW-34
INNER REARVIEW MIRROR

19.Inner Rearview Mirror

A: REMOVAL
NOTE:
The spring cannot be reused. Prepare a new spring
before removal.
1) Turn the mirror base 90 degrees clockwise or
counterclockwise to remove it.
B5M1059
2) Remove the spring from mirror base.
B5M1060
CAUTION:
Be careful not to damage the mirror surface.
B: INSTALLATION
C: INSPECTION
Do not let the mirror be damaged.
Do not let the spring deteriorate.
GW-35
INNER REARVIEW MIRROR

GW-36
BODY STRUCTURE
BS
1.
2.
3.
Page
Datum Points...............................................................................................3
Datum Dimensions....................................................................................11
GENERAL DESCRIPTION
BODY STRUCTURE
A: PREPARATION TOOL
TOOL NAME
Tram tracking gauge
Tape measure
REMARKS
Used for measuring dimension.
Used for measuring dimension.
BS-2
DATUM POINTS
BODY STRUCTURE
2. Datum Points
A: LOCATION
NOTE:
Datum points are specified for body repair.
Guide holes, locators, and indents are provided to facilitate panel replacement and to increase alignment
accuracy.
Both right and left reference points are symmetrical.
1. WAGON/SEDAN
(12)
(70)
(74)
(24)
(4)
(12)
(3)
(10)
(2)
(9)
(22)
(73)
(20)
(8)
(62)
(21)
(1)
(71)
(18)
(5)
(1)
(4)
(3)
(2)
(5)
(19)
(75)
(7)
BO0404
(1)
(2)
(3)
(4)
(5)
(7)
(8)
(9)
Radiator attaching hole 12 mm

(0.47 in) dia. (Symmetrical)
Fender attaching hole 7 mm (0.28
in) dia. (Symmetrical)
Fender attaching hole 10 mm
Hood hinge attaching hole 12 mm
Radiator panel side gauge hole 20
mm (0.79 in) dia. (Symmetrical)
Fender attaching hole 9 mm (0.35
Gauge hole 12 mm (0.47 in) dia.
(Symmetrical)
Front suspension cross member
attaching hole 12.4 mm (0.488 in)
dia. (Symmetrical)
(10)
(12)
(18)
(19)
(20)
(21)
(22)
Cowl panel attaching hole 6 mm

(0.24 in) dia. (Vehicle center)
Front glass attaching hole Right
6.5 mm (0.256 in) dia. Left 6.5
10 mm (0.256 0.39 in) dia.
(24)
(62)

Outer panel center pillar gauge
hole 12 mm (0.47 in) dia. (Symmetrical)
Outer panel center pillar gauge
Weather strip patch attaching hole
5.2 mm (0.205 in) dia. (Symmetrical)
(71)
BS-3
(70)
(73)
(74)
(75)
Roof panel repair locator hollow

Belt anchor attaching hole 11 mm
Trim clip attaching hole 8.5 mm
Harness clip attaching hole 7 mm
Trim clip attaching hole 10 mm
Insulator attaching hole 8 mm
DATUM POINTS
BODY STRUCTURE
2. WAGON (REAR SECTION)
(30)
(72)
(72)
(31)
(32)
(77)
(58)
(67)
(33)
(65)
(31)
(77)
(30)
(31)
(32)
Child anchor attaching hole 11

mm (0.43 in) dia.
Washer hose attaching hole Left 7
mm (0.28 in) dia.
Rear combination light mounting
(33)
(58)
(65)
(58)
(67)
Two striker attaching hole 15 mm

(0.59 in) dia.
Rear bumper plate nut attaching
Floor mat clip attaching hole 8 mm
(0.31 in) dia.
BS-4
(32)
BO0405
(67)
(72)
(77)
Gusset floor rear side gauge hole

Trim upper clip attaching hole 8.5
DATUM POINTS
BODY STRUCTURE
3. SEDAN (REAR SECTION)
(50)
(51)
(63)
(65)
(66)
(51)
(69)
(60)
(55)
(67)
(56)
(68)
(76)
(63)
(58)
(66)
(76)
(68)
(55)
(56) (58) (67)

BO0406
(50)
(51)
(55)
(56)
Repair locator hollow (Vehicle

center)
Glass attaching hole Right 6.5 mm
(0.256 in) dia. Left 6.5 10 mm
(0.256 0.39 in) dia.
Rear combination light mounting
(58)
Bumper attaching hole 7 mm

(66)
(60)
(63)
(65)
Rear bumper attaching hole 11

Choke coil harness attaching hole
5.4 mm (0.213 in) dia.
Feeder line fixing hole 7 mm (0.28
in). (Symmetrical)
Floor mat clip attaching hole 8 mm
(0.31 in) dia.
Bulkhead rear gauge hole 10 mm
BS-5
(67)
(68)
(69)
(76)
Gusset floor rear side gauge hole

Rear skirt inner side gauge hole
10 mm (0.39 in) dia. (Symmetrical)
Rear panel (reinforcement) repair
locator hollow (Vehicle center)
Press location hole 15 mm (0.59
DATUM POINTS
BODY STRUCTURE
4. UNDERBODY SECTION
(81)
(92) (82) (90)
(83) (84)
(85)
(94)
(86)
(87)
(88)
(87)
(88)
(91)
(89)
(93)
(89)
(93)
(80)
(80)
(81)
(92) (82) (90)
(83) (84)
(85)
(86)
(94)
(91)
BO0407
(80)
(81)
(82)
(83)
(84)
Radiator lower frame gauge hole

Side frame gauge hole 20 mm
Front crossmember (Ft) attaching
hole 12.4 mm (0.488 in) dia.
(Symmetrical)
Suspension attaching hole 17 mm
(85)
(86)
(87)
(88)
(89)
Transmission mount attaching

hole 14 mm (0.55 in) dia.
Rear differential attaching hole 16
Rear suspension attaching hole
Rear side frame gauge hole 15
BS-6
(90)
(91)
(92)
(93)
(94)
Strut mount attaching hole 9.5 mm

Strut mount attaching hole 10 mm
Sub frame attaching hole 16 mm
Bumper beam attaching hole
Right 15 mm (0.59 in) dia. Left 19
15 mm (0.75 0.59 in) dia.
DATUM POINTS
BODY STRUCTURE
(1)
(2)
(18)
(5)
(19)
(7)
BO0408
BO0413
(4)
(20)
(90)
(3)
(21)
(10)
BO0409
BO0414
(22)
(8)
(9)
BO0410
BO0415
WAGON
(24)
(30)
(12)
BO0411
BS-7
BO0417
DATUM POINTS
BODY STRUCTURE
WAGON
SEDAN
(50)
(31)
(51)
(77)
(72)
(91)
BO0418
WAGON
BO0422
SEDAN
(32)
(55)
(56)
(58)
(58)
BO0419
WAGON
BO0424
SEDAN
(33)
(60)
BO0420
BO0425
SEDAN
(63)
(66)
(65)
BO0421
BS-8
BO0426
DATUM POINTS
BODY STRUCTURE
(70)
(67)
(74)
BO0427
BO0431
SEDAN
(68)
(76)
(75)
BO0428
SEDAN
BO0432
(69)
(80)
(81)
BO0429
BO0433
(62)
(73)
(82)
(71)
(92)
BO0430
BS-9
BO0434
DATUM POINTS
BODY STRUCTURE
(83)
(84)
(94)
(86)
(88)
(85)
(89)
(93)
BO0435
(87)
BO0436
BS-10
BO0437
DATUM DIMENSIONS
BODY STRUCTURE
3. Datum Dimensions
A: MEASUREMENT
Refer to LOCATION for details on measurement
points. <Ref. to BS-3, LOCATION, Datum Points.>
NOTE:
Using a tram tracking gauge, measure all the dimensions.
When using a tape measure, carefully measure
dimensions without letting the tape measure sag or
twist.
Measure the linear dimensions between cores of
holes.
Suffixes RH and LH indicate right-hand and
left-hand.
G5M0122
Measure at the center of the circle around the

outside of the body panel.
B5M1133A
BS-11
DATUM DIMENSIONS
BODY STRUCTURE
1. CENTER STRUCTURE
*2
(91)
674
620
*2
(90)
(81)
157
8 20
12
485 (83) (84) 159
380
206
694
(90)
(82)
(83)
(92)
(93)
633
673
(87)
1258
1358
(89) (93)
(91)
(88)
(94) (86)
(85)
1110
1205
920
780
1128
(80)
(85)
(92)
(81)
776
257
800
856
1065
860
910
906
529
(80)
(82)
(83)
(90)
(84)
(94) (86)
(88)
(87)
(91)
(89)(93)
(89)(93)
(87)
(81) (92) (82)
12
69
71
12
1
95 5
87
854
11
09
05
12
24
10
11
13
(94)(86)
(81)
11
92
12
47
(84)
924
940
500
982
76
(87)
(84)
(89)
206
206
206
77
317
*1
(88)
(85)
13 (94)
205
(81)
(92) (82)
(88)
(83)
*1: Side sill

*2: Upper surface
BO0438
BS-12
DATUM DIMENSIONS
BODY STRUCTURE
2. WAGON/SEDAN (FRONT STRUCTURE)
(4)
(2)
(4)
(3)
(10)
(90)
(3)
(8)
(18)
(9)
(90)
(1)
(1)
(5)
(2)
(19)
(7)
(5)
Point to point
(10) to (1) RH
(10) to (1) LH
(10) to (90) RH
(10) to (90) LH
(10) to (8) RH
(10) to (8) LH
(10) to (2) RH
(10) to (2) LH
(4) RH to (2) RH
(4) LH to (2) LH
(4) RH to (3) RH
(4) LH to (3) LH
(90) RH to (90) LH
(8) RH to (8) LH
(8) RH to (4) LH
(8) LH to (4) RH
(3) RH to (2) RH
(3) LH to (2) LH
(4) RH to (4) LH
BO0439
Dimension
912 (35.91)
912 (35.91)
566 (22.28)
566 (22.28)
581 (22.87)
581 (22.87)
947 (37.28)
947 (37.28)
778 (30.63)
778 (30.63)
430 (16.93)
430 (16.93)
1,065 (41.93)
894 (35.20)
1,210 (47.64)
1,210 (47.64)
349 (13.74)
349 (13.74)
1,417 (55.79)
Point to point
(2) RH to (2) LH
(5) RH to (5) LH
(7) RH to (18) RH
(7) LH to (18) LH
(7) RH to (19) RH
(7) LH to (19) LH
(4) RH to (2) LH
(4) LH to (2) RH
(3) RH to (3) LH
(3) RH to (4) LH
(3) LH to (4) RH
(2) RH to (3) LH
(2) LH to (3) RH
(9) RH to (9) LH
(9) RH to (8) LH
(9) LH to (8) RH
(9) RH to (4) LH
(9) LH to (4) RH
BS-13
Unit: mm (in)
Dimension
1,341 (52.80)
720 (28.35)
1,138 (44.80)
1,138 (44.80)
1,116 (43.94)
1,116 (43.94)
1,583 (62.32)
1,583 (62.32)
1,396 (54.96)
1,470 (57.87)
1,470 (57.87)
1,412 (55.59)
1,412 (55.59)
860 (33.86)
931 (36.65)
931 (36.65)
1,280 (50.39)
1,280 (50.39)
DATUM DIMENSIONS
BODY STRUCTURE
(12)
(70)
(73)
(12)
(24)
(22)
(4)
(65)
(73)
(20)
(10)
(21)
(4)
(18)
(19)
BO0440
Point to point
(4) RH to (24)
(4) LH to (24)
(10) to (24)
(10) to (24)
(10) to (12) RH
(10) to (12) RH
(10) to (12) LH
(10) to (12) LH
(12) RH to (12) LH
(12) RH to (12) LH
(18) RH to (21) RH
(18) LH to (21) LH
(19) RH to (20) RH
Dimension
1,127 (44.37) Wagon
1,110 (43.70) Sedan
957 (37.68) Wagon
935 (36.81) Sedan
1,122 (44.17) Wagon
1,106 (43.54) Sedan
1,122 (44.17) Wagon
1,106 (43.17) Sedan
1,029 (40.51) Wagon
1,042 (41.02) Sedan
1,049 (41.30)
1,049 (41.30)
1,089 (42.87)
Point to point
(19) LH to (20) LH
(20) RH to (22) RH
(20) LH to (22) LH
(21) RH to (22) RH
(21) LH to (22) LH
(24) to (65)
(24) to (65)
(65) to (70) RH
(65) to (70) LH
(65) to (73) RH
(65) to (73) LH
(73) RH to (73) LH
BS-14
Unit: mm (in)
Dimension
1,089 (42.87)
869 (34.21)
869 (34.21)
985 (38.78)
985 (38.78)
1,232 (48.50) Wagon
1,237 (48.70) Sedan
1,067 (42.01)
1,067 (42.01)
830 (32.68)
830 (32.68)
1,394 (54.88)
DATUM DIMENSIONS
BODY STRUCTURE
3. WAGON/SEDAN (REAR STRUCTURE)
(74)
(70)
(75)
(74)
(62)
(71)
(70)
(91)
(75)
(62)
(73)
(65)
(71)
(67)
(91)
(73)
(58)
(67)
(58)
BO0441
Point to point
(58) RH to (58) LH
(62) RH to (62) LH
(62) RH to (65)
(62) LH to (65)
(62) RH to (73) RH
(62) LH to (73) LH
(62) RH to (73) LH
(62) LH to (73) RH
(62) RH to (74) RH
(62) LH to (74) LH
(65) to (67) RH
(65) to (67) LH
(65) to (71) RH
(65) to (71) LH
(65) to (74) RH
(65) to (74) LH
(65) to (75) RH
(65) to (75) LH
(65) to (91) RH
(65) to (91) LH
Dimension
1,128 (44.41)
1,332 (52.44)
915 (36.02)
915 (36.02)
762 (30.00)
762 (30.00)
1,561 (61.46)
1,561 (61.46)
592 (23.31) Wagon
603 (23.74) Sedan
1,501 (59.09)
1,501 (59.09)
823 (32.40)
823 (32.40)
1,275 (50.20) Wagon
1,282 (50.47) Sedan
1,450 (57.09)
1,450 (57.09)
1,064 (41.89)
1,064 (41.89)
Point to point
(67) RH to (67) LH
(67) RH to (91) LH
(67) LH to (91) RH
(70) RH to (70) LH
(70) RH to (73) RH
(70) LH to (73) LH
(70) RH to (73) LH
(70) LH to (73) RH
(70) RH to (75) RH
(70) LH to (75) LH
(70) RH to (91) LH
(70) LH to (91) RH
(71) RH to (71) LH
(71) RH to (74) RH
(71) LH to (74) LH
(74) RH to (74) LH
(74) RH to (74) LH
(75) RH to (75) LH
(91) RH to (91) LH
BS-15
Unit: mm (in)
Dimension
1,110 (43.70)
1,381 (54.37)
1,381 (54.37)
1,060 (41.73)
948 (37.32)
948 (37.32)
1,542 (60.71)
1,542 (60.71)
1,443 (56.81)
1,443 (56.81)
1,532 (60.32)
1,532 (60.32)
1,361 (53.58)
954 (37.56) Wagon
949 (37.36) Sedan
1,135 (44.69) Wagon
1,147 (45.16) Sedan
1,399 (55.08)
1,205 (47.44)
DATUM DIMENSIONS
BODY STRUCTURE
4. WAGON (FRONT STRUCTURE)
(72)
(77)
(33)
(62)
(71)
(72)
(65)
(77)
(62)
(71)
BO0442
Point to point
(33) RH to (65)
(33) LH to (65)
(33) RH to (72) LH
(33) LH to (72) RH
(62) RH to (72) RH
(62) LH to (72) LH
(65) to (72) RH
(65) to (72) LH
Dimension
1,534 (60.39)
1,534 (60.39)
1,344 (52.91)
1,344 (52.91)
732 (28.82)
732 (28.82)
1,076 (42.36)
1,076 (42.36)
Point to point
(65) to (77) RH
(65) to (77) LH
(71) RH to (72) RH
(71) LH to (72) LH
(72) RH to (72) LH
(72) RH to (77) LH
(72) LH to (77) RH
(77) RH to (77) LH
BS-16
Unit: mm (in)
Dimension
1,538 (60.55)
1,538 (60.55)
1,223 (48.15)
1,223 (48.15)
1,226 (48.27)
1,544 (60.79)
1,544 (60.79)
898 (35.35)
DATUM DIMENSIONS
BODY STRUCTURE
5. WAGON (REAR STRUCTURE)
(30)
(91)
(31)
(32)
(65)
(77)
(91)
(58)
(31)
(32)
(33)
(77)
(58)
BO0443
Point to point
(30) to (32) RH
(30) to (32) LH
(30) to (33) RH
(30) to (33) LH
(30) to (65)
(31) RH to (31) LH
(32) RH to (32) LH
Dimension
850 (33.46)
850 (33.46)
904 (35.59)
904 (35.59)
1,292 (50.87)
1,212 (47.72)
1,038 (40.87)
Point to point
(32) RH to (58) LH
(32) LH to (58) RH
(33) RH to (91) LH
(33) LH to (91) LH
(77) RH to (91) LH
(77) LH to (91) RH
BS-17
Unit: mm (in)
Dimension
1,139 (44.84)
1,139 (44.84)
993 (39.09)
993 (39.09)
1,289 (50.75)
1,289 (50.75)
DATUM DIMENSIONS
BODY STRUCTURE
6. SEDAN (FRONT STRUCTURE)

(66)
(66)
(63)
(50)
(60)
(62)
(63)
(71)
(65)
(62)
(71)
BO0444
Point to point
(50) to (71) RH
(50) to (71) LH
(60) to (62) RH
(60) to (62) LH
(62) RH to (63) RH
(62) LH to (63) LH
(62) RH to (66) LH
(62) LH to (66) RH
Dimension
1,562 (61.50)
1,562 (61.50)
1,338 (52.68)
1,338 (52.68)
773 (30.43)
773 (30.43)
1,449 (57.05)
1,449 (57.05)
Point to point
(63) RH to (65)
(63) LH to (65)
(63) RH to (71) RH
(63) LH to (71) LH
(65) to (66) RH
(65) to (66) LH
(66) RH to (66) LH
BS-18
Unit: mm (in)
Dimension
1,118 (44.02)
1,118 (44.02)
1,283 (50.51)
1,283 (50.51)
956 (37.64)
956 (37.64)
840 (33.07)
DATUM DIMENSIONS
BODY STRUCTURE
7. SEDAN (REAR STRUCTURE)
(51)
(63)
(51)
(50)
(63)
(60) (69)
(65)
(55)
(68)
(67)
(58)
(76)
(55)
(67)
(56)
(68)
(58)
(76)
(56)
BO0445
Point to point
(50) to (60)
(50) to (65)
(51) RH to (51) LH
(51) RH to (60)
(55) RH to (55) LH
(55) RH to (58) LH
(55) LH to (58) RH
(56) RH to (56) LH
(60) to (63) RH
(60) to (63) LH
(63) RH to (63) LH
(65) to (76) RH
Dimension
501 (19.72)
1,082 (42.60)
1,025 (40.35)
734 (28.90)
1,406 (55.35)
1,297 (51.06)
1,297 (51.06)
1,426 (56.14)
764 (30.08)
764 (30.08)
1,183 (46.57)
1,544 (60.79)
Point to point
(65) to (76) LH
(65) to (68) RH
(65) to (68) LH
(67) RH to (69)
(67) LH to (69)
(68) RH to (68) LH
(68) RH to (69)
(68) LH to (69)
(69) to (76) RH
(69) to (76) LH
(76) RH to (76) LH
BS-19
Unit: mm (in)
Dimension
1,544 (60.79)
1,581 (62.24)
1,581 (62.24)
784 (30.87)
784 (30.87)
1,020 (40.16)
681 (26.81)
681 (26.81)
537 (21.14)
537 (21.14)
600 (23.62)
DATUM DIMENSIONS
BODY STRUCTURE
BS-20
IDI
1.
2.
3.
4.
5.
6.
7.
8.
Page
Combination Meter System .........................................................................4
Combination Meter Assembly ...................................................................15
Speedometer.............................................................................................17
Tachometer ...............................................................................................18
Fuel Gauge ...............................................................................................19
Water Temperature Gauge .......................................................................20
Ambient Sensor.........................................................................................21
GENERAL DESCRIPTION
A: SPECIFICATIONS
Combination meter
Speedometer
Temperature gauge
Fuel gauge
Tachometer
Turn signal indicator light
Oil pressure indicator light
ABS warning light
CHECK ENGINE warning light
(Malfunction indicator light)
HI-beam indicator light
Door open warning light
Seat belt warning light
Brake fluid and parking brake warning
light
FWD indicator light
AIRBAG warning light
Meter illumination light
AT OIL TEMP. warning light
LO indicator light
HOLD indicator light
Immobilizer indicator light
AT select lever position indicator light
LCD back light
Electric pulse type

Thermistor cross coil type
Resistance cross coil type
Electric impulse type
14 V 1.4 W
LED
LED
LED
LED
14 V 1.4 W
LED
LED
LED
LED
LED
14 V 3 W, 14 V 2 W
LED
LED
LED
LED
14 V 2 W
LED
14 V 100 mA
14 V 1.4 W
IDI-2
GENERAL DESCRIPTION
B: CAUTION
Be careful not to damage meters and instrument panel.

Be careful not to damage meter glasses.
Make sure that electrical connector is connected securely.
After installation, make sure that each meter operates normally.
Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces.
Do not apply excessive force to the printed circuit.
Do not drop or otherwise apply impact.
C: PREPARATION TOOL
1. GENERAL TOOLS
TOOL NAME
Circuit Tester
REMARKS
IDI-3
COMBINATION METER SYSTEM

2. Combination Meter System

A: SCHEMATIC
1. COMBINATION METER
<Ref. to
Meter.>
WI-98,
SCHEMATIC,
Combination
2. OUTSIDE TEMPERATURE INDICATOR

<Ref. to WI-225, SCHEMATIC, Outside Temperature Display System.>
IDI-4

B: INSPECTION
CAUTION:
When measuring voltage and resistance of the ECM, TCM, or each sensor, use a tapered pin with a
diameter of less than 0.64 mm (0.025 in) in order to avoid poor contact. Do not insert the pin more
than 2 mm (0.08 in).
1. SYMPTOM CHART
Symptom
Combination meter assembly does not operate.
Repair order
(1) Power supply
(2) Ground circuit
Speedometer does not operate.
(1) (MT) Vehicle speed sensor

(AT) Transmission control module
(2) Harness
(3) Speedometer
Tachometer does not operate.
(1) Engine control module

(2) Harness
(3) Tachometer
Fuel gauge does not operate.
(1) Fuel level sensor

(2) Harness
(3) Fuel gauge
Water temperature gauge does not operate.
(1) Engine coolant temperature sensor

(2) Harness
(3) Water temperature gauge
Outside temperature indicator does not operate.
(1) Ambient sensor

(2) Harness
(3) Combination meter
(4) Auto A/C control module
IDI-5
Reference
<Ref. to IDI-6, CHECK
POWER SUPPLY AND
GROUND CIRCUIT,
INSPECTION, Combination Meter System.>
MT: <Ref. to IDI-7,
CHECK VEHICLE
SPEED SENSOR,
AT: <Re. to IDI-<Ref. to
IDI-8, CHECK TRANSMISSION CONTROL
MODULE, INSPECTION, Combination
Meter System.>
ENGINE CONTROL
MODULE, INSPECTION, Combination
Meter System.>
FUEL LEVEL SENSOR, INSPECTION,
Combination Meter
System.>
ENGINE COOLANT
TEMPERATURE SENSOR, INSPECTION,
Combination Meter
System.>
OUTSIDE TEMPERATURE INDICATOR,

2. CHECK POWER SUPPLY AND GROUND CIRCUIT
Step
CHECK POWER SUPPLY FOR COMBINATION METER.
1)Remove the combination meter. <Ref. to IDI15, REMOVAL, Combination Meter Assembly.>
2)Disconnect the combination meter harness
connector.
Measure the voltage between combination
CHECK GROUND CIRCUIT OF COMBINATION METER.
combination meter connector and chassis
ground.
Check
Yes
No
Check the harness
for open or short
between ignition
switch and combination meter.
Check the harness

for open or short
between fuse and
combination
meter.

?
IDI-6

printed circuit.
Repair the wiring

harness.

3. CHECK VEHICLE SPEED SENSOR
Step
Check
CHECK VEHICLE SPEED SENSOR.
Is the voltage less than 1V
1)Lift-up the vehicle and support it with safety more than 4 V?
stands.
2)Remove the combination meter with harness
connector.
Warning:
Be careful not to get caught in the running
wheels.
3)Drive the vehicle at a speed greater than 20
km/h (12 MPH).
CHECK VEHICLE SPEED SENSOR POWER
SUPPLY.
2)Disconnect the vehicle speed sensor harness connector.
4)Measure the voltage between vehicle speed
sensor connector and engine ground.
CHECK HARNESS BETWEEN VEHICLE
SPEED SENSOR AND ENGINE GROUND.
2)Measure the resistance between vehicle
speed sensor connector and engine ground.
SPEED SENSOR AND COMBINATION
METER.
meter.
speed sensor harness connector and combination meter harness connector.
(B17) No. 1 (i10) No. 2:
Yes
Check the speedometer. <Ref. to
IDI-17,
REMOVAL,
Speedometer.>
No
Go to step 2.
Check the harness

for open or short
between ignition
switch and vehicle
speed sensor.

?
Go to step 4.
Repair the wiring

harness.

?
Replace the vehicle speed sensor.
Repair the wiring

harness.
IDI-7

4. CHECK TRANSMISSION CONTROL MODULE
Step
CHECK TRANSMISSION CONTROL MODULE SIGNAL.
1)Lift-up the vehicle and support it with safety
stands.
Check
more than 4 V?
Warning:
Be careful not to get caught in the running
wheels.
2)Drive the vehicle faster than 10 km/h (6
MPH).
3)Measure the voltage between transmission
control module connector and chassis ground.
CHECK HARNESS BETWEEN TRANSMIS- Is the resistance less than 10
SION CONTROL MODULE AND COMBINA- ?
TION METER.
control module and combination meter.
3)Measure the resistance between transmission control module harness connector and
combination meter harness connector.
(B56) No. 17 (i10) No. 2:
IDI-8
Yes
Go to step 2.
No
Check the transmission control
module. <Ref. to
AT-2, Basic Diagnostic Procedure.>
Check the speed

meter. <Ref. to
IDI-17,
REMOVAL,
Speedometer.>
Repair the wiring

harness.

5. CHECK ENGINE CONTROL MODULE
Step
Check
CHECK ENGINE CONTROL MODULE SIG- Is the voltage 0 13 V or
NAL.
more?
1)Start the engine.
2)Measure the voltage between engine control
module connector and engine ground.
Turbo engine model:
CHECK HARNESS BETWEEN COMBINAIs the resistance less than 10

TION METER AND ENGINE CONTROL MOD- ?
ULE.
2)Disconnect the connector from engine control module and combination meter.
3)Measure the resistance between engine
control module harness connector and combination meter harness connector.
Turbo engine model:
(B136) No. 9 (i10) No. 5:
(B134) No. 30 (i10) No. 5:
IDI-9
Yes
Go to step 2.
No
Check the engine
control module.
<Ref. to EN-2,
Basic Diagnostic
Procedure.> or
<Ref. to EN(w/
oOBD)-2, Basic
Diagnostic Procedure.> or <Ref. to
EN(TURBO)-2,
Basic Diagnostic
Procedure.>
Check the tachom- Repair the wiring
eter. <Ref. to IDI- harness.
18, REMOVAL,
Tachometer.>

6. CHECK FUEL LEVEL SENSOR
1
2
Step
CHECK ENGINE TYPE.
1)Remove the fuel level sensor. <Ref. to
FU(TURBO)-62, REMOVAL, Fuel Level Sensor.>
sensor terminals when setting the float to
FULL and EMPTY position.
Terminals
No. 3 No. 5:
FU(TURBO)-63, REMOVAL, Fuel Sub Level
Sensor.>
level sensor terminals when setting the float to
Terminals
No. 1 No. 2:
CHECK HARNESS BETWEEN FUEL SUB
LEVEL SENSOR AND COMBINATION
METER.
meter.
level sensor harness connector terminal and
combination meter harness connector terminal.
(R59) No. 1 (i12) No. 2:
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. 3 (R59) No.2:
CHECK FUEL LEVEL SENSOR GROUND
CIRCUIT.
sensor harness connector terminal and chassis ground.
1)Remove the fuel level sensor. <Ref. to FU65, REMOVAL, Fuel Level Sensor.> or <Ref.
to FU(w/oOBD)-62, REMOVAL, Fuel Level
Sensor.>
sensor terminals when setting the float to
Terminals
No. 3 No. 5:
Check
Is the engine equipped with
turbocharger?
Is the resistance 0.5 to 2.5
(FULL) and 50 to 52
(EMPTY)?
Yes
Go to step 2.
No
Go to step 7.
Go to step 3.
Replace the fuel

level sensor.
Is the resistance 0.5 to 2.5

(FULL) and 42 to 44
(EMPTY)?
Go to step 4.
Replace the fuel

sub level sensor.

?
Go to step 5.
Repair the wiring

harness.

?
Go to step 6.
Repair the wiring

harness.

?
Check the fuel

gauge. <Ref. to
IDI-19,
REMOVAL, Fuel
Gauge.>
Repair the wiring

harness.
Is the resistance 2 to 5
(FULL) and 92 to 95
(EMPTY)?
Go to step 8.
Replace the fuel

level sensor.
IDI-10

Step
CHECK HARNESS BETWEEN FUEL LEVEL
SENSOR AND COMBINATION METER.
meter.
sensor harness connector terminal and combination meter harness connector terminal.
(R58) No. 3 (i12) No. 2:
CHECK FUEL LEVEL SENSOR GROUND
CIRCUIT.
Check
?
Yes
Go to step 9.

?
Check the fuel

Repair the wiring
gauge. <Ref. to
harness.
IDI-19, Removal.>
IDI-11
No
Repair the wiring
harness.

7. CHECK ENGINE COOLANT TEMPERATURE SENSOR
Step
SENSOR.
Check the engine coolant temperature sensor.
<Ref. to EN-2, Basic Diagnostic Procedure.>
or <Ref. to EN(w/oOBD)-2, Basic Diagnostic
Procedure.> or <Ref. to EN(TURBO)-2, Basic
Diagnostic Procedure.>
COMBINATION METER.
2)Disconnect the connector from engine coolant temperature sensor and combination
meter.
3)Measure the resistance between engine
coolant temperature sensor harness connector
and combination meter harness connector.
(E8) No. 3 (i12) No. 9:
Check
Yes
Is the engine coolant tempera- Go to step 2.
ture sensor OK?

?
IDI-12
No
Replace the
engine coolant
temperature sensor.
Check the water

Repair the wiring
temperature
harness.
gauge. <Ref. to
IDI-20,
REMOVAL, Water
Temperature
Gauge.>

8. CHECK OUTSIDE TEMPERATURE INDICATOR
1
2
Step
CHECK AIR CONDITIONER TYPE.
CHECK POWER SUPPLY FOR AMBIENT
SENSOR.
meter.
meter terminal and chassis ground.
CHECK HARNESS BETWEEN AMBIENT
3)Measure the resistance between ambient
sensor harness connector terminal and combination meter harness connector terminal.
LHD model:
(F78) No. 1 (i11) No. 11:
(F78) No. 2 (i11) No. 8:
RHD model:
(F78) No. 2 (i11) No. 11:
(F78) No. 1 (i11) No. 8:
1)Remove the ambient sensor.
2)Check the ambient sensor. <Ref. to IDI-21,
INSPECTION, Ambient Sensor.>
CHECK OUTSIDE TEMPERATURE INDICATOR.
1)Connect the combination meter harness
connector.
2)Connect a resistor (2.2 k) between terminals of ambient sensor harness connector.
3)Turn the ignition switch to ON and check the
outside temperature indicator display.
2)Disconnect the connector from auto A/C control module.
4)Measure the voltage between auto A/C control module terminal and chassis ground.
(B282) No. 11 (+) chassis ground ():
Check
Is the vehicle equipped with
auto A/C?
Yes
Go to step 6.
No
Go to step 2.
Go to step 3.

printed circuit.

?
Go to step 4.
Repair the wiring

harness.
Is the ambient sensor OK?
Go to step 5.
Is the outside temperature indi- Repair the poor

Replace the comcator indicating 25C (77F)? contact of ambient bination meter
sensor harness
printed circuit.
connector.
IDI-13
Go to step 7.
Replace the auto

A/C control module.

10
11
Step
CHECK HARNESS BETWEEN AUTO A/C
CONTROL MODULE AND COMBINATION
METER.
meter.
3)Measure the resistance between auto A/C
control module harness connector terminal
and combination meter harness connector terminal.
(B282) No. 11 (i11) No. 12:
CHECK POWER SUPPLY FOR AMBIENT
SENSOR.
2)Measure the voltage between auto A/C control module terminal and chassis ground.
(B283) No. 9 (+) chassis ground ():
CHECK HARNESS BETWEEN AMBIENT
3)Measure the resistance between ambient
sensor harness connector terminal, combination meter harness connector terminal and
auto
A/C control module harness connector terminal.
LHD model:
(F78) No. 1 (i11) No. 11:
(F78) No. 1 (B283) No. 9:
(F78) No. 2 (i11) No. 8:
RHD model:
(F78) No. 2 (i11) No. 11:
(F78) No. 2 (B283) No. 9:
(F78) No. 1 (i11) No. 8:
1)Remove the ambient sensor.
2)Check the ambient sensor. <Ref. to IDI-21,
INSPECTION, Ambient Sensor.>
CHECK OUTSIDE TEMPERATURE INDICATOR.
1)Connect the combination meter and auto
A/C control module harness connector.
2)Connect a resistor (2.2 k) between terminals of ambient sensor harness connector.
3)Turn the ignition switch to ON and check the
outside temperature indicator display.
Check
?
Yes
Go to step 8.
No
Repair the wiring
harness.
Go to step 9.
Replace the auto

A/C control module.

?
Go to step 10.
Repair the wiring

harness.
Is the ambient sensor OK?
Go to step 11.
Is the outside temperature indi- Repair the poor

Replace the comcator indicating 25C (77F)? contact of ambient bination meter
sensor harness
printed circuit.
connector.
IDI-14
COMBINATION METER ASSEMBLY

3. Combination Meter Assembly

A: REMOVAL
2) Set the tilt steering at lowest position.
3) Remove the screws and detach meter visor.
: Hook pawl
BO0012
4) Remove the screws of combination meter and

pull out the meter toward you.
BO0013
5) Disconnect the connector in the upper area 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 that electrical connector is connected securely.
Make sure that each meter operates normally.
IDI-15
COMBINATION METER ASSEMBLY

C: DISASSEMBLY
CAUTION:
Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces.
1) Disengage the claw (F) to remove case (B) from back cover (A).
2) Disengage the claw (G) to remove meter glass (E), reflector (D), and window plate (C) from inner case.
BO0014
3) Pull up the claw (A) in portion (B) of combination

meter printed circuit (C) with combination pliers.
Push out the speedometer and tachometer assembly (D) and fuel gauge and water temperature
gauge assembly (E) using hole (F).
4) Pull up the claw in center of combination meter
printed circuit (C), and remove the printed circuit
from case (G).
1. BULB REPLACEMENT
BO0016
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
BO0015
Tachometer
Speedometer and tachometer
Turn RH
HI-beam
Speedometer
POWER
Turn LH
Fuel gauge
Temperature gauge
LCD (Outside temperature indicator)
LCD (Odometer and tripmeter)
D: ASSEMBLY
IDI-16
SPEEDOMETER
4. Speedometer
A: REMOVAL
Disassemble the combination meter, and then remove the speedometer and tachometer assembly.
<Ref. to IDI-16, DISASSEMBLY, Combination
Meter Assembly.>
B: INSTALLATION
C: INSPECTION
Measure the speedometer resistance.
B6M1232A
Terminal
Terminals SIN+ and SIN
Terminals COS+ and COS
Resistance
2008
2008
If NG, replace the speedometer and tachometer

assembly.
If OK, replace the combination meter printed circuit.
IDI-17
TACHOMETER
5. Tachometer
A: REMOVAL
Disassemble the combination meter, and then remove the speedometer and tachometer assembly.
<Ref. to IDI-16, DISASSEMBLY, Combination
Meter Assembly.>
B: INSTALLATION
C: INSPECTION
Measure the tachometer resistance.
B6M1232A
Terminal
Terminals SIN+ and SIN
Terminals COS+ and COS
Resistance
2008
2008
If NG, replace the speedometer and tachometer

assembly.
IDI-18
FUEL GAUGE
6. Fuel Gauge
A: REMOVAL
Disassemble the combination meter, and then remove the water temperature gauge and fuel gauge
assembly. <Ref. to IDI-16, DISASSEMBLY, Combination Meter Assembly.>
B: INSTALLATION
C: INSPECTION
Measure the fuel gauge resistance.
B6M1233A
Terminal
Terminals IGN and GND
Terminals IGN and UNIT
Terminals UNIT and GND
Resistance
17010
3510
13610
If NG, replace the water temperature gauge and

fuel gauge assembly.
IDI-19
WATER TEMPERATURE GAUGE

7. Water Temperature Gauge

A: REMOVAL
Disassemble the combination meter, and then remove the tachometer and water temperature
gauge and fuel gauge assembly. <Ref. to IDI-16,
DISASSEMBLY, Combination Meter Assembly.>
B: INSTALLATION
C: INSPECTION
Measure the water temperature gauge resistance.
B6M1233A
Terminal
Terminals IGN and GND
Terminals IGN and UNIT
Terminals UNIT and GND
Resistance
20810
5610
26410
If NG, replace the water temperature gauge and

fuel gauge assembly.
IDI-20
AMBIENT SENSOR
8. Ambient Sensor
A: REMOVAL
2) Disconnect the ambient sensor connector.
3) Remove the ambient sensor (A) from radiator
lower panel.
(A)
BO0277
B: INSTALLATION
C: INSPECTION
Measure the ambient sensor resistance.
B6M1537
Terminal
1 and 2
Resistance
2.2 k/25C (77F)
If NG, replace the ambient sensor.
IDI-21
AMBIENT SENSOR
IDI-22
SEATS
SE
1.
2.
3.
Page
Front Seat ...................................................................................................6
Rear Seat ..................................................................................................11
GENERAL DESCRIPTION
SEATS
A: COMPONENT
1. FRONT SEAT
(1)
(2)
T2
(3)
T2
T2
(6)
(5)
(4)
T1
(8)
(9)
(5)
T1
T1
(7)
(4)
T1
BO0245
(1)
(2)
(3)
(4)
(5)
Front seat ASSY

Rail cover IN
Rail cover OUT
Slide rail OUT
Slide rail IN
(6)
(7)
(8)
(9)
Seat hinge
Seat hinge cover
Seat lifter lever
Reclining lever
SE-2

T1: 30 (3.1, 22)
T2: 53 (5.4, 39)
GENERAL DESCRIPTION
SEATS
2. REAR SEAT (SEDAN)
(6)
T
(1)
(2)
(4)
(5)
T
T
(3)
BO0355
(1)
(2)
(3)
Backrest
Head restraint
Cushion
(4)
(5)
(6)
Arm rest
Center through frame
Hook
SE-3

T: 24.5 (2.5, 18.1)
GENERAL DESCRIPTION
SEATS
3. REAR SEAT (WAGON)
(2)
(4)
(3)
(5)
(1)
T
T
T
BO0247
(1)
(2)
(3)
Cushion
Backrest RH
Backrest LH
(4)
(5)
Head restraint
Striker
SE-4

T:
24.5 (2.5, 18.1)
GENERAL DESCRIPTION
SEATS
B: CAUTION
Take care not to contaminate or damage the seat surface.
While loading to or unloading to the vehicle, take care not to contact body.
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
REMARKS
Used for removing and installing hog ring
SE-5
FRONT SEAT
SEATS
2. Front Seat
8) Remove the two bolts at front side of seat rail.
A: REMOVAL
2) While pressing the headrest lock button, remove
the headrest.
G5M0344
9) Disconnect the side airbag connector under the

seat. (Side airbag equipped vehicle)
10) Disconnect the connector of seat belt warning.
H5M0704
3) Tilt forward the backrest.

4) Move the seat to full front end.
5) Remove the bolt cover at rear end of slide rail.
BO0161
11) Remove the front seat from vehicle.
BO0159
6) Remove the two bolts at rear side of seat rail.
CAUTION:
When removing the seat from vehicle, take care
not to damage body, seat, or trim.
B: INSTALLATION
CAUTION:
Confirm that the seat can move smoothly and
be locked securely at any position.
Tightening torque:
Refer to COMPONENT in General Description. <Ref. to SE-2, FRONT SEAT,
BO0160
7) Move the seat to full rear end.
C: DISASSEMBLY
1. DRIVERS SEAT
1) Remove the seat from vehicle. <Ref. to SE-6,
REMOVAL, Front Seat.>
SE-6
FRONT SEAT
SEATS
2) Remove the reclining hinge cover.
: Clip
: Hook
6) Turn the cover, and remove the two bolts from

hinge.
BO0356
BO0166
3) Remove the hook at bottom of seat backrest.
7) Loosen the bolt and nuts to remove slide rail.
BO0163
4) Remove the hinge cover and screw.
BO0167
BO0164
8) Remove the hog rings, and then remove the seat

back rest cover.
Without side airbag MODEL
5) Remove the two bolts.
BO0165
: Hog ring
BO0168
SE-7
FRONT SEAT
SEATS
With side airbag MODEL
: Hog ring
3) Turn the cover, and remove the two bolts from

hinge.
BO0169

cushion cover.
Standard type MODEL
B5M0979
4) Remove the hinge screw cover and screw, and

remove the seat back rest from hinge.
: Hog ring
BO0170
B5M0978
5) Remove the reclining lever cover and hinge cover.
Sporty type MODEL
: Hog ring
BO0171
B5M0970
2. PASSENGERS SEAT
1) Remove the seat from vehicle. <Ref. to SE-6,
REMOVAL, Front Seat.>
2) Remove the hook at bottom of seat back rest.
BO0163
SE-8
FRONT SEAT
SEATS
6) Loosen the four bolts to remove seat cushion.

back rest cover.
Without side airbag MODEL
: Hog ring
BO0168
With side airbag MODEL
B5M0969
7) Loosen the four screws to remove hinge.

: Hog ring
BO0169
10) Remove the hog rings, and then remove the

seat cushion cover.
Standard type MODEL
B5M0959
8) Loosen the two bolts to remove slide rail.

: Hog ring
BO0170
Sporty type MODEL
B5M0958A
: Hog ring
BO0171
SE-9
FRONT SEAT
SEATS
D: ASSEMBLY
1. DRIVERS SEAT
NOTE:
Do not contaminate or damage the cover.
While installing the hog rings, prevent the seat
from getting wrinkled.
2. PASSENGERS SEAT
NOTE:
Tightening torque:
Refer to COMPONENT in General Description. <Ref. to SE-2, FRONT SEAT,
SE-10
REAR SEAT
SEATS
3. Rear Seat
2. SEDAN
A: REMOVAL
1) Remove the bolts, and then detach the rear seat

cushion.
1. WAGON
1) Remove the bolts, and then detach the rear seat
cushion.
BO0172
2) Remove the bolts securing lower portion of

backrest and then open the center trunk through
lid.
BO0172
2) Remove the headrest.

3) Remove the luggage floor mat. <Ref. to EI-54,
REMOVAL, Luggage Floor Mat.>
4) Turn over the mat to remove bolts.
B5M0811
3) Lift the rear seat backrest and then remove it.
B: INSTALLATION
BO0173
1. WAGON
5) Remove the rear seat backrest.
Tightening torque:
Refer to COMPONENT in General Description. <Ref. to SE-4, REAR SEAT (WAGON),
2. SEDAN
1) Hook and fasten the upper-back side of the rear
seat backrest to the body hook.
BO0174
G5M0348
SE-11
REAR SEAT
SEATS
2) Tighten the bolts.
3) Remove the hog rings on front side of cushion

pad, and remove the cover.
: Hog ring
B5M0811
3) Hook and fasten the seat cushion to the hook on

the lower part of the rear seat backrest.
BO0177
4) Remove the hog rings from around the seat

cushion.
BO0175
: Hog ring
BO0178
Tightening torque:
Refer to COMPONENT in General Description. <Ref. to SE-4, REAR SEAT (WAGON),
5) Remove the hog rings, and then remove the cover.
C: DISASSEMBLY
1. WAGON
1) Remove the rear seat. <Ref. to SE-11, WAGON,
REMOVAL, Rear Seat.>
backrest.
: Hog ring
BO0179
2. SEDAN
1) Remove the rear seat. <Ref. to SE-11, SEDAN,
: Hog ring
BO0176
SE-12
REAR SEAT
SEATS

backrest.
Armrest through type MODEL
4) Remove the hog rings around the seat cushion.
: Hog ring
BO0184
: Hog ring

cover.
BO0180
Unified type MODEL
: Hog ring
BO0185
: Hog ring
BO0181

cover.
Armrest through type MODEL
D: ASSEMBLY
1. WAGON
NOTE:
2. SEDAN
: Hog ring
BO0182
Unified type MODEL
NOTE:
: Hog ring
BO0183
SE-13
REAR SEAT
SEATS
SE-14
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 ..........................................................................8
Keyless Entry System ...............................................................................12
Front Inner Remote ...................................................................................18
Front Outer Handle ...................................................................................19
Front Door Latch Assembly.......................................................................20
Front Door Lock Actuator ..........................................................................21
Rear Inner Remote....................................................................................22
Rear Outer Handle ....................................................................................23
Rear Door Latch Assembly .......................................................................24
Rear Door Lock Actuator...........................................................................25
Rear Gate Outer Handle ...........................................................................26
Rear Gate Latch Assembly .......................................................................27
Rear Gate Latch Lock Actuator.................................................................28
Trunk Lid Lock Assembly ..........................................................................29
Front Hood Lock Assembly .......................................................................30
Remote Openers.......................................................................................31
Ignition Key Lock.......................................................................................32
Key Lock Cylinders ...................................................................................33
Immobilizer Control Module ......................................................................34
Immobilizer Antenna .................................................................................35
Keyless Entry Control Module...................................................................36
Keyless Transmitter ..................................................................................37
GENERAL DESCRIPTION
SECURITY AND LOCKS
A: COMPONENT
1. DOOR LOCK ASSEMBLY
FRONT
(1)
(7)
(3)
(8)
T2
T3
(2)
(6)
T1
(5)
(4)
(7)
T3
(6)
REAR
(3)
(1)
T2
T1
(5)
(2)
(4)
BO0464
(1)
(2)
(3)
(4)
(5)
Inner remote ASSY

Inner remote cover
Bell crank
Auto-door lock actuator
Door latch
(6)
(7)
(8)
Striker
Door outer handle
Key cylinder
SL-2

T1: 6.4 (0.65, 4.7)
T2: 7.4 (0.75, 5.5)
T3: 17.6 (1.8, 13.0)
GENERAL DESCRIPTION
SECURITY AND LOCKS
2. TRUNK LID AND REAR GATE LOCK
REAR GATE
TRUNK
T1
(1)
(5)
T2
(4)
(1)
(6)
(7)
(2)
(3)
T2
T2
(3)
BO0465
(1)
(2)
(3)
(4)
Key cylinder
Cable
Striker
Trunk lid lock ASSY
(5)
(6)
(7)
Rear gate outer handle

Rear gate actuator
Rear gate latch
SL-3

T1: 4.5 (0.45, 3.3)
T2: 25 (2.5, 18.4)
GENERAL DESCRIPTION
SECURITY AND LOCKS
3. HOOD LOCK AND REMOTE OPENERS
WAGON
SEDAN
HOOD
B5M1198A
(1)
(2)
(3)
(4)
Hood lock ASSY

Lever ASSY
Cable
Cover
(5)
Pull handle ASSY
SL-4

T1: 6.4 (0.65, 4.7)
T2: 32 (3.3, 23.9)
GENERAL DESCRIPTION
SECURITY AND LOCKS
4. IMMOBILIZER SYSTEM
BO0010
(1)
(2)
Antenna
Immobilizer indicator light (LED bulb)
(3)
(4)
Immobilizer control module (IMM ECM)

Transponder
NOTE:
IMM ECM location for RHD model is symmetrically opposite.
SL-5
GENERAL DESCRIPTION
SECURITY AND LOCKS
5. KEYLESS ENTRY SYSTEM
BO0192
(1)
Keyless entry control module
(2)
Rear gate latch switch (Wagon)
B: CAUTION
Before disassembling or reassembling parts,
always disconnect the ground cable from battery. When repairing radio, control module, etc.
which are provided with memory functions,
record
the
memory
contents
before
disconnecting the ground cable from battery.
Otherwise, these contents are cancelled upon
disconnection.
Reassemble parts in the reverse order of
disassembly procedure unless otherwise
indicated.
Adjust parts to specifications contained in
this manual if so designated.
Connect the connectors and hoses securely
during reassembly.
After reassembly, ensure all functional parts
operate smoothly.
Airbag system wiring harness is routed near
the electrical parts and switch.
All airbag system wiring harness and
connectors are colored yellow. Do not use
electrical test equipment on these circuits.
wiring harness when servicing the ignition key
cylinder.
SL-6
(3)
Door switch
GENERAL DESCRIPTION
SECURITY AND LOCKS
C: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
925580000
DESCRIPTION
PULLER
REMARKS
Used for removing trim clip
B5M1120
2. GENERAL TOOLS
TOOL NAME
Circuit Tester
Drill
REMARKS
Used for replacing ignition key lock.
SL-7
DOOR LOCK CONTROL SYSTEM

SECURITY AND LOCKS
2. Door Lock Control System

A: SCHEMATIC
<Ref. to WI-105, SCHEMATIC, Door Lock System.>
B: INSPECTION
1. SYMPTOM CHART
Symptom
The door lock control system does
not operate.
Repair order
1. Check the fuse.
2. Check the power supply and ground circuit for

the door lock timer (without keyless entry) or keyless entry control module (with keyless entry).
3. Check the door lock switch and circuit.
4. Check the door lock actuator and circuit.
The door lock switch (knob) does not

operate.
Check the door lock switch and circuit.
A specific door lock actuator does not

operate.
Check the door lock actuator and circuit.
Reference
<Ref. to SL-8, CHECK FUSE,
INSPECTION, Door Lock Control
System.>
<Ref. to SL-9, CHECK POWER
SUPPLY AND GROUND CIRCUIT,
System.>
<Ref. to SL-9, CHECK DOOR LOCK
SWITCH AND CIRCUIT, INSPECTION, Door Lock Control System.>
<Ref. to SL-10, CHECK DOOR
LOCK ACTUATOR AND CIRCUIT,
System.>
<Ref. to SL-9, CHECK DOOR LOCK
SWITCH AND CIRCUIT, INSPECTION, Door Lock Control System.>
LOCK ACTUATOR AND CIRCUIT,
System.>
2. CHECK FUSE
Step
CHECK FUSE.
Remove and visually check the fuse No. 2 (in
the main fuse box) and No. 3 (in the fuse and
relay box).
Check
Is the fuse blown (15A)?
SL-8
Yes
Replace the fuse
with a new one.
No
Check the power
supply and ground
circuit. <Ref. to
SL-9, CHECK
POWER SUPPLY
AND GROUND
CIRCUIT,
INSPECTION,
Door Lock Control
System.>

SECURITY AND LOCKS
Step
Check
CHECK POWER SUPPLY.
1)Disconnect the door lock timer or keyless
entry control module harness connector.
2)Measure the voltage between harness connector terminal and chassis ground.
Without keyless entry:
With keyless entry:
CHECK GROUND CIRCUIT.
Measure the resistance between harness con- ?
nector terminal and chassis ground.
With keyless entry:
Yes
Go to step 2.
No
Check the harness
for open circuits or
shorts between
the door lock timer
or keyless entry
control module
and fuse.
Power supply and Repair the harground circuit is

ness.
OK.
4. CHECK DOOR LOCK SWITCH AND CIRCUIT
1
2
Step
CHECK DOOR LOCK CONTROL SYSTEM
TYPE.
CHECK DOOR LOCK SWITCH CIRCUIT.
1)Disconnect the door lock timer harness connector.
2)Measure the resistance between harness
connector terminal and chassis ground when
moving the driver's door lock knob to
UNLOCK.
Measure the resistance between harness connector terminal and chassis ground when the
driver's door lock knob is moved to LOCK.
CHECK DOOR LOCK SWITCH.
1)Disconnect the driver's door lock switch harness connector.
2)Measure the resistance between door lock
switch terminals when moving the door lock
knob to UNLOCK.
Terminal
No. 1 No. 2:
Measure the resistance between door lock
knob to LOCK.
Terminal
No. 1 No. 2:
Check
Is the vehicle equipped with
keyless entry system?
?
Yes
Go to step 6.
No
Go to step 2.
Go to step 3.
Go to step 4.

?
Go to step 4.
The door lock

switch is OK.

?
Go to step 5.
Replace the door

lock switch.

M ?
Check the harness Replace the door

for open circuits or lock switch.
shorts between
door lock timer
and door lock
switch.
SL-9

SECURITY AND LOCKS
Step
1)Disconnect the keyless entry control module
harness connector.
connector terminal and chassis ground when
moving the driver's door lock knob to
UNLOCK.
Measure the resistance between harness connector terminal and chassis ground when the
driver's door lock knob is moved to LOCK.
1)Disconnect the driver's door lock switch
(actuator) harness connector.
2)Measure the resistance between door lock
knob to UNLOCK.
Terminal
No. 2 No. 4:
Measure the resistance between door lock
knob to LOCK.
Terminal
No. 2 No. 4:
Check
?
Yes
Go to step 7.
No
Go to step 8.

?
Go to step 8.
The door lock

switch is OK.

?
Go to step 9.
Replace the door

lock switch (actuator).

M ?

for open circuits or lock switch (actuator).
shorts between
keyless entry control module and
door lock switch.
5. CHECK DOOR LOCK ACTUATOR AND CIRCUIT
Step
Check
Yes
CHECK OUTPUT SIGNAL.
Measure the voltage between harness connector terminal and chassis ground when moving
the door lock knob to LOCK.
With keyless entry:
Measure the voltage between harness connector terminal and chassis ground when moving
the door lock knob to UNLOCK.
With keyless entry:
SL-10
No
Replace the door
lock timer or keyless entry control
module.
Replace the door

lock timer or keyless entry control
module.

SECURITY AND LOCKS
Step
Check
CHECK DOOR LOCK ACTUATOR.
Is the door lock actuator OK?
Check the door lock actuator.
Front door lock actuator: <Ref. to SL-21, Front
Door Lock Actuator.>
Rear door lock actuator: <Ref. to SL-25, Rear
Door Lock Actuator.>
Rear gate latch lock actuator: <Ref. to SL-28,
Rear Gate Latch Lock Actuator.>
SL-11
Yes
No
for open circuits or lock actuator.
shorts between
the door lock timer
or keyless entry
control module
and door lock
actuator.
KEYLESS ENTRY SYSTEM

SECURITY AND LOCKS
3. Keyless Entry System

A: SCHEMATIC
<Ref. to WI-186, SCHEMATIC, Keyless Entry System.>
B: ELECTRICAL SPECIFICATION
B5M1141
Content
Key warning switch
Registration connector
Door switch
Power supply
Ground
Door lock switch
Empty
Empty
Empty
Room light/Ignition switch illumination
Terminal No.
1 (INPUT)
2 (INPUT)
3 (INPUT)
5
6
7 (INPUT)
8
9
10
Turn signal light (Right)
12 (OUTPUT)
Turn signal light (Left)
13 (OUTPUT)
Ground
Power supply (Hazard light)
Power supply
Door and rear gate lock actuator
(Unlock)
Door and rear gate lock actuator
(Lock)
14
15
16
Measuring condition
Battery voltage is present when inserting the key into ignition switch.
0 V is present when connecting the registration connector.
0 V is present when any door is open.
Battery voltage is constantly present.
0 V is constantly present.
0 V is present when driver's door is unlocked.
0 V is present when pressing the transmitter OPEN button.

0 V is present when any door is open.
Battery voltage is present when pressing the transmitter OPEN or LOCK
button.
Battery voltage is present when pressing the transmitter OPEN or LOCK
button.
0 V is constantly present.
17 (OUTPUT)
Battery voltage is present when pressing the transmitter OPEN button.
18 (OUTPUT)
Battery voltage is present when pressing the transmitter LOCK button.
11 (OUTPUT)
SL-12

SECURITY AND LOCKS
C: INSPECTION
1. SYMPTOM CHART
Symptom
None of the functions of keyless entry
system operate.
Repair order
1. Check the transmitter battery.
2. Check the fuse.
3. Check the keyless entry control module power

supply and ground circuit.
4. Replace the keyless entry control module.

The transmitter cannot be registered.
2. Check the registration connector circuit.

The door lock or unlock does not
operate.
NOTE:
If the door lock control system does 2. Check the key warning switch.
not operate when using the door lock
switch, check the door lock control
system. <Ref. to SL-8, INSPECTION,
3. Check the door switch.
System.>
The hazard light does not operate.
1. Check the transmitter battery
2. Check the key warning switch.
4. Check the hazard light operation.
SL-13
Reference
<Ref. to SL-14, CHECK TRANSMITTER BATTERY, INSPECTION, Keyless Entry System.>
<Ref. to SL-14, CHECK FUSE,
INSPECTION, Keyless Entry System.>
<Ref. to SL-14, CHECK POWER
SUPPLY AND GROUND CIRCUIT,
<Ref. to SL-36, Keyless Entry Control
Module.>
<Ref. to SL-15, CHECK REGISTRATION CONNECTOR CIRCUIT,
Module.>
<Ref. to SL-16, CHECK KEY WARNING SWITCH, INSPECTION, Keyless
Entry System.>
SWITCH, INSPECTION, Keyless
Entry System.>
Module.>
Entry System.>
Entry System.>
<Ref. to SL-17, CHECK HAZARD
LIGHT OPERATION, INSPECTION,
Keyless Entry System.>
Module.>

SECURITY AND LOCKS
Symptom
Repair order
The room light and ignition switch illu- 1. Check the transmitter battery.
mination operation does not activate.
2. Check the room light operation.
3. Check the ignition switch illumination circuit.
4. Check the key warning switch.
Reference
<Ref. to SL-17, CHECK ROOM
LIGHT OPERATION, INSPECTION,
<Ref. to SL-17, CHECK IGNITION
SWITCH ILLUMINATION CIRCUIT,
Entry System.>
Entry System.>
Module.>
2. CHECK TRANSMITTER BATTERY
Step
CHECK TRANSMITTER BATTERY.
1)Remove the battery from transmitter. <Ref.
to SL-37, REMOVAL, Keyless Transmitter.>
2)Check the battery voltage. <Ref. to SL-37,
INSPECTION, Keyless Transmitter.>
Check
Is the battery voltage OK?
Yes
No
Further inspection Replace the transis necessary, refer mitter battery.
to SYMPTOM
CHART. <Ref. to
SL-13, SYMPTOM CHART,
INSPECTION,
3. CHECK FUSE
Step
Check
CHECK FUSE.
Is the fuse blown? (15 A and
Remove and visually check the fuse No. 2 (in 30 A)
the main fuse box), No. 3 (in the fuse and relay
box) and SBF-6 (in the main fuse box)
Yes
Replace the fuse
with a new one.
No
Check the power
supply and ground
circuit. <Ref. to
SL-14, CHECK
POWER SUPPLY
AND GROUND
CIRCUIT,
INSPECTION,
Step
Check
Yes
CHECK POWER SUPPLY.
harness connector.
(B176) No. 5, No. 15, No. 16 (+) Chassis ground ():
SL-14
No
Check the harness
for open circuits or
shorts between
fuse.

SECURITY AND LOCKS
Step
Check
Measure the resistance between harness con- ?
nector terminal and chassis ground.
(B176) No. 6, No. 14 Chassis ground:
Yes
No
The power supply Repair the harand ground circuit ness.
are OK.
5. CHECK REGISTRATION CONNECTOR CIRCUIT
Step
Check
REGISTRATION CONNECTOR INPUT VOLT- Is the voltage more than 10 V?
AGE INSPECTION
1)Disconnect the registration connector.
2)Measure the voltage between keyless entry
control module harness connector and chassis
ground.
REGISTRATION CONNECTOR INPUT VOLT- Is the voltage 0 V?
AGE INSPECTION
1)Connect the registration connector.
control module harness connector and chassis
ground.
Yes
Go to step 2.
No
Repair the harness, and (or) connector.
Registration connector circuit is

OK.
Repair the harness, and (or) connector.
6. CHECK DOOR SWITCH
Step
CHECK DOOR SWITCH CIRCUIT.
Measure the voltage between keyless entry
and chassis ground.
CHECK DOOR SWITCH CIRCUIT.
Measure the voltage between keyless entry
and chassis ground.
Check
Yes
Is the voltage 0 V when each Go to step 2.
door and rear gate is opened?
No
Go to step 3.
Is the voltage more than 10 V The door switch is Go to step 3.

when each door and rear gate OK.
is closed?
CHECK DOOR SWITCH.

1)Disconnect the door switch harness connec- M when door switch is
tor.
pushed?
2)Measure the resistance between door switch
terminals.
Terminal
Rear gate No. 1 No. 2:
SL-15
Go to step 4.
Replace the door

switch.

SECURITY AND LOCKS
Step
CHECK DOOR SWITCH.
Measure the resistance between door switch
terminals.
Terminal
Rear gate 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 circuits or switch.
shorts between
door switch.
7. CHECK KEY WARNING SWITCH
Step
CHECK FUSE.
Remove and visually check the fuse No. 6 (in
the main fuse box).
CHECK KEY WARNING SWITCH CIRCUIT.
harness connector.
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.
Terminal
No. 1 No. 2:
CHECK KEY WARNING SWITCH.
2)Measure the resistance between key warning switch terminals.
Terminal
No. 1 No. 2:
Check
Is the fuse blown? (15A)
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 following:

Harness for
open circuits or
shorts between
the key warning
switch and fuse
Harness for
open circuits and
shorts between
the keyless entry
control module
and key warning
switch
Replace the key

warning switch.
SL-16

SECURITY AND LOCKS
8. CHECK HAZARD LIGHT OPERATION
Step
Check
CHECK HAZARD LIGHT OPERATION.
Does the hazard light blink?
Make sure the hazard light blinks when hazard
switch is turned ON.
2)Close all doors and rear gate.
and chassis ground when LOCK or OPEN button of transmitter is pressed.
(B176) No. 12, No. 13 (+) Chassis
ground ():
Yes
Go to step 2.
No
Check the hazard
light circuit.
Check the harness Replace the keyfor open or short less entry control
between keyless module.
entry control module and turn signal
lights.
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 ON.
CHECK HARNESS BETWEEN ROOM LIGHT Is the resistance less than 10
AND KEYLESS ENTRY CONTROL MODULE. ?
harness connector and room light harness
connector.
2)Measure the resistance between keyless
entry control module harness connector terminal and room light harness connector terminal.
(B176) No. 11 (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 circuits or
OK.
shorts between
room light.
10.CHECK IGNITION SWITCH ILLUMINATION CIRCUIT
Step
Check
CHECK IGNITION SWITCH ILLUMINATION Is the voltage more than 10 V?
POWER SUPPLY.
1)Disconnect the ignition switch illumination
harness connector.
illumination harness connector terminal and
chassis ground.
CHECK HARNESS BETWEEN IGNITION
SWITCH ILLUMINATION AND KEYLESS EN- ?
TRY CONTROL MODULE.
harness connector.
2)Measure the resistance between keyless
entry harness connector terminal and ignition
switch illumination harness connector.
(B176) No. 11 (B224) No. 2:
SL-17
Yes
Go to step 2.
No
Check the harness
for open circuit or
shorts between
ignition switch illumination and fuse.
Check the ignition Repair the harswitch illuminaness.

tion. If NG, replace
the ignition switch
illumination.
FRONT INNER REMOTE

SECURITY AND LOCKS
4. Front Inner Remote

A: REMOVAL
3) Remove the screw and two rod joints.
4) Remove the front inner remote.
BO0104
B: INSTALLATION
NOTE:
Make sure the inner remote works properly after installation.
C: INSPECTION
1) Make sure the rod is not deformed.
2) Make sure the lever and rod work smoothly.
SL-18
FRONT OUTER HANDLE

SECURITY AND LOCKS
5. Front Outer Handle

A: REMOVAL
3) Remove the bolt (A).
4) Move the front door glass downward. Remove
the bolt and rod clamp.
5) Remove the front outer handle.
BO0107
CAUTION:
Do not use excessive force to remove the door
panel. This will deform it.
B: INSTALLATION
NOTE:
Make sure the outer handle works properly after installation.
C: INSPECTION
SL-19
FRONT DOOR LATCH ASSEMBLY

SECURITY AND LOCKS
6. Front Door Latch Assembly

A: REMOVAL
4) Remove the front inner remote. <Ref. to SL-18,
REMOVAL, Front Inner Remote.>
5) Remove the three screws and bolt.
BO0105
6) Disconnect the connector. Remove the front

door latch assembly.
B: INSTALLATION
NOTE:
Make sure the lock works properly after installation.
C: INSPECTION
SL-20
FRONT DOOR LOCK ACTUATOR

SECURITY AND LOCKS
7. Front Door Lock Actuator

A: REMOVAL
1) Remove the front door latch assembly. <Ref. to
SL-20, REMOVAL, Front Door Latch Assembly.>
2) Loosen the two screws to remove front door lock
actuator.
BO0106
B: INSTALLATION
NOTE:
C: INSPECTION
1) Disconnect the door lock actuator harness connector.
2) Connect the battery to door lock actuator terminals.
2 1
4 3
2 1
4 3
BO0186
Terminal No.
No. 3 (+) and No. 1 ()
No. 1 (+) and No. 3 ()
Actuator operation
Unlocked Locked
Locked Unlocked
If NG, replace the door lock actuator.
SL-21
REAR INNER REMOTE

SECURITY AND LOCKS
8. Rear Inner Remote

A: REMOVAL
3) Remove the screw and two rod joints.
4) Remove the inner remote.
BO0108
B: INSTALLATION
NOTE:
Make sure the inner remote works properly after installation.
C: INSPECTION
3) Make sure the child safety lock on rear doors
work properly, when applicable.
SL-22
REAR OUTER HANDLE

SECURITY AND LOCKS
9. Rear Outer Handle

A: REMOVAL
3) Remove the rear inner remote. <Ref. to SL-22,
REMOVAL, Rear Inner Remote.>
4) Remove the rear door latch assembly. <Ref. to
SL-24, REMOVAL, Rear Door Latch Assembly.>
5) Loosen the two bolts and nut to remove rear outer handle.
BO0111
CAUTION:
Do not use excessive force to remove the door
panel. This will deform it.
B: INSTALLATION
NOTE:
C: INSPECTION
SL-23
REAR DOOR LATCH ASSEMBLY

SECURITY AND LOCKS
10.Rear Door Latch Assembly

A: REMOVAL
4) Remove the rear inner remote. <Ref. to SL-22,
REMOVAL, Rear Inner Remote.>
5) Remove the three screws and bolt.
BO0109
6) Disconnect the connector, and then remove the

rear door latch assembly.
B: INSTALLATION
NOTE:
C: INSPECTION
SL-24
REAR DOOR LOCK ACTUATOR

SECURITY AND LOCKS
11.Rear Door Lock Actuator

A: REMOVAL
1) Remove the rear door latch assembly. <Ref. to
SL-24, REMOVAL, Rear Door Latch Assembly.>
2) Loosen the two screws to remove rear door lock
actuator.
BO0110
B: INSTALLATION
NOTE:
C: INSPECTION
2 1
4 3
2 1
4 3
BO0186
Terminal No.
No. 3 (+) and No. 1 ()
No. 1 (+) and No. 3 ()
Actuator operation
Unlocked Locked
Locked Unlocked
If NG, replace the door lock actuator.
SL-25
REAR GATE OUTER HANDLE

SECURITY AND LOCKS
12.Rear Gate Outer Handle

A: REMOVAL
2) Remove the rear gate latch assembly. <Ref. to
SL-27, REMOVAL, Rear Gate Latch Assembly.>
3) Loosen the two nuts to remove rear gate outer
handle.
BO0114
B: INSTALLATION
NOTE:
C: INSPECTION
1) Inspect the rod for deformation.
2) Make sure the lever and rod move smoothly.
SL-26
REAR GATE LATCH ASSEMBLY

SECURITY AND LOCKS
13.Rear Gate Latch Assembly

A: REMOVAL
3) Remove the rear gate key cylinder rod clamp.
4) Remove the three bolts.
BO0112
5) Disconnect the connectors, and then remove the

rear gate latch assembly.
B: INSTALLATION
NOTE:
C: INSPECTION
SL-27
REAR GATE LATCH LOCK ACTUATOR

SECURITY AND LOCKS
14.Rear Gate Latch Lock Actuator

A: REMOVAL
2) Loosen the two screws to remove rear gate lock
actuator.
BO0113
B: INSTALLATION
NOTE:
C: INSPECTION
2 1
2 1
BO0191
Terminal No.
No. 1 (+) and No. 2 ()
No. 2 (+) and No. 1 ()
Actuator operation
Unlocked Locked
Locked Unlocked
If NG, replace the rear gate latch lock actuator.
SL-28
TRUNK LID LOCK ASSEMBLY

SECURITY AND LOCKS
15.Trunk Lid Lock Assembly

A: REMOVAL
1) Remove the trunk lid key cylinder rod clamp.
2) Loosen the two bolts to remove trunk lid lock assembly.
BO0115
B: INSTALLATION
NOTE:
Apply grease to parts that rub.
C: INSPECTION
1) Check the striker for bending or abnormal wear.
2) Check the safety lever for improper movement.
3) Check other levers and the spring for rust formation and unsmooth movement.
SL-29
FRONT HOOD LOCK ASSEMBLY

SECURITY AND LOCKS
16.Front Hood Lock Assembly

A: REMOVAL
1) Open the hood.
2) Remove the bolt. Remove the hood lock assembly.
3) Remove the release cable from lock assembly.
BO0187
B: INSTALLATION
NOTE:
Apply grease to parts that rub.
Make sure the release cable works properly after
installation.
C: ADJUSTMENT
Loosen the bolt. Adjust the lock assembly while
moving it up and down.
BO0188
D: INSPECTION
1) Check the striker for bending or abnormal wear.
2) Check the safety lever for improper movement.
3) Check other levers and the spring for rust formation and unsmooth movement.
SL-30
REMOTE OPENERS
SECURITY AND LOCKS
17.Remote Openers
3. FUEL FLAP OPENER
A: REMOVAL

2) Remove the center pillar lower trim and side sill
cover on passenger side. Remove the rear pillar
lower trim. Pull back the floor mat. Remove the clip
holding the cable.
3) Remove the bolt. Remove the opener pull handle.
1. HOOD OPENER
1) Remove the release cable from hood lock.
2) Remove the bolt. Remove the opener lever.
B5M0751
2. TRUNK LID OPENER

2) Remove the center pillar lower trim and side sill
cover on passenger side. Remove the rear pillar
lower trim. Pull back the floor mat. Remove the clip
holding the cable.
3) Remove the bolt. Remove the opener pull handle.
G5M0151
4) Remove the cable from opener pull handle.

5) Remove the right rear quarter trim. <Ref. to EI46, REMOVAL, Rear Quarter Trim.>
6) Rotate the fuel lock inside the quarter panel to
left and remove.
B5M1067
G5M0151
4) Remove the cable from opener pull handle.

5) Remove the striker from trunk lid.
6) Remove the cable from striker.
B: INSTALLATION
1. HOOD OPENER
2. TRUNK LID OPENER

3. FUEL FLAP OPENER

C: INSPECTION
Make sure the fuel flap opens and closes smoothly.
G5M0147
SL-31
IGNITION KEY LOCK

SECURITY AND LOCKS
18.Ignition Key Lock

A: REPLACEMENT
1) Remove the ground cable from battery.
2) Remove the steering column. <Ref. to PS-29,
REMOVAL, Tilt Steering Column.>
3) Secure the steering column in a vise. Remove
the bolt with a drill.
B5M1061
4) Remove the ignition key lock.

5) Use a new torn bolt. Tighten the torn bolt to end
of thread.
S6M0162A
B: INSPECTION
2) Remove the lower column cover.
3) Unfasten the holddown clip which secures harness and disconnect the connector of ignition
switch from body harness.
4) Turn the ignition key plate to each position and
check the continuity between terminals of ignition
connector.
Switch position
LOCK
ACC
ON
ST
Terminal No.
No. 1 and No. 2

No. 1 and No. 2
No. 1 and No. 4
No. 2 and No. 4
No. 1 and No. 3
No. 1 and No. 4
No. 3 and No. 4
Standard
Less than 1
Less than 1
Less than 1
If NG, replace the ignition switch.
SL-32
KEY LOCK CYLINDERS

SECURITY AND LOCKS
19.Key Lock Cylinders
3. REAR GATE
A: REPLACEMENT
2) Remove the rod clamp. Remove the lock plate.
Replace the key cylinder.
1. FRONT DOOR
2) Pull back the sealing cover. <Ref. to EB-14, REMOVAL, Front Sealing Cover.>
3) Move the front door glass downward.
4) Remove the rod clamp. Remove the bolt. Replace the key cylinder.
BO0190
BO0189
2. TRUNK LID
1) Remove the trunk trim. <Ref. to EI-52, REMOVAL, Trunk Trim.>
2) Remove the rod clamp. Remove the lock plate.
Replace the key cylinder.
B5M1085
SL-33
IMMOBILIZER CONTROL MODULE

SECURITY AND LOCKS
20.Immobilizer Control Module

A: REMOVAL
NOTE:
The following positions for removal and installation
are for LHD models. The positions for RHD models
are symmetrically opposite.
3) Disconnect the connector from immobilizer control module.
4) Remove the immobilizer control module.
BO0193
B: INSTALLATION
SL-34
IMMOBILIZER ANTENNA
SECURITY AND LOCKS
21.Immobilizer Antenna
A: REMOVAL
3) Remove the screws, separate upper column
cover and lower column cover.
B6M1184
4) Disconnect the immobilizer antenna connector

(A) from immobilizer control module.
5) Remove the screw, and detach the immobilizer
antenna (B).
BO0502
B: INSTALLATION
SL-35
KEYLESS ENTRY CONTROL MODULE

SECURITY AND LOCKS
22.Keyless Entry Control Module

A: REMOVAL
3) Remove the nut, and then remove the keyless
entry control module while disconnecting connector.
BO0194
4) Disconnect the keyless entry control module and

other electrical control module.
B: INSTALLATION
SL-36
KEYLESS TRANSMITTER
SECURITY AND LOCKS
23.Keyless Transmitter
If NG, replace the battery. (Use CR1620 or equivalent.)
A: REMOVAL
D: REPLACEMENT
1. TRANSMITTER BATTERY
1. TRANSMITTER REGISTRATION
Remove the battery from transmitter.

NOTE:
To prevent static electricity damage to transmitter
printed circuit board, touch the steel area of building with hand to discharge the static electricity carried on body or clothes before disassembling
transmitter.
B5M1182
B: INSTALLATION
C: INSPECTION
Measure the voltage between battery (+) terminal
and () terminal.
NOTE:
A maximum of three transmitters can be registered for each individual vehicle.
When replacing the transmitter (key), registration
to immobilizer system is also necessary.
1) Remove the side sill cover at driver's side, then
connect the registration connectors at front pillar
lower section.
2) Unlock the door lock.
3) Press any button of the transmitter twice to be
registered.
4) The door lock will automatically lock and unlock
in sequence. This indicates the completion of transmitter registration for first transmitter.
5) If the registration of a second transmitter is now
to be carried out, press any button of that transmitter twice.
6) The door lock will automatically lock and unlock
in sequence. This indicates the completion of transmitter registration for second transmitter.
7) If the registration of third transmitter is now to be
carried out, repeat the procedure 5) and 6).
8) Disconnect the registration connectors after the
completion of all registration operations. After confirming the operation of door lock using newly registered transmitter(s), reinstall the side sill cover at
driver's side.
NOTE:
Battery discharge occurs during measurement.
Complete the measurement within 5 seconds.
During battery voltage measurement, voltage
falls more than 1.8 volts in 3 seconds period.
Resistance 300
BO0195
Tester connection
(+)
()
Battery (+) termiBattery () terminal
nal
Standard
2.5 3.0 V
SL-37
KEYLESS TRANSMITTER
SECURITY AND LOCKS
SL-38
IM
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Page
Immobilizer Control Module I/O Signal........................................................6
Subaru Select Monitor.................................................................................7
Read Diagnostic Trouble Code (DTC) ........................................................9
Diagnostics Chart for Immobilizer Indicator Light......................................12
Diagnostics Chart with Diagnostic Trouble Code (DTC) ...........................17


A: PROCEDURE
1
2
3
Step
CHECK ILLUMINATION OF IMMOBILIZER
INDICATOR LIGHT.
Turn the ignition switch to ON.
CHECK ENGINE START.
Turn the ignition switch to START position.
INDICATOR LIGHT.
1)Turn the ignition switch to OFF or ACC position.
2)Wait at least 60 seconds.
Check
Yes
Does the immobilizer indicator Go to step 2.
light illuminate?
No
Go to step 3.
Is the engine hard to start?
Go to step 3.
Go to step 5.
Does the immobilizer indicator Go to step 4.

light blink?
Check the immobilizer indicator light

circuit.<Ref. to IM12, CHECK
IMMOBILIZER
INDICATOR CIRCUIT, Diagnostics
Chart for Immobilizer Indicator
Light.>
Check the key
switch circuit.
<Ref. to IM-14,
CHECK KEY
SWITCH CIRCUIT, Diagnostics
Chart for Immobilizer Indicator
Light.>
Repair the related
parts.

INDICATOR LIGHT.
Remove the key from ignition switch.
Does the immobilizer indicator The immobilizer

light begin to blink within 1 sec- system is OK.
ond after the key is removed?
CHECK INDICATION OF DTC ON DISPLAY.

link connector. <Ref. to IM-7, Subaru Select
Monitor.>
3)Turn the ignition switch and Subaru Select
4)Read any DTC on the display.
1)Inspect using Diagnostics Chart with Trouble Code.<Ref. to IM-17, Diagnostics Chart
2)Repair the trouble cause.
4)Read any DTC again.
Are DTCs indicated on display?
Go to step 6.
Are DTCs indicated on display?
Inspect using
Finish the diagDiagnostic Chart nostics.
with Trouble
Code. <Ref. to
IM-17, Diagnostics Chart with
IM-2
GENERAL DESCRIPTION
When repeatedly turning the ignition ON or

OFF while diagnostic items are being checked,
it should be switched in cycles of ON for at
least 5 seconds OFF for at least 8 seconds.
A: CAUTION
CAUTION:
The airbag system wiring harness is routed
near the immobilizer control module. All airbag
system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits.
wiring harness when servicing the immobilizer
control module.
While diagnostic items are being checked, do
not operate radios, portable telephones, etc.
which emit electromagnetic waves near or
inside the vehicle.
B6M0618A
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.
Start the engine again.
Before checking the diagnostic items, obtain
all keys for the vehicle to be checked
possessed by owner.
B6M0616
When the ignition switch is being turned ON

or OFF while diagnostic items are being
checked, do not allow keys with different ID
codes close to the ignition switch. If the ignition
key is in a key holder, remove it from the holder
before carrying out diagnoses.
B6M0617
IM-3
GENERAL DESCRIPTION
B: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
24082AA190
CARTRIDGE
REMARKS
B2M3876
22771AA030
SELECT MONITOR
KIT

English:
German:
French:
Spanish:
B2M3877
2. GENERAL TOOLS
TOOL NAME
Circuit Tester
REMARKS
IM-4


A: LOCATION
BO0010
(1)
(2)
(3)
(4)
Antenna
Immobilizer indicator light (LED bulb)
Immobilizer control module (IMM ECM)
Transponder
NOTE:
IMM ECM location for RHD model is symmetrically
opposite.
IM-5
IMMOBILIZER CONTROL MODULE I/O SIGNAL

4. Immobilizer Control Module

I/O Signal
A: SCHEMATIC
1. IMMOBILIZER
<Ref. to WI-181, SCHEMATIC, Immobilizer System.>
IM-6

5) Turn the ignition switch to ON (engine OFF), and

then Subaru Select Monitor switch to ON.
A: OPERATION
S2M0288A
6) Using the Subaru Select Monitor, call up any

DTCs and various data, and then record them.

(DTC) FOR ENGINE.
S2M0285
Refer to Read Diagnostic Trouble Code for information about how to indicate DTC. <Ref. to IM-9,

Monitor.
3. INTERFACE CHECK
NOTE:
The communication line between ECM and IMM
ECM can be checked in System Operation Check
Mode. This is referred to as interface check.
1) Connect the select monitor.
2) Set the System Operation Check Mode menu
display screen, and then select Immobilizer System.
3) Screen indicates as shown.
S2M0286A

connector.
(1) Data link connector is located in the lower
portion of the instrument panel (on drivers side).
S6M0210
EN0768

connector.
CAUTION:
Do not connect the scan tools except for Subaru Select Monitor.
IM-7

4) Start the interface check.

5) Does Communication Line not Shorted appear
on screen?
If YES. Go to step 6).
If NO. Go to step 7).
S6M0211
6) After diagnostic results, it is determined that the

short circuit is not a diagnostic item. This completes
interface check.
7) If a problem is detected, repair. <Ref. to IM-18,
DTC P1572 IMM CIRCUIT FAILURE (EXCEPT
ANTENNA CIRCUIT), Diagnostics Chart with Diagnostic Trouble Code (DTC).>
IM-8


A: OPERATION
1) On the Main Menu display screen, select the {Each System Check}, and then press the [YES] key.
2) On the System Selection Menu display screen, select the {Engine Control System}, and then press the
[YES] key.
4) On the Engine Diagnosis display screen, select the {Diagnostic Code(s) Display}, and then press the
[YES] key.
5) On the Diagnostic Code(s) Display display screen, select the {Current Diagnostic Code(s)} or {History
Diagnostic Code(s)}, and then press the [YES] key.
NOTE:
to IM-16, LIST, List of Diagnostic Trouble Code (DTC).>
IM-9
CLEAR MEMORY MODE


A: OPERATION
1) On the Main Menu display screen, select the {2. Each System Check}, and then press the [YES] key.
2) On the System Selection Menu display screen, select the {Engine Control System}, and then press the
[YES] key.
4) On the Engine Diagnosis display screen, select the {Clear Memory}, and then press the [YES] key.
5) When the `Done' and `Turn Ignition Switch OFF' are shown on the display screen, turn the Subaru Select
NOTE:
After the memory has been cleared, the ISC must be initialized. To do this, turn the ignition switch to ON
position. Wait 3 seconds before starting the engine.
IM-10
CLEAR MEMORY MODE

IM-11
DIAGNOSTICS CHART FOR IMMOBILIZER INDICATOR LIGHT

8. Diagnostics Chart for Immobilizer Indicator Light

A: INSPECTION
1. CHECK IMMOBILIZER INDICATOR CIRCUIT
WIRING DIAGRAM:
BATTERY
M/B No.2
SBF-1
IGNITION
SWITCH
LHD
RA
F/B No.11
SBF-4
RM
SBF-5
B38
3
20
B36
21
B61
F44
i3
LHD
B36
i1
i1
RHD
RM
LHD
RA
LHD
COMBINATION METER
A:
i10
B:
i11
RHD
LHD : LHD MODEL
IMMOBILIZER
INDICATOR
LIGHT
RHD : RHD MODEL
A10
RA : RHD AT MODEL
B6
RM : RHD MT MODEL
i2
1
1 : LHD MODEL: 17
B37
12
11
10
: RHD MODEL: 22
B141 IMMOBILIZER CONTROL MODULE
B141
i1
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
i2
A:
LHD
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
i2
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
F44
B:
i10
i11
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4 5 6 7 8 9 10
LHD
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
B36
RHD
i3
RHD
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
LHD
1 2 3 4
5 6 7 8
BO0459
IM-12

Step
CHECK IMMOBILIZER INDICATOR LIGHT
COMES ON.
2)Disconnect the harness connector from IMM
ECM.
3)Connect a resistor (750 ) between IMM
ECM harness connector terminal No. 9 and
chassis ground.
CHECK IMM ECM GROUND CIRCUIT.
Measure the resistance between IMM ECM
harness connector terminal and chassis
ground.
(B141) No. 2, No. 3 Chassis ground:
CHECK IMM ECM IGNITION CIRCUIT.
1)Turn the ignition switch to ON. (engine OFF.)
2)Measure the voltage between IMM ECM harness connector terminal and chassis ground.
CHECK IMM ECM POWER SUPPLY CIRCUIT.
(B141) No. 10, No. 11 (+) Chassis
ground ():
Check
Does the indicator light come
on?
Yes
Go to step 2.
No
Go to step 5.

?
Go to step 3.
Repair the open

circuit of IMM ECM
ground circuit.
Check the harness

for open or short
between IMM
ECM and ignition
switch.
Is the voltage more than 10 V? Replace the IMM

ECM <Ref. to SL34, Immobilizer
Control Module.>
and then replace
all ignition keys
(including the transponder). Then
perform teaching
operation. Refer to
teaching operation manual (Pub.
No. S0820GZ).
Check the harness

for open or short
between IMM
ECM and fuse.
CHECK COMBINATION METER CIRCUIT.

meter harness connector terminal and chassis
ground.
CHECK COMBINATION METER CIRCUIT.
?
harness connector terminal and combination
meter harness connector terminal.
(B141) No. 9 (i11) No. 6:
IM-13
Check the harness

for open or short
fuse.
Faulty LED bulb. Repair the harReplace the com- ness or connector.
bination meter
printed circuit.
<Ref. to IDI-16,
DISASSEMBLY,
Combination
Meter Assembly.>

2. CHECK KEY SWITCH CIRCUIT

WIRING DIAGRAM:
BATTERY
M/B No.6
RHD
LHD
23
F45
RHD
B62
LHD
LHD : LHD MODEL
RHD : RHD MODEL
KEY WARNING
SWITCH
2
1
B74
B141
IMMOBILIZER
CONTROL
MODULE
B74
B141
F45
1
2
1 2 3
4 5
6 7 8 9 10 11 12
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
BO0150
IM-14

Step
CHECK POWER SUPPLY CIRCUIT.
1)Disconnect the harness connector from key
warning switch.
2)Turn the ignition switch to ACC or LOCK
position (The key inserted).
3)Measure the voltage between key warning
switch harness connector terminal and chassis
ground.
CHECK KEY SWITCH.
1)Insert the ignition key to the ignition switch.
(OFF or ACC position)
2)Measure the resistance between key warning switch connector terminals.
No. 1 No. 2:
CHECK KEY SWITCH.
1)Remove the ignition key from the ignition
switch.
2)Measure the resistance between key warning switch connector terminals.
No. 1 No. 2:
CHECK HARNESS BETWEEN KEY SWITCH
AND IMM ECM.
1)Disconnect the harness connector from key
warning switch.
ECM.
3)Measure the resistance between key warning switch harness connector terminal and
IMM ECM harness connector terminal.
(B74) No. 1 (B141) No. 4:
Check
Yes
No
Check the harness
for open or short
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 IMM

Control Module.>
and then replace
all ignition keys
perform teaching
operation. Refer to
teaching operation manual (Pub.
No. S0820GZ).
Repair the harness between key

warning switch
and IMM ECM.
IM-15

9. List of Diagnostic Trouble Code (DTC)

A: LIST
DTC
Without
With
OBD
OBD
53
Item
P1571
Reference Code Incompatibility

between IMM ECM and ECM
P1572
IMM Circuit Failure

(Except Antenna Circuit)
Communication failure between

IMM ECM and ECM
P1574
Key Communication Failure
Failure of IMM ECM to verify key

(transponder) ID code
P0153
Use of Unregistered Key
Incorrect immobilizer key (Use of

unregistered key in IMM ECM)
P1576
EGI Control Module

EEPROM
ECM malfunctioning
P1577
IMM Control Module

EEPROM
IMM ECM malfunctioning
P1570
ANTENNA
Faulty antenna
Index No.
<Ref. to IM-17, DTC P1571 REFERENCE CODE INCOMPATIBILITY, Diagnostics Chart with Diagnostic Trouble
Code (DTC).>
Chart with Diagnostic Trouble Code
(DTC).>
UNREGISTERED KEY), Diagnostics
(DTC).>
<Ref. to IM-22, DTC P1576 EGI CONTROL MODULE EEPROM, Diagnostics
(DTC).>
<Ref. to IM-22, DTC P1577 IMM CONTROL MODULE EEPROM, Diagnostics
(DTC).>
<Ref. to IM-24, DTC P1570 ANTENNA,
Diagnostics Chart with Diagnostic Trouble Code (DTC).>
NOTE:
If any DTC except for the above immobilizer trouble code has been output, carry out diagnosis for the engine trouble code. <Ref. to EN-83, List of Diagnostic Trouble Code (DTC).> or <Ref. to EN(w/oOBD)-63, List
of Diagnostic Trouble Code (DTC).> or <Ref. to EN(TURBO)-75, List of Diagnostic Trouble Code (DTC).>
IM-16
DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE (DTC)

10.Diagnostics Chart with Diagnostic Trouble Code (DTC)

A: DTC P1571 REFERENCE CODE INCOMPATIBILITY
DIAGNOSIS:
Reference code incompatibility between IMM ECM and ECM
Step
Check
PERFORM TEACHING OPERATION ON IG- Is teaching operation for all
NITION KEY.
keys completed?
Perform teaching operation on all keys of the
vehicle. Refer to the teaching operation manual.
IM-17
Yes
END
No
Replace the ECM
<Ref. to FU-51,
Engine Control
Module.>, <Ref. to
FU(w/oOBD)-48,
Engine Control
Module.> or <Ref.
to FU(TURBO)-49,
Engine Control
Module.>, IMM
Control Module.>
and then replace
all ignition keys
perform teaching
operation. Refer to
the teaching operation manual (Pub.
No. S0820GZ).

B: DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT)

DIAGNOSIS:
Communication failure between IMM ECM and ECM
WIRING DIAGRAM:
IGNITION
SWITCH
BATTERY
SBF-1
F/B No.11
SBF-4
SBF-5
LHD
RHD

B61
F44
RHD : RHD MODEL
RHD
LHD : LHD MODEL
LHD
1 : LHD MODEL: B5
: RHD MODEL: B14
2 : LHD MODEL: B14

: RHD MODEL: B5
TB
NA
B: B135
B: B135
ENGINE
CONTROL
MODULE
NA
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
20 21
24 25 26
27 28
22 23
B: B135
B: B135
ENGINE
CONTROL
MODULE
TB
1 2 3 4 5 6
7 8 9
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
12
11
10
B22
B23
TB
NA
B141
F44
1 2 3
4 5
6 7 8 9 10 11 12
1 2 3 4
5 6 7 8
BO0460
IM-18

Step
CHECK POWER SUPPLY CIRCUIT OF IMM
ECM.
ECM.
(B141) No. 10, No.11 (+) Chassis
ground ():
CHECK POWER SUPPLY CIRCUIT OF IMM
ECM.
CHECK GROUND CIRCUIT OF IMM ECM.
2)Measure the resistance between IMM ECM
harness connector terminal and chassis
ground.
(B141) No. 2, No.3 Chassis ground:
CHECK HARNESS BETWEEN IMM ECM
AND ECM.
1)Disconnect the harness connector from ECM
and IMM ECM.
2)Measure the resistance between IMM ECM
harness connector terminal and ECM harness
connector terminal.
Non-turbo engine model
(B141) No. 1 (B135) No. 22:
LHD turbo engine model
(B141) No. 1 (B135) No. 14:
RHD turbo engine model
(B141) No. 1 (B135) No. 5:
CHECK HARNESS BETWEEN IMM ECM
AND ECM.
harness connector terminal and ECM harness
connector terminal.
(B141) No. 6 (B135) No. 23:
LHD turbo engine model
(B141) No. 6 (B135) No. 5:
RHD turbo engine model
(B141) No. 6 (B135) No. 14:
CHECK HARNESS OF COMMUNICATION
LINE.
1)Turn the ignition switch to ON. (Engine
OFF.)
(B141) No. 1, No.6 (+) Chassis ground
():
Check
Yes
No
Check the harness
for open or short
between IMM
ECM and fuse.
Check the harness

for open or short
between IMM
ECM and ignition
switch.

?
Go to step 4.
Repair the open

circuit of IMM ECM
ground circuit.

?
Go to step 5.
Repair the open

circuit of harness
between IMM
ECM and ECM.

?
Go to step 6.
Repair the open

circuit of harness
between IMM
ECM and ECM.
Is the voltage 0 V?
Go to step 7.
Repair the harness between IMM

ECM and ECM,
because there is
short circuit with
battery voltage line
or ignition switch
ON line.
IM-19

Step
CHECK HARNESS OF COMMUNICATION
LINE.
Measure the voltage between ECM harness
connector terminal and engine ground.
(B135) No. 22, No.23 (+) Engine
ground ():
Turbo engine model
(B135) No. 5, No.14 (+) Engine
ground ():
CHECK ECM BY INTERFACE CHECK.
1)Connect the harness connector to ECM.
ECM.
3)Perform interface check. <Ref. to IM-7,
INTERFACE CHECK, Subaru Select Monitor.>

Perform interface check.
10

Perform interface check.
Check
Is the voltage 0 V?
Yes
Go to step 8.
Does Commun. Line Shorted Replace the ECM.

to Ground appear on the
<Ref. to FU-51,
screen?
Engine Control
Module.>, <Ref. to
FU(w/oOBD)-48,
Engine Control
Module.> or <Ref.
to FU(TURBO)-49,
Engine Control
Module.> Then
perform teaching
operation. Refer to
No. S0820GZ).
Does Commun. Line Shorted Replace the ECM.
to Battery appear on the
<Ref. to FU-51,
screen?
Engine Control
Module.>, <Ref. to
FU(w/oOBD)-48,
Engine Control
Module.> or <Ref.
to FU(TURBO)-49,
Engine Control
Module.> Then
perform teaching
operation. Refer to
No. S0820GZ).
Does Communication Line not Replace the IMM
Shorted appear on the
ECM <Ref. to SLscreen?
34, Immobilizer
Control Module.>
and then replace
all ignition keys
perform teaching
operation. Refer to
No. S0820GZ).
IM-20
No
ECM and ECM,
because there is
short circuit with
or ignition switch
ON line.
Go to step 9.
Go to step 10.
When Check
(Time Out)
appears on the
screen, perform
interface check
again.

C: DTC P1574 KEY COMMUNICATION FAILURE

DIAGNOSIS:
Failure of IMM ECM to verify key (transponder) ID code
Step
CHECK IMM ECM FUNCTION.
Insert the key to ignition switch (LOCK position), measure changes in voltage between
Antenna connector.
(B142) No. 1 No. 2:
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.
IM-21
No
Replace the IMM
Control Module.>
and then replace
all ignition keys
perform teaching
operation. Refer to
No. S0820GZ).
Replace the igni- Replace the IMM
tion key (including ECM <<Ref. to SLthe transponder). 34, Immobilizer
Then perform
Control Module.>
teaching operaand then replace
tion. Refer to the all ignition keys
teaching opera(including the trantion manual (Pub. sponder). Then
No. S0820GZ).
perform teaching
operation. Refer to
No. S0820GZ).

D: DTC P0153 INCORRECT IMMOBILIZER KEY (USE OF UNREGISTERED KEY)

DIAGNOSIS:
Use of unregistered key in IMM ECM
Step
PERFORM TEACHING OPERATION ON IGNITION KEY.
Perform teaching operation on all keys of the
vehicle. Refer to the teaching operation manual (Pub. No. S0820GZ).
PERFORM TEACHING OPERATION ON IGNITION KEY.
Perform teaching operation on all keys with
vehicle. Refer to the teaching operation manual (Pub. No. S0820GZ).
Check
Is teaching operation for all
keys completed?
Is teaching operation for all

keys completed?
Yes
END
END
No
Replace all ignition
keys (including the
transponder). Go
to step 2.
Replace the IMM
Control Module.>
and then replace
all ignition keys
perform teaching
operation. Refer to
No. S0820GZ).
E: DTC P1576 EGI CONTROL MODULE EEPROM

DIAGNOSIS:
ECM malfunctioning
1. REPLACE ECM.
Replace the ECM.
<Ref. to FU-51, Engine Control Module.>, <Ref. to FU(w/oOBD)-48, Engine Control Module.> or <Ref. to
FU(TURBO)-49, Engine Control Module.>
Then perform teaching operation. Refer to the teaching operation manual (Pub. No. S0820GZ).
F: DTC P1577 IMM CONTROL MODULE EEPROM

DIAGNOSIS:
IMM ECM malfunctioning
1. REPLACE IMM ECM.

Replace the IMM ECM <Ref. to SL-34, Immobilizer Control Module.>, and then replace all ignition keys (including the transponder). Then perform teaching operation. Refer to the teaching operation manual (Pub.
No. S0820GZ).
IM-22

IM-23

G: DTC P1570 ANTENNA

DIAGNOSIS:
Faulty antenna
WIRING DIAGRAM:
B6M1534
IM-24

Step
CHECK ANTENNA CIRCUIT.
2)Disconnect the harness antenna connector
from IMM ECM. <Ref. to SL-35, Immobilizer
Antenna.>
3)Measure the resistance of antenna circuit.
(B142) No. 1 No. 2:
Measure the resistance between antenna harness connector and chassis ground.
Measure the resistance between antenna harness connector and chassis ground.
2)Measure the voltage between antenna harness connector and chassis ground.
Measure the voltage between antenna harness connector and chassis ground.
Check
?
Yes
Go to step 2.
No
Replace the
antenna. <Ref. to
SL-35, Immobilizer Antenna.>

?
Replace the
antenna. <Ref. to
Go to step 3.

?
Replace the
antenna. <Ref. to
Go to step 4.
Is the voltage 0 V?
Go to step 5.
Replace the
antenna. <Ref. to
Is the voltage 0 V?
Go to step 6.

ECM and antenna,
because there is
short circuit with
or ignition switch
ON line.
CHECK IMM ECM FUNCTION.
Is the voltage 30 to 30 V?
Go to step 7.
Replace the IMM
(Approx. 0.1 second after
ECM <Ref. to SL2)Connect the antenna harness connector to inserting the key) Is the voltage
34, Immobilizer
IMM ECM.
0 V? (Approx. 1 second after
Control Module.>
3)Insert the key to ignition switch, measure
inserting the key)
and then replace
changes in voltage between antenna harness
all ignition keys
connector.
(including the tranConnector & terminal
sponder). Then
(B142) No. 1 (+) No. 2 ():
perform teaching
operation. Refer to
No. S0820GZ).
CHECK IGNITION KEY (TRANSPONDER).
Replace the igni- Replace the IMM
tion key (including ECM <Ref. to SL2)Start the engine using other keys that have
the transponder). 34, Immobilizer
undergone the teaching operation, furnished
Then perform
Control Module.>
with vehicle.
teaching operaand then replace
tion. Refer to the all ignition keys
teaching opera(including the trantion manual (Pub. sponder). Then
No. S0820GZ).
perform teaching
operation. Refer to
No. S0820GZ).
IM-25

IM-26
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)
SR
1.
2.
3.
4.
5.
6.
Page
Sunroof Control System ..............................................................................4
Sunroof Lid..................................................................................................5
Sunroof Assembly .......................................................................................6
Sunroof Motor .............................................................................................8
Sunroof Switch ............................................................................................9
GENERAL DESCRIPTION
SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF)
A: COMPONENT
BO0136
(1)
(2)
(3)
(4)
(5)
Glass lid
Guide rail cover
Sunshade
Drain tube
Sunroof bracket
(6)
(7)
(8)
Motor cover
Motor ASSY
Frame ASSY
SR-2

T: 7.4 (0.75, 5.4)
GENERAL DESCRIPTION
B: CAUTION
Before disassembling or reassembling parts, always disconnect battery ground cable. When replacing radio, control module, and other parts
C: PREPARATION TOOL
1. GENERAL TOOLS
TOOL NAME
Circuit Tester
REMARKS
Used for measuring resistance and
voltage.
SR-3
SUNROOF CONTROL SYSTEM

2. Sunroof Control System

A: SCHEMATIC
1. SUNROOF
<Ref. to WI-259, SCHEMATIC, Sunroof System.>
B: INSPECTION
Symptom
Water leaks.
Booming noise
Abnormal motor noise
Failure of sunroof
(Motor operates properly.)
Motor does not rotate or rotates improperly.
Checking order
(1) Check roof panel and sunroof lid for improper or poor sealing.
(2) Check drain tube for clogging.
(3) Check sunroof frame seal and body for improper fit.
(1) Check sunroof lid and roof panel for improper clearance.
(2) Check sunshade and roof trim for improper clearance.
(1) Check motor for looseness.
(2) Check gears and bearings for wear.
(3) Check cables 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.
(6) Check clutch adjustment nut for improper tightness.
(1) Check fuse for blow-out.
(2) Check switch for improper function.
(3) Check motor for incorrect terminal voltage.
(4) Check relay for improper operation.
(5) Check poor grounding system.
(6) Check harness for open or short and terminals for poor connections.
(7) Check limit switch for improper operation.
SR-4
SUNROOF LID
3. Sunroof Lid
B: INSTALLATION
A: REMOVAL
1) Completely close the rear sunroof lid and open

the sunshade.
2) Remove the covers (A) then remove the nuts
(B).
C: ADJUSTMENT
1. ALIGNMENT OF HEIGHT BETWEEN
SUNROOF LID AND ROOF PANEL
Loosen the sunroof lid installation nuts and then
adjust height by adding (max: two pieces) or extracting (max: one piece) shims (A) (standard: one
piece) between sunroof lid (B) and body.
Difference in height between sunroof lid and
roof panel: L
L: 2.00.5 mm (0.0790.020 in)
B5M1029A
(A)
3) Remove the sunroof lid carefully.

L
(B)
BO0314
SR-5
SUNROOF ASSEMBLY
4. Sunroof Assembly
9) Remove the nuts then detach the sunroof frame.
A: REMOVAL
2) Remove the roof trim. <Ref. to EI-48, REMOVAL, Roof Trim.>
3) Remove the sunroof lid. <Ref. to SR-5, REMOVAL, Sunroof Lid.>
4) Disconnect the drain tubes from sunroof frame.
5) Remove the room lamp harness clip (A).
BO0141
(A)
BO0315
6) Disconnect the sunroof harness connector.

7) Remove the motor cover.
BO0139
8) Remove the assist grip bracket (A) and sunroof

bracket (B).
(B)
(A)
BO0316
SR-6
SUNROOF ASSEMBLY
B: INSTALLATION
E: INSPECTION
1. CHECK FOR MOVEMENT OF SUNSHADE
CAUTION:
Be careful not to snag the harness.
NOTE:
Make sure to connect the harness connector.
When installing the drain tube, insert it securely
onto drain pipe.
1) Place a cloth on sunshade, and attach a spring

scale to sunshade edge using a cloth.
Length A:
B5M0317
2) Pull the spring scale to measure force required

to move the sunshade.
G5M0205
Force required to move rear sunshade:

Less than 24.54.9 N (2.50.5 kgf, 551.1 lb)
NOTE:
Considerable force is required to start sunshade
moving, so take a scale reading when it begins to
move smoothly.
3) If the force required exceeds specifications,
check the following points:
Sunroof lid, sunshade and guide rail assembly for
improper installation.
C: DISASSEMBLY
1) Remove the sunroof frame.
2) Remove the rail stoppers (A).
(A)
BO0317
3) Pull out the sunshade (A) from sunroof frame.
(A)
BO0318
D: ASSEMBLY
SR-7
SUNROOF MOTOR
5. Sunroof Motor
B: INSTALLATION
A: REMOVAL
CAUTION:
Never rotate the sunroof motor while removed.
Be careful not to move the sunroof cable
when installing sunroof motor.
1) Check the matching mark (A) of sunroof motor.
CAUTION:
When removing the clip, use great care to not
damage the roof trim.
2) Completely close the sunroof.
3) Remove the sunroof lid. <Ref. to SR-5, REMOVAL, Sunroof Lid.>
4) Confirm the matching mark (A) of sunroof bracket link and the guide from sunroof opening. (If the
mark does not match, adjust to match the mark.)
BO0144
2) Confirm the matching mark (A) of sunroof bracket link.
B5M1036A

6) Remove the motor cover.
B5M1036A
BO0139

the sunroof motor mounting screw.
3) Install the sunroof motor.

4) After installing the motor, reconfirm the matching
marks of motor side and sunroof bracket link side.
5) Connect the sunroof motor harness connector
and then connect the battery ground cable.
6) Check the sunroof operation with the procedure
as shown in the table.
Operation
(1) Completely close sunroof.
(2) Tilt-up sunroof to most upper position.
(3) Lower sunroof completely.
(4) Open sunroof to near the completely
open position.
(5) Completely open sunroof.
(6) Close sunroof 150 mm (5.91 in) away
from completely closed position.
(7) Completely close sunroof.
Switch position
Closed
Tilt-up
Tilt-down
Open
Open
Closed
Closed
7) Install the sunroof lid and trims in the reverse order of removal.
SR-8
SUNROOF SWITCH
6. Sunroof Switch
A: REMOVAL
2) Remove the spot light lens (A) and sunroof
switch mounting screw (B).
(A)
(B)
BO0319

the sunroof switch.
B: INSTALLATION
C: INSPECTION
Measure the sunroof switch resistance.
B5M1042A
Switch position
Open
Close
Tilt-up
Tilt-down
Terminal No.
S1: 3 and 4
S1: 1 and 3
S2: 3 and 4
S2: 1 and 3
Standard
Less than 1
Less than 1
Less than 1
Less than 1
SR-9
SUNROOF SWITCH
SR-10
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.
Page
Front Grille ................................................................................................17
Hood Grille ................................................................................................18
Front Under Cover ....................................................................................21
Front Bumper ............................................................................................22
Rear Bumper.............................................................................................29
Mud Guard ................................................................................................31
Cowl Panel ................................................................................................32
Roof Spoiler ..............................................................................................33
Rear Spoiler ..............................................................................................34
Side Sill Spoiler .........................................................................................35
Front Door Trim .........................................................................................36
Rear Door Trim .........................................................................................37
Glove Box..................................................................................................38
Roof Rail ...................................................................................................39
Console Box..............................................................................................40
Instrument Panel Assembly ......................................................................41
Upper Inner Trim .......................................................................................44
Lower Inner Trim .......................................................................................45
Rear Quarter Trim .....................................................................................46
Sun Visor...................................................................................................47
Roof Trim ..................................................................................................48
Rear Gate Trim .........................................................................................50
Rear Shelf Trim .........................................................................................51
Trunk Trim.................................................................................................52
Floor Mat ...................................................................................................53
Luggage Floor Mat ....................................................................................54
Trunk Room Mat .......................................................................................55
GENERAL DESCRIPTION
A: COMPONENT
1. FRONT GRILLE
(3)
(1)
(2)
BO0293
(1)
Front grille
(2)
Front grille emblem
(3)
Clip
2. UNDER COVER
(1)
(3)
(2)
BO0294
(1)
(2)
Under cover
Clip (side)
(3)
Clip

T: 14 (1.42, 10.3)
EI-2
GENERAL DESCRIPTION
3. HOOD GRILLE
(3)
(1)
(7)
(6)
(5)
(4)
(9)
(2)
(5)
(6)
T
(8)
(5)
BO0496
(1)
(2)
(3)
(4)
(5)
Hood grille
Bolt
Grille duct
Grille lower duct
Clip
(6)
(7)
(8)
(9)
Black clip
White clip
Packing
Packing

T: 4.4 (0.45, 3.25)
EI-3
GENERAL DESCRIPTION
4. FRONT BUMPER
T2
(6)
(5)
(2)
T2
T2
(3)
T1
(4)
(1)
BO0497
(1)
(2)
(3)
Bumper face
Head light side cover
Bumper corner bracket
(4)
(5)
(6)
License plate bracket

Bumper energy absorber
Bumper back beam
EI-4

T1: 32 (3.3, 24)
T2: 69 (7.0, 51)
GENERAL DESCRIPTION
5. REAR BUMPER
T2
(8)
(1)
T1
(7)
(2)
(6)
(3)
T3
T3
(4)
(5)
BO0282
(1)
(2)
(3)
(4)
Bumper face
Bumper upper beam
Bumper corner bracket
Bumper side bracket
(5)
(6)
(7)
(8)
Bumper side cover

License plate base
Bumper energy absorber
Bumper back beam
EI-5

T1: 33 (3.4, 24)
T2: 34 (3.5, 25)
T3: 95 (9.7, 70)
GENERAL DESCRIPTION
6. MUD GUARD
(2)
(1)
(5)
(3)
(4)
BO0296
(1)
(2)
Mud guard
Clip
(3)
(4)
Sub frame cover

Brake duct plate
(5)
Mud guard plate
7. COWL PANEL
(2)
(3)
(1)
(4)
(2)
BO0297
(1)
(2)
Cowl panel
Cowl side panel
(3)
(4)
Protector
Seal
EI-6
GENERAL DESCRIPTION
8. ROOF SPOILER
(1)
(2)
(3)
BO0298
(1)
(2)
Roof spoiler
Cap
(3)
Clip

T: 7.35 (0.749, 5.42)
9. REAR SPOILER
(1)
(5)
(2)
(6)
(3)
T
(4)
BO0299
(1)
(2)
(3)
Rear spoiler
Protector
Clip
(4)
(5)
(6)
Grommet
Seal (only RH side)
High mount stop lamp
EI-7

T: 7.4 (0.75, 5.46)
GENERAL DESCRIPTION
10.SIDE SILL SPOILER
(2)
(4)
(1)
(5)
(3)
(6)
(4)
BO0300
(1)
(2)
Side sill spoiler

End cover
(3)
(4)
Protector
Rivet clip
(5)
(6)
Clip (Side sill spoiler)

Clip
11.ROOF RAIL
(1)
T
BO0301
(1)
Roof rail

T: 7.4 (0.75, 5.46)
EI-8
GENERAL DESCRIPTION
12.DOOR TRIM
(4)
(5)
(1)
(3)
(6)
(2)
(4)
(2)
(5)
FRONT
(3)
(6)
REAR
(7)
BO0253
(1)
(2)
(3)
Gusset cover
Bracket
Weatherstrip upper
(4)
(5)
(6)
Clip
Trim panel
Power window switch cover
EI-9
(7)
Lower trim
GENERAL DESCRIPTION
13.CONSOLE BOX
(1)
(2)
(5)
(4)
(6)
(3)
(13)
(14)
(7)
(8)
(15)
(9)
(16)
(11)
(10)
(12)
BO0302
(1)
(2)
(3)
(4)
(5)
(6)
Console cover
Cup holder
Bracket
Strip
Upper lid
Lid hinge
(7)
(8)
(9)
(10)
(11)
(12)
Rear lid
Console box
Console pocket
Upper bracket
Pad
Lower bracket
EI-10
(13)
(14)
(15)
(16)
Lock
Front cover (MT)
Boot
Front cover (AT)
GENERAL DESCRIPTION
14.INSTRUMENT PANEL
(6)
(2)
T
(3)
(1)
T
(4)
(5)
(10)
(8)
(9)
T
(7)
(4)
(19)
(11)
(17)
T
(18)
(12)
(15)
(13)
(16)
(14)
BO0303
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Pad & frame

Center upper panel
Air vent grille (Defroster)
Grille cover
Meter visor
Defroster grille
Cup holder
Air vent grille (Center)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Air vent grille (Side)

Lower cover
Console cover
Center panel
Center pocket
Ash tray
Audio bracket
Glove box lid
EI-11
(17)
(18)
(19)
Glove box panel

Console rein forcement
Coin box

T: 7 (0.71, 5.2)
GENERAL DESCRIPTION
15.INNER TRIM (SEDAN)

(13)
(3)
(2)
(1)
(8)
(4)
(9)
(10)
(12)
(11)
(7)
(6)
(5)
BO0380
(1)
(2)
(3)
(4)
(5)
Front pillar upper trim

Center pillar upper trim
Rear pillar upper trim
Rear shelf trim
Rear bulk trim
(6)
(7)
(8)
(9)
(10)
Trunk rear trim

Trunk side trim
Rear pillar lower trim
Side sill rear cover
Center pillar lower trim
EI-12
(11)
(12)
(13)
Side sill front cover

Front garnish
Rear garnish
GENERAL DESCRIPTION
16.INNER TRIM (WAGON)
(3)
(2)
(4)
(1)
(13)
(6)
(9)
(10)
(5)
(12)
(7)
(11)
(8)
BO0381
(1)
(2)
(3)
(4)
(5)
Front pillar upper trim

Center pillar upper trim
Rear pillar upper trim
Rear rail trim
Rear pillar lower trim
(6)
(7)
(8)
(9)
(10)
Rear quarter lower trim

Hook
Rear skirt trim
Side sill rear cover
Center pillar lower trim
EI-13
(11)
(10)
(11)
(12)
(13)
Side sill front cover

Front garnish
Rear garnish
Front garnish
Rear garnish
GENERAL DESCRIPTION
17.ROOF TRIM (SEDAN)
(1)
BO0304
(1)
Roof trim
18.ROOF TRIM (WAGON)
(2)
(1)
(3)
BO0305
(1)
Roof trim
(2)
Roof trim (sun roof model)
EI-14
(3)
Sun roof garnish
GENERAL DESCRIPTION
19.LUGGAGE FLOOR MAT
(4)
(3)
(2)
(5)
(1)
BO0306
(1)
(2)
Front floor mat

Floor box
(3)
(4)
Side floor mat (RH)

Center floor mat
EI-15
(5)
Side floor mat (LH)
GENERAL DESCRIPTION
20.INNER ACCESSORIES
(1)
(4)
(2)
(3)
BO0508
(1)
(2)
Hook
Sun visor
(3)
(4)
Assist grip
Center visor
B: PREPARATION TOOL
TOOL NAME
Clip remover
REMARKS
Used for removal of trim.
EI-16
FRONT GRILLE
2. Front Grille
A: REMOVAL
1) Open the hood.
2) Remove the four clips.
: Clip
BO0055
3) Remove the two hooks.
BO0056
B: INSTALLATION
EI-17
HOOD GRILLE
3. Hood Grille
A: REMOVAL
1) Remove the four clips of hood insulator.
BO0371
2) Remove the seven bolts and clip (A) to remove

hood duct.
(A)
BO0372
3) Remove the five nuts.
BO0498
4) Remove the white clip and two black clips to remove hood grille.
BO0499
EI-18
HOOD GRILLE
B: INSTALLATION
(A)
(5)
(B)
(6)
(2)
(4)
(8)
(3)
(1)
(B)
(7)
(C)
(A)
White clip
(B)
Black clip
1) Replace the black clip (1), (2) with a new one. Install the clip with arrow mark facing the front side of
grille (A).
(A)
BO0500
(C)
Bolt
4) Insert the hood grille clip and engage the three

clips.
CAUTION:
Make sure that the anchor portion of each clip
is firmly engaged.
BO0376
2) Replace the white clip (3) with a new one.

3) Attach the metal washer (A) only to bolt (4), (5),
(6), (7), (8).
BO0499
5) Install the five nuts.

Tightening torque:
4.4 Nm (0.45 kgf-m, 3.25 ft-lb)
(6)
(A)
BO0501
BO0498
EI-19
HOOD GRILLE
6) Catch the two hooks of hood duct to the hood

holes.
(A)
BO0379
7) Install the hood duct with clip (A) and seven

bolts.
(A)
BO0372
8) Install the hood insulator with four new clips.
BO0371
C: INSPECTION
Make sure that the clip is firmly engaged.
Make sure that there is no abnormal gap at whole
periphery of hood grille.
Make sure that there is no damage on hood grille.
EI-20
FRONT UNDER COVER

4. Front Under Cover

A: REMOVAL
2) Loosen the bolts and clips to remove under cover.
BO0275
B: INSTALLATION
Tightening torque:
14 Nm (1.42 kgf-m, 10.3 ft-lb)
EI-21
FRONT BUMPER
5. Front Bumper
6) Disconnect the fog light connector to remove

bumper.
A: REMOVAL
CAUTION:
Handle the bumper carefully to avoid damage
to bumper face.
Do not damage the body during removal or
installation of bumper.
To avoid damage to bumper, lay the removed
bumper on sheet spread on the floor. Do not lay
it directly on the floor.
2) Remove the front grille. <Ref. to EI-17, REMOVAL, Front Grille.>
3) Loosen the three clips to remove the front grille
side.
BO0059
7) Remove the E/A FORM from bumper beam.

CAUTION:
E/A FORM may easily break. Do not apply excessive force to it during removal.
BO0057
4) Pull off the front side of front mud guard to remove clip.
BO0060
8) Remove the bumper beam.
BO0061
BO0058
5) Remove the clips, and pull out the bumper slightly.
EI-22
FRONT BUMPER
B: INSTALLATION
CAUTION:
to bumper face.
2) Fit the slider (A) to guide plate (B) securely.
BO0062
Tightening torque:
<Ref. to EI-3, HOOD GRILLE, COMPONENT,
General Description.>14 Nm (1.42 kgf-m,
10.3 ft-lb)
EI-23
FRONT BUMPER
C: REPAIR
1. COATING METHOD FOR PP BUMPER
Process
No.
Process name
Bumper mounting
Job contents
Set the bumper on paint worktable if required.

Use paint worktable conforming to inner shape
of bumper when possible.
G5M0164
Masking
Degreasing, cleaning
Primer paint
Drying
Top coat paint (I)
Drying
Top coat paint (II)
Drying
10
11
Inspection
Masking removal
Mask specified part (black base) with masking tape. Use masking tape for PP (example, Nichiban
No. 533, etc.).
Clean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt, oil, fat, etc.
Apply primer one to all parts to be painted, using air gun. Use primer (clear).
Dry at normal temperature [10 to 15 min. at 20C (68F)].
In half-dried condition, PP primer paint is dissolved by solvent, e.g. thinner, etc.
Therefore, if dust or dirt must be removed, use ordinary alcohol, etc.
Solid color
Metallic color
Use section (block) paint for top coat.
Use section (block) paint for top coat.
Paint in use (for each color):
Paint in use (for each color):
Metallic paint
Solid paint
Hardener PB
Hardener PB
Thinner T-306
Thinner T-301
Mixing ratio:
Mixing ratio:
Main agent vs. hardener = 10:1
Main agent vs. hardener = 4:1
Viscosity: 10 13 sec/20C (68F)
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 [10 min. or more at
Not required.
20C (68F)].
In half-dried condition, avoid dust, dirt.
Apply a clear coat to parts with top coat paint
(I), three times, at 5 7 minutes intervals.
Paint in use:
Metallic paint
Hardener PB
Thinner T-301
Not required.
Mixing ratio: Clear vs. hardener = 6:1
(2.5 3.5 kg/cm2, 36 50 psi)
60C (140F), 60 min. or 80C (176F), 30 min.
If higher than 80C (176F), PP may be deformed. Keep maximum temperature of 80C (176F).
Paint check.
Remove the masking in process No. 2.
EI-24
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. Damage limited to shallow scratches that cause only a change in the lustre of
the base material or coating, can be almost fully restored. Before repairing a damaged area, explain this point
to the customer and get an understanding about the matter. Repair methods are outlined below, based on a
classification of the extent of damage.
Minor damage causing only a change in the lustre of the bumper due to a light touch
Almost restorable.
Process
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 operation as for the
mended wax: NITTO KASEI Soft 99 TIRE WAX resin section or process No. 18 and subseBLACK, or equivalent.
quent operations in the (3) section, depending
Polish the waxed area with a clean cloth after 5 on the degree and nature of damage.
to 10 minutes.
Deep damage caused by scratching 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 the 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-25
FRONT BUMPER
Deep damage such as a break or hole that requires filling

Much of the peripheral grained surface must be sacrificed for repair, and the degree of restoration is not really
worth the expense. (The surface, however, will become almost flush with adjacent areas.)
Recommended repair kit: PP Part Repair Kit (NRM)
Process
No.
1
2
Process name
Job contents
Bumper removal
Part removal
Remove the bumper as required.

Remove the parts built into bumper as required.
Bumper placement
Place the bumper on a paint worktable as

required.
It is recommended that contour of worktable
accommodate internal shape of bumper.
G5M0164
Surface preparation
Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable solvent
(NRM No. 900 Precleno, white gasoline, or alcohol).
Cutting
If nature of damage are cracks or holes, cut a

guide slit of 20 to 30 mm (0.79 to 1.18 in) in
length along the crack or hole up to the
bumper's base surface. Then, bevel or veeout the affected area using a knife or grinder.
G5M0165
6
7
Sanding (I)
Cleaning
Temporary welding
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.
G5M0166
NOTE:
Do not melt the welding rod until it flows out. This results in reduced strength.
Leave the welded spot unattended until it cools completely.
EI-26
FRONT BUMPER
Process
No.
Process name
Job contents
Using a heater gun and PP welding rod, weld the beveled spot while melting the rod and damaged area.
Welding
G5M0167
NOTE:
Melt the sections indicated by hatched area.
Do not melt 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)
G5M0168
11
Masking
12
Cleaning/
degreasing
13
Primer coating
14
Leave unattended.
15
Primer surfacer
coating
16
17
18
Drying
Sanding (III)
Cleaning/
degreasing
Sand the welded spot smooth with #240 sand paper.

Mask the black substrate section using masking tape.
Recommended masking tape: Nichiban No. 533 or equivalent
Completely clean the entire coated area, using solvent similar to that used in Process No. 4.
Apply a coat of primer to the repaired surface and its surrounding areas. Mask these areas, if necessary.
Recommended primer: Mp/ 364 PP Primer
NOTE:
Be sure to apply one coat of primer at a spraying pressure of 245 to 343 kPa
(2.5 to 3.5 kg/cm2, 36 to 50 psi) with a spray gun.
Leave the repaired area unattended at 20C (68F) for 10 to 15 minutes until primer is half-dry.
NOTE:
If dirt or dust comes in contact with the coated area, wipe it off with a cloth dampended with alcohol.
(Do not use thinner since the coated area tends to melt.)
Apply a coat of primer surfacer to the repaired area two or three times at an interval of 3 to 5 minutes.
Recommended surfacer:
UPS 300 Flex Primer
No. 303 UPS 300 Exclusive hardener
NPS 725 Exclusive Reducer (thinner)
Mixing ratio: 2 : 1 (UPS 300: No. 303)
Coated film thickness: 40 50
Allow the coated surface to dry for 60 minutes at 20C (68F) [or 30 minutes at 60C (140F)].
Sand the coated surface and its surrounding areas using #400 sand paper and water.
Same as Process No. 12.
EI-27
FRONT BUMPER
Process
No.
Process name
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
Solid color
Use a block coating method.
Recommended paint:
Suncryl (SC)
No. 307 Flex Hardener
SC Reducer (thinner)
Mixing ratio: 3 : 1
Suncryl (SC) vs. No. 307 Flex Hardener
Spraying thickness: 245 343 kPa
(2.5 3.5 kg/cm2, 36 50 psi)
Metallic color
Use a block coating method.
Recommended paint:
Suncryl (SC)
Mixing ratio: 3 : 1
Spraying thickness: 245 343 kPa
(2.5 3.5 kg/cm2, 36 50 psi)
Leave unattended at 20C (68F) for at least 10
minutes until the topcoated area is half-dry.
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: 3 : 1
(2.5 3.5 kg/cm2, 36 50 psi)
Allow the coated surface to dry at 20C (68F) for two hours or 60C (140F) for 30 minutes.
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 the parts on bumper in reverse order of removal.
Install the bumper.
EI-28
REAR BUMPER
6. Rear Bumper
7) Pull off the rear end of rear quarter lower trim,

and then loosen the two nuts from each side to remove rear bumper.
A: REMOVAL
1. WAGON
CAUTION:
to bumper face.
To avoid damage to bumper, lay the removed
bumper on sheet spread on the floor. Do not lay
it directly on the floor.
2) Remove the bolts and clips.
BO0065
8) Loosen the clips to remove bumper beam.
BO0066
2. SEDAN
Refer to rear bumper removal WAGON. <Ref. to
EI-29, WAGON, REMOVAL, Rear Bumper.>
B: INSTALLATION
1. WAGON
BO0063

<Ref. to LI-20, REMOVAL, Rear Combination Light
Assembly.>
4) Remove the screw and two clips from each side.
CAUTION:
to bumper face.
Tightening torque:
<Ref. to EI-5, Rear Bumper.>
BO0064
5) Remove the floor box.

6) Remove the rear skirt trim.
EI-29
REAR BUMPER
2. SEDAN
CAUTION:
to bumper face.
Tightening torque:
<Ref. to EI-5, Rear Bumper.>
C: REPAIR
Refer to front bumper repair. <Ref. to EI-22, REMOVAL, Front Bumper.>
EI-30
MUD GUARD
7. Mud Guard
A: REMOVAL
1) Jack-up the vehicle.
2) Remove the screws and clips to remove mud
guard.
BO0124
B: INSTALLATION
Insert the hook into body, and tighten it with screw
and clip.
Tightening torque:
14 Nm (1.42 kgf-m, 10.3 ft-lb)
EI-31
COWL PANEL
8. Cowl Panel
A: REMOVAL
1) Open the hood.
2) Remove the wiper arm. <Ref. to WW-13, REMOVAL, Front Wiper Arm.>
3) Remove the front panel seal.
B5M0995
4) Loosen the clips to remove cowl panel.
: Clip
BO0067
B: INSTALLATION
EI-32
ROOF SPOILER
9. Roof Spoiler
A: REMOVAL
1) Remove the bolt cap, then remove the two bolts.
2) Detach the roof spoiler.
BO0307
B: INSTALLATION
Tightening torque:
7.35 Nm (0.749 kgf-m, 5.42 ft-lb)
EI-33
REAR SPOILER
10.Rear Spoiler
A: REMOVAL
2) Open the trunk lid.
3) Remove the electrical connector (A) of highmounted stop light.
4) Loosen the mounting nut of rear spoiler to remove rear spoiler.
CAUTION:
When removing the nut, do not drop it into
trunk lid.
Pay attention to avoid damage during removal or installation.
BO0083
B: INSTALLATION
2) Clean the mounting surfaces of trunk lid and
spoiler before installation.
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.46 ft-lb)
EI-34
SIDE SILL SPOILER

11.Side Sill Spoiler

A: REMOVAL
Remove the clips (1 on front, 6 on lower), then remove the side spoiler.
BO0084
B: INSTALLATION
EI-35
FRONT DOOR TRIM

12.Front Door Trim
B: INSTALLATION
A: REMOVAL
CAUTION:
Do not apply excessive force to the clip. Otherwise the clip may be broken.
2) Pull up the inner remote cover toward you to remove upper hook. Pull down it to remove the lower
hook. Remove the inner remote cover.
B5M1011
3) Remove the screw.

4) Remove the power window switch assembly and
disconnect the harness connector. (for models with
power window)
Remove the pull handle and panel. (for models
without power window)
BO0068
5) Remove the screw.

6) Remove the clips of trim panel using clip remover to remove trim panel.
: Clip
BO0069
EI-36
REAR DOOR TRIM

13.Rear Door Trim
5) Disconnect the power window harness connector. (for models with power window)
A: REMOVAL
CAUTION:
Do not apply excessive force to the clip. Otherwise the clip may be broken.
2) Pull up the inner remote cover toward you to remove upper hook. Pull down it to remove the lower
hook. Remove the inner remote cover.
: Clip
B: INSTALLATION
B5M1011
3) Remove the screw and clip.
BO0070
4) Remove the clips of trim panel using clip remover to remove trim panel.
EI-37
BO0071
GLOVE BOX
14.Glove Box
A: REMOVAL
1) Open the glove box.
2) Loosen the screws to remove glove box.
BO0011
B: INSTALLATION
EI-38
ROOF RAIL
15.Roof Rail
A: REMOVAL
2) Remove the four mounting nuts and then detach the roof rail carefully.
BO0128
B: INSTALLATION
CAUTION:
Be careful not to scratch the body panels with
roof rail stud bolts when removing and installing them.
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.46 ft-lb)
EI-39
CONSOLE BOX
16.Console Box
B: INSTALLATION
A: REMOVAL

: Hook pawl
: Clip
BO0466
3) Remove the shift knob (MT model) and front

cover.
: Hook pawl
BO0073
4) Loosen the screws to remove console box.
BO0074
EI-40
INSTRUMENT PANEL ASSEMBLY

17.Instrument Panel Assembly
6) Loosen the four screws and two nuts to remove

lower console panel.
A: REMOVAL
WARNING:
harness when servicing the instrument panel.
NOTE:
The following location are for LHD model.
The locations for RHD model are symmetrically opposite.
2) Loosen the screws and clips to remove lower
cover.
BO0118
7) Loosen the hooks to remove defroster panel.
BO0119
8) Remove the two nuts and disconnect the two

connectors.
S5M0044A
3) Loosen the clips to remove center console panel.
BO0120
Clip
BO0117

5) Remove the passenger airbag module. <Ref. to
EI-41

9) Remove the instrument panel mounting bolts.
BO0121
EI-42

10) Remove the instrument panel.
B: INSTALLATION
CAUTION:
Do not pull the harness when disconnecting the
connector.
NOTE:
If necessary, make matching marks for easy reassembly.
CAUTION:
Take care not to scratch the instrument panel
and related parts.
When storing the removed instrument panel,
place it standing up on the floor.
CAUTION:
Be careful not to snag the harness.
Make sure to connect the harness connector.
Take care not to scratch the instrument panel
and related parts.
NOTE:
When setting the instrument panel into position,
push the hook into grommet (A) on the body panel.
BO0152
G5M0602
EI-43
UPPER INNER TRIM

18.Upper Inner Trim

A: REMOVAL
1) Remove the lower inner trim. <Ref. to EI-45, REMOVAL, Lower Inner Trim.>
2) Remove the front mole (A).
3) Remove the front pillar upper trim (B).
4) Detach the front seat belt shoulder anchor, then
remove the center pillar upper trim (C).
B5M1021A
B: INSTALLATION
CAUTION:
Be sure to securely hook pawls of inner trim
panel to body flange.
NOTE:
When installing the center pillar upper trim and
front pillar upper trim, be sure to set the front mole
B5M0673A
EI-44
LOWER INNER TRIM

19.Lower Inner Trim

A: REMOVAL
1) Remove the side sill front cover (A).
2) Remove the rear seat cushion <Ref. to SE-11,
REMOVAL, Rear Seat.>, then remove side sill rear
cover (B).
3) Remove the center pillar lower trim (C).
Hook pawl
BO0075
B: INSTALLATION
CAUTION:
EI-45
REAR QUARTER TRIM

20.Rear Quarter Trim
B: INSTALLATION
A: REMOVAL
1. SEDAN
2) Remove the side sill rear cover. <Ref. to EI-45,
REMOVAL, Lower Inner Trim.>
3) Remove the rear pillar lower cover (A).
4) Remove the seatbelt lower anchor bolt, and then
remove the rear pillar upper trim (B).
CAUTION:
NOTE:
When installing the rear quarter upper trim, be sure
to set the rear mole as shown in the figure.
B5M0673A
Clip
BO0076
2. WAGON
2) Remove the side sill rear cover.
3) Remove the rear rail trim (A).
4) Loosen the screws and clips to remove rear
quarter upper trim (B).
5) Remove the rear skirt trim (C).
6) Loosen the bolts and clips to remove rear quarter lower trim (D).
Clip
BO0077
EI-46
SUN VISOR
21.Sun Visor
A: REMOVAL
Remove the mounting screws then detach the sun
visor (A), hook (B) and center visor (C).
BO0078
B: INSTALLATION
EI-47
ROOF TRIM
22.Roof Trim
2. WAGON
A: REMOVAL

2) Remove the sunroof switch. (Sunroof equipped
model) <Ref. to SR-9, REMOVAL, Sunroof
Switch.>
3) Remove the room light. <Ref. to LI-29, REMOVAL, Room Light.>
4) Remove the sun visor and hook or both sides.
<Ref. to EI-47, REMOVAL, Sun Visor.>
5) Remove the assist-grips (A).
CAUTION:
When removing the clip, use great care not to
damage the roof trim.
1. SEDAN
2) Remove the sunroof switch. (Sunroof equipped
model) <Ref. to SR-9, REMOVAL, Sunroof
Switch.>
3) Remove the spot light. <Ref. to LI-28, REMOVAL, Spot Light.>
4) Remove the room light. <Ref. to LI-29, REMOVAL, Room Light.>
5) Remove the sun visor and hook or both sides.
<Ref. to EI-47, REMOVAL, Sun Visor.>
6) Remove the assist-grips (A).
B5M1025A
6) Remove the upper inner trim. <Ref. to EI-44, REMOVAL, Upper Inner Trim.>
7) Remove the rear quarter upper trim shown in the
figure.
8) Remove the rear rail trim (A).
9) Remove the rear quarter upper trim (B) of both
sides.
B5M1025A
7) Remove the upper inner trim. <Ref. to EI-44, REMOVAL, Upper Inner Trim.>
8) Remove the quarter upper trim. <Ref. to EI-46,
9) Remove the clips, and then remove the roof trim.
BO0126
Clip
BO0077
EI-48
ROOF TRIM
10) Remove the clips, and then remove the roof

trim.
BO0125
B: INSTALLATION
EI-49
REAR GATE TRIM

23.Rear Gate Trim

A: REMOVAL
CAUTION:
Be careful not to damage the clips or their
holes.
1) Remove the clips and detach the rear gate trim.
BO0079
B: INSTALLATION
EI-50
REAR SHELF TRIM

24.Rear Shelf Trim

A: REMOVAL
2) Remove the high-mounted stop light.
B5M0816
3) Remove the rear quarter upper trim. <Ref. to EI46, REMOVAL, Rear Quarter Trim.>
4) Remove the seat belt center lower anchor bolt.
5) Remove the rear shelf trim.
: Clip
BO0127
B: INSTALLATION
EI-51
TRUNK TRIM
25.Trunk Trim
A: REMOVAL
1) Remove the rear seat backrest. <Ref. to SE-11,
SEDAN, REMOVAL, Rear Seat.>
2) Remove the clip (A).
3) Loosen the clips, and then detach the trunk rear
trim (B).
4) Loosen the clips to remove trunk side trim (C).
Clip
BO0080
B: INSTALLATION
EI-52
FLOOR MAT
26.Floor Mat
A: REMOVAL
1) Remove the front seats. <Ref. to SE-6, REMOVAL, Front Seat.>
2) Remove the rear seat cushion. <Ref. to SE-11,
4) Remove the side sill front cover, side sill rear
cover and center pillar lower trim. <Ref. to EI-45,
REMOVAL, Lower Inner Trim.>
5) Remove the clips from floor mat.
6) Remove the mat hook.
7) Remove the mat from toe board area.
8) Remove the mat from rear heater duct.
9) Roll the mat, and then take it out of opened rear
door.
BO0123
B: INSTALLATION
NOTE:
Secure the mat firmly with hook and Velcro tape.
Insert the mat edge firmly into the groove of side
sill cover.
EI-53
LUGGAGE FLOOR MAT

27.Luggage Floor Mat

A: REMOVAL
Remove the clips, then detach the rear floor mats
and boxes.
BO0081
B: INSTALLATION
EI-54
TRUNK ROOM MAT

28.Trunk Room Mat

A: REMOVAL
Draw out the trunk room mat.
BO0082
B: INSTALLATION
EI-55
TRUNK ROOM MAT

EI-56
EB
1.
2.
3.
4.
5.
6.
7.
8.
9.
Page
Front Hood ................................................................................................10
Fender Panel.............................................................................................11
Front Door Panel.......................................................................................12
Front Sealing Cover ..................................................................................14
Rear Door Panel .......................................................................................15
Rear Sealing Cover...................................................................................17
Trunk Lid Panel .........................................................................................18
Rear Gate Panel .......................................................................................19
GENERAL DESCRIPTION
A: SPECIFICATIONS
Front hood
Front fender
Front fender
Front door
SECTION B
SECTION A
Rear door
Front door
SECTION C
Door panel
Side sill
Rear door
Rear quarter
SECTION D
SECTION E,F
BO0260
Section
Part
Front hood to Front fender
B
C
D
E, F
Front fender to Front door

Front door to Rear door
Rear door to Rear quarter
Door panel to Side sill
Specification
NA: 4.0 1.0 mm (0.16 0.04 in)
TURBO: 3.7 1.0 mm (0.15 0.04 in)
4.6 1.0 mm (0.18 0.04 in)
5.0 mm (0.20 in)
4.6 mm (0.18 in)
5.9 mm (0.23 in)
EB-2
GENERAL DESCRIPTION
B: COMPONENT
1. FRONT HOOD
(9)
(8)
BO0364
(1)
(2)
(3)
(4)
(5)
Front hood
Seal (Front panel)
Hinge
Hood grille
Packing
(6)
(7)
(8)
Clip
Locking piece
Seal (Intake duct)
(Only Turbo model)
(9)
Seal (Hood)
EB-3

T: 7.4 (0.75, 5.5)
T1: 24.5 (2.5, 18.1)
GENERAL DESCRIPTION
2. FRONT FENDER PANEL
(1)
BO0321
(1)
Front fender panel

T: 7.4 (0.75, 5.5)
EB-4
GENERAL DESCRIPTION
3. FRONT DOOR PANEL
BO0365
(1)
(2)
(3)
(4)
(5)
Gusset
Weatherstrip (Outer)
Clip (Weatherstrip, outer)
Stabilizer (Outer)
Stabilizer (Inner)
(6)
(7)
(8)
(9)
(10)
Sealing cover
Checker
Lower hinge
Upper hinge
Door panel
EB-5

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
BO0366
(1)
(2)
(3)
(4)
(5)
(6)
Weatherstrip (Outer)
Clip (Weatherstrip, outer)
Stabilizer (Outer)
Stabilizer (Inner)
Door panel
Bracket
(7)
(8)
(9)
(10)
Sealing cover
Checker
Lower hinge
Upper hinge
EB-6

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
BO0251
(1)
(2)
(3)
Torsion bar
Trunk lid
Weatherstrip
(4)
Hinge ASSY
EB-7

T1: 7.5 (0.76, 5.5)
T2: 14 (1.43, 10.3)
GENERAL DESCRIPTION
6. REAR GATE PANEL
T1
T1
T
BO0367
(1)
(2)
(3)
Gas stay
Hinge
Rear gate

T: 14 (1.43, 10.3)
T1: 25 (2.5, 18.1)
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 the mounting bolts, using assistance devices such as a support jack will help support the panel.
Be careful not to lose small parts.
EB-8
GENERAL DESCRIPTION
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
925610000
DESCRIPTION
WRENCH
REMARKS
Used for removing and installing door hinge.
REMOVER
Used for removing and installing trunk torsion

bar.
B5M1117
927780000
B5M1118
2. GENERAL TOOL
TOOL NAME
Support Jack
REMARKS
Used for supporting door panel.
EB-9
FRONT HOOD
2. Front Hood
C: ADJUSTMENT
A: REMOVAL
1) Use the hinge mounting holes to align the front

hood longitudinally and laterally.
1) Open the front hood to remove washer nozzles.

2) Release the clips to remove hood insulator.
B5M0747
B5M1090
3) Remove the bolts to disconnect hood from hinges.
2) Adjust the height at front end of hood. <Ref. to

SL-30, ADJUSTMENT, Front Hood Lock Assembly.>
3) Rotate the hood buffer to adjust lateral height.
B5M0747
B5M0750
B: INSTALLATION
2) Adjust the clearance between hood and fender.
Clearance must be equal at both sides.
Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
EB-10
FENDER PANEL
3. Fender Panel
A: REMOVAL
2) Remove the side sill spoilers. <Ref. to EI-35,
Side Sill Spoiler.> (If fitted)
3) Remove the front bumper face. <Ref. to EI-22,
REMOVAL, Front Bumper.>
4) Remove the mud guard. <Ref. to EI-31, REMOVAL, Mud Guard.>
5) Loosen the bolts to remove front fender.
BO0153
B: INSTALLATION
2) When the fender panel is installed, clearance
between fender panel and hood or front fender
must be equal.
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.5 ft-lb)
EB-11
FRONT DOOR PANEL

4. Front Door Panel
11) Remove the door-side bolts for upper and lower hinges to remove the door.
A: REMOVAL
3) Remove the outer mirror assembly. <Ref. to
GW-18, REMOVAL, Outer Mirror Assembly.>
4) Remove the front door glass. <Ref. to GW-12,
REMOVAL, Front Door Glass.>
5) Remove the front door regulator and motor.
<Ref. to GW-16, REMOVAL, Front Regulator and
Motor Assembly.>
6) Remove the front door latch assembly. <Ref. to
SL-20, REMOVAL, Front Door Latch Assembly.>
7) Remove the front outer handle. <Ref. to SL-19,
REMOVAL, Front Outer Handle.>
8) Remove the front pillar lower trim to disconnect
the connector from body harness.
G5M0385
CAUTION:
During removal and installation of doors, do
not damage the body.
Doors are heavy. Be careful not to drop and
damage them.
B: INSTALLATION
2) Apply grease to the sliding area of door hinges.
Tightening torque:
<Ref. to EB-5, FRONT DOOR PANEL,
B5M0726
9) Put a wooden block on jack and place jack under

door. Support the door with a support jack to protect it from damage.
S5M0518
10) Remove the checker bolts.
S5M0183
EB-12
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 vertically.
ST 925610000
DOOR HINGE WRENCH
B5M0933A
2) Loosen the screw (A) and tap striker (B) using a

plastic hammer to adjust striker to align the position
of front door panel vertically and laterally at the
front end.
CAUTION:
Do not use an impact wrench. Welding area on
the striker nut plate is easily broken.
B5M0934A
EB-13
FRONT SEALING COVER

5. Front Sealing Cover

A: REMOVAL
3) Remove the front speaker. <Ref. to ET-6, REMOVAL, Front Speaker.>
CAUTION:
Carefully remove the butyl tape. Excessive
force will easily break the cover.
If the cover gets broken, replace it with a new
one.
G5M0391
B: INSTALLATION
2) When replacing the sealing cover, use butyl tape
sealer.
3) Press the sealer-applied area firmly to prevent
any floating on surface.
Butyl tape:
3M8626 or equivalent
CAUTION:
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 is damaged, replace it with a
new one.
EB-14
REAR DOOR PANEL

6. Rear Door Panel
10) Remove the checker bolts.
A: REMOVAL
CAUTION:
During removal and installation of doors, do
not damage the body.
Doors are heavy. Be careful not to drop and
damage them.
3) Remove the rear door glass. <Ref. to GW-23,
REMOVAL, Rear Door Glass.>
4) Remove the rear door regulator and motor assembly. <Ref. to GW-25, REMOVAL, Rear Regulator and Motor Assembly.>
5) Remove the rear door latch. <Ref. to SL-24, REMOVAL, Rear Door Latch Assembly.>
6) Remove the rear outer handle. <Ref. to SL-23,
REMOVAL, Rear Outer Handle.>
8) Disconnect the connector of door harness.
S5M0183
11) Remove the door-side bolts for upper and lower hinges to remove the door.
G5M0385
B: INSTALLATION
2) Apply grease to the sliding area of door hinges.
Tightening torque:
<Ref. to EB-6, REAR DOOR PANEL,
BO0154
9) Put a wooden block on the jack and place the

jack under the door. Support the door with the jack
to protect it.
S5M0518
EB-15
REAR DOOR PANEL

C: ADJUSTMENT
1) Open the front door, loosen the door-side bolts
of upper and lower hinges to align the position of
rear door panel longitudinally and vertically.
G5M0385
2) Loosen the screw (A) and tap striker (B) using

plastic hammer to adjust striker to align the position
of front door panel vertically and laterally at the rear
end.
CAUTION:
Do not use an impact wrench. The welding area
on the striker nut plate is easily broken.
B5M0934A
EB-16
REAR SEALING COVER

7. Rear Sealing Cover

A: REMOVAL
3) Remove the rear speaker. <Ref. to ET-8, REMOVAL, Rear Speaker.>
CAUTION:
Carefully remove the butyl tape. Excessive
force will easily break the cover.
If the cover gets broken, replace it with a new
one.
G5M0391
B: INSTALLATION
2) When replacing the sealing cover, use butyl
tape.
3) Press the sealer-applied area firmly to prevent
any floating on surface.
Butyl tape:
3M8626 or equivalent
CAUTION:
Apply an 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 is damaged, replace it with a
new one.
EB-17
TRUNK LID PANEL

8. Trunk Lid Panel
B: INSTALLATION
A: REMOVAL
1. TRUNK LID
1. TRUNK LID

2) Install the trunk lid with uniform clearance.

2) Disconnect the trunk lid connector.
3) Loosen the trunk lid mounting bolts to remove
the trunk lid from hinges.
Tightening torque:
14 Nm (1.43 kgf-m, 10.3 ft-lb)
2. TORSION BAR
2) Apply grease to the rotating area of hinges and
mating surface of torsion bar.
G5M0144
2. TORSION BAR
2) Using the ST, remove the torsion bar from hinge
link.
ST 927780000
REMOVER
CAUTION:
During removal and installation, carefully handle the torsion bar. It will generate reactive
force.
G5M0145
3) Remove the right/left torsion bars.

CAUTION:
After the torsion bar is removed, the trunk lid
will slam shut. Be careful not to get hit by the
trunk lid.
EB-18
REAR GATE PANEL

9. Rear Gate Panel

A: REMOVAL
1. REAR GATE PANEL
2) Open the rear gate.
3) Remove the rear gate outer handle. <Ref. to SL26, REMOVAL, Rear Gate Outer Handle.>
5) Remove the rear gate key lock cylinders. <Ref.
to SL-33, REAR GATE, REPLACEMENT, Key
Lock Cylinders.>
6) Remove the rear wiper. <Ref. to WW-18, REMOVAL, Rear Wiper Motor.>
7) Disconnect the connectors of rear wiper, rear
defogger, and other lighting devices.
8) Disconnect the washer hose.
9) Remove the rubber duct (A) connection, and pull
out the harness and washer hose from rear gate.
CAUTION:
When the rear gate is released, it may hit and
damage the body. To prevent this, place a shop
cloth between the body and gate.
11) Loosen the rear gate bolts to remove rear gate.
BO0278
2. GAS STAY
1) Open the rear gate. Use a support jack to support the rear gate.
BO0262
B5M0733A
10) Using a support, support the rear gate while removing gas stay mounting bolts.
CAUTION:
After the gas stay is removed, the rear gate
cannot stay open. Supporting the rear gate with
a jack, remove the bolts.
Do not damage the piston rods and oil seals.
Never disassemble the cylinders: They contain gas.
BO0262
BO0155
EB-19
REAR GATE PANEL

2) Loosen the bolts to remove the gas stay from

rear gate.
2) Firmly install the gas stay (B) to mounting bolt

(A).
(B)
(A)
BO0368
CAUTION:
After supporting the rear gate with a jack, start
operation.
C: DISPOSAL
1. GAS STAY
CAUTION:
Gas is colorless, odorless, and harmless. However, gas pressure may spray cutting powder or
oil. Be sure to wear dust-resistant goggles.
1) Cover with a vinyl case as shown in the figure.
BO0156
B: INSTALLATION
1. REAR GATE PANEL
Gas stay

2) Install the rear gate panel with uniform clearance
to the body.
Refer to COMPONENT of General Description for
tightening torque. <Ref. to EB-8, REAR GATE
PANEL, General Description.>
Vinyl sack
CAUTION:
Do not damage the painted surfaces of body
and rear gate.
BO0264
2. GAS STAY
1) Install the mounting bolt (A) to the rear gate panel and body.
Tightening torque:
14 Nm (1.43 kgf-m, 10.3 ft-lb)
CAUTION:
Prevent the vinyl case from being caught by
drill cutting edge
2) Lift the body side slightly with piston rods fully
extended, and secure the body side on vise stand.
Drill a hole in 2 to 3 mm (0.08 to 0.12 in) diameter at
a point 10 to 200 mm (0.39 to 7.87 in) from the door
side, and bleed the gas stay completely.
Body side
Door side
190mm
(7.48 in)
10mm
(0.39 in)
Portion to be drilled
Piston rod
EB-20
Cylinder
BO0263
CC
1.
2.
3.
4.
5.
6.
7.
8.
Page
Actuator.......................................................................................................3
Cruise Control Module ................................................................................4
Cruise Control Main Switch.........................................................................5
Cruise Control Command Switch ................................................................6
Stop and Brake Switch................................................................................7
Clutch Switch ..............................................................................................8
Inhibitor Switch............................................................................................9
GENERAL DESCRIPTION
A: COMPONENT
BO0002
(1)
(2)
(3)
Actuator
Inhibitor switch (AT)
Cruise control command switch
(4)
(5)
(6)
Cruise control main switch

Clutch switch (MT)
Stop and brake switch
B: CAUTION
repairing the radio, control module and other parts
with memory functions, make note of the memory
before disconnecting the battery ground cable. All
memory will be erased.
Reassemble parts in the reverse order of disassembly unless otherwise indicated.
Adjust parts to specifications specified in this
manual.
(7)

After reassembly, ensure functional parts operate properly.
C: PREPARATION TOOL
CC-2
TOOL NAME
Circuit Tester
REMARKS
ACTUATOR
2. Actuator
B: INSTALLATION
A: REMOVAL
CAUTION:
Be careful not to apply excessive load to the
wire cable when adjusting and/or installing;
otherwise, the actuator may be deformed or
damaged.
Do not bend the cable sharply with a radius
less than 100 mm (3.94 in); otherwise, cable
may bend permanently, resulting in poor performance.
When installing the cable, be careful not to
sharply bend or pinch the inner cable; otherwise, the cable may break.
2) Remove the clip bands from cruise control cable.
3) Loosen the nut which secures cruise control cable end to throttle cam, and then remove the cable
from throttle cam.
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
NOTE:
(A): Must be adjusted when the cable end outer is
fixed in place, so that gap between throttle cam and
lever is 0 1 mm (0 0.04 in).
(Must be attached while the throttle cam is being
pulled by wire cable.)
(B): Must be coated evenly on the cam end inner
connection.
(C): Cover must be inserted securely, until tip of cable touches cover stopper.
B6M1213A
C: INSPECTION
Measure the cruise control actuator resistance.
S6M0088
4) Remove the actuator attaching bolts.

5) Remove the actuator while disconnecting the
connector.
B6M1568
Terminal No.
4 and 1
4 and 2
4 and 5
3 and 6
BO0003
Standard
Approx. 5
Approx. 5
Approx. 5
Approx. 39
If NG, replace the cruise control actuator.
CC-3
CRUISE CONTROL MODULE

3. Cruise Control Module

A: REMOVAL
2) Remove the side sill front cover.
: Hook pawl
BO0004
3) Disconnect the connector from cruise control

module.
4) Remove the bolt, then detach the cruise control
module (A).
(A)
BO0493
B: INSTALLATION
CC-4
CRUISE CONTROL MAIN SWITCH

4. Cruise Control Main Switch
C: INSPECTION
A: REMOVAL
Measure the cruise control main switch resistance.

2) Remove the screws and clip from instrument
panel lower cover.
G6M0244
Switch position
OFF
ON
BO0006
4) Disconnect the connector from cruise control

main switch.
Cruise control
main switch
Terminal No.
3 and 5
3 and 5
Standard
More than 1 M
Less than 1
If NG, replace the cruise control main switch.
BO0007
5) Remove the main switch by pushing it outward.
BO0008
B: INSTALLATION
CC-5
CRUISE CONTROL COMMAND SWITCH

5. Cruise Control Command

Switch
7) Disconnect the horn and cruise control command switch connector, then remove the cruise
control command switch.
A: REMOVAL
WARNING:
Before servicing, be sure to read the notes in
the AB section for proper handling of the driver's airbag module. <Ref. to AB-3, CAUTION,
1) Set the front wheels in straight ahead position.
3) Disconnect the ground cable from battery and
4) Using the TORX BIT T30 (Tamper resistant
type), loosen the two TORX bolts which secure
driver's airbag module.
S6M0096
B: INSTALLATION
C: INSPECTION
Measure the cruise control command switch resistance.
H5M0662A
5) Disconnect the airbag module connector on

back of airbag module.
6) Remove the horn switch from steering wheel as
shown.
B6M1406
Switch
CANCEL
SET/COAST
RESUME/
ACCEL
Position
ON
ON
OFF
ON
OFF
ON
Terminal No.
Standard
1 (+) and 2 ()
Less than 1
1 (+) and 3 ()
Less than 1
1 and 2
More than 1 M
1 and 2
Less than 1
1 and 3
More than 1 M
1 and 3
Less than 1
If NG, replace the cruise control command switch.

S6M0095
CC-6
STOP AND BRAKE SWITCH

6. Stop and Brake Switch

A: REMOVAL
2) Disconnect the connector from stop and brake
switch, and then remove the switch. <Ref. to BR69, REMOVAL, Stop Light Switch.>
B: INSTALLATION
C: INSPECTION
Measure the brake switch (A) and stop light switch
(B) resistance.
B6M1564B
Switch
Brake
Stop light
Pedal
Released
Depressed
Released
Depressed
Terminal No.
Standard
1 and 4
Less than 1
1 and 4
More than 1 M
2 and 3
More than 1 M
2 and 3
Less than 1
If NG, replace the stop and brake switch.
CC-7
CLUTCH SWITCH
7. Clutch Switch
A: REMOVAL
2) Disconnect the connector from clutch switch,
and then remove the switch. <Ref. to CL-43, DISASSEMBLY, Clutch Pedal.>
B: INSTALLATION
C: INSPECTION
Measure the clutch switch resistance.
G6M0184
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-8
INHIBITOR SWITCH
8. Inhibitor Switch
A: REMOVAL
2) Disconnect the connector from inhibitor switch,
and then remove the switch. <Ref. to AT-29, REMOVAL, Inhibitor Switch.>
B: INSTALLATION
C: INSPECTION
Measure the inhibitor switch resistance.
B6M1530
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-9
INHIBITOR SWITCH
CC-10

(DIAGNOSTICS)
CC
1.
2.
3.
4.
5.
6.
7.
8.
Page
Cruise Control Module I/O Signal................................................................8
Diagnostics Chart with Symptom ..............................................................13
Diagnostics Chart with Trouble Code........................................................29

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

A: PROCEDURE
1
Step
Check
START DIAGNOSIS.
Is the cruise control main
1)Perform the pre-inspection. <Ref. to CC-5, switch turned ON?
INSPECTION, General Description.>
2)Check the cruise control main switch operation.
2
3

PERFORM CRUISE CANCEL CONDITIONS
DIAGNOSIS.
Perform the cruise cancel conditions diagnosis. <Ref. to CC-11, Subaru Select Monitor.>
Is the select monitor available?

Are any trouble codes indicated?
CHECK CRUISE CONTROL SET OPERATION.

Check the cruise control set operation.
Can the cruise control be set

while driving at 40 km/h (25
MPH)?
CHECK VEHICLE SPEED IS HELD WITHIN Is the vehicle speed held within
SET SPEED.
set speed 3 km/h (2 MPH) ?
Make sure the vehicle speed is held within set
speed.
CHECK RESUME/ACCEL OPERATION.

Check the RESUME/ACCEL operation.
Does the vehicle speed

increase or return to set speed
after RESUME/ACCEL switch
has been pressed?
CHECK SET/COAST OPERATION.

Check the SET/COAST operation.
Does the vehicle speed

decrease after SET/COAST
switch has been pressed?
CHECK CANCEL OPERATION.

Check the CANCEL operation.
Is the cruise control released

after CANCEL switch has been
pressed?
CHECK CRUISE CONTROL RELEASE OPERATION.

Check the cruise control release operation.

after brake pedal has been
depressed?
CC-2
Yes
Go to step 2.
No
Go to symptom 1.
<Ref. to CC-13,
SYMPTOM
CHART, Diagnostics Chart with
Symptom.>
Go to step 3.
Go to step 4.
Go to List of Diag- Go to step 4.
nostic Trouble
Code (DTC).
<Ref. to CC-28,
List of Diagnostic
Trouble Code
(DTC).>
Go to step 5.
Go to symptom 2.
<Ref. to CC-13,
SYMPTOM
Symptom.>
Go to step 6.
Go to symptom 3.
<Ref. to CC-13,
SYMPTOM
Symptom.>
Go to step 7.
Go to symptom 4.
<Ref. to CC-13,
SYMPTOM
Symptom.>
Go to step 8.
Go to symptom 5.
<Ref. to CC-13,
SYMPTOM
Symptom.>
Go to step 9.
Go to symptom 6.
<Ref. to CC-13,
SYMPTOM
Symptom.>
Go to step 10.
Go to symptom 7.
<Ref. to CC-13,
SYMPTOM
Symptom.>

10
Step
CHECK CRUISE CONTROL RELEASE OPERATION.
Check the cruise control release operation.
Check
after clutch pedal has been
depressed? (MT)
CC-3
Yes
Finish the diagnostics.
No
Go to symptom 8.
<Ref. to CC-13,
SYMPTOM
Symptom.>
GENERAL DESCRIPTION
A: CAUTION
1. SUPPLEMENTAL RESTRAINT SYSTEM
AIRBAG
cruise control module and cruise control command
switch.
CAUTION:
wiring harness when servicing the cruise control module and cruise control command
switch.
B: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
24082AA190
CARTRIDGE
REMARKS
B2M3876
22771AA030
SELECT MONITOR
KIT

English:
German:
French:
Spanish:
B2M3877
2. GENERAL TOOLS
TOOL NAME
Circuit Tester
REMARKS
CC-4
GENERAL DESCRIPTION
C: INSPECTION
5. CABLE FREE PLAY
1. BATTERY
electrolyte.
Standard voltage:
12 V, or more
Specific gravity:
Above 1.260
2. CRUISE CONTROL CABLE
B6M0241A
Check that the throttle cam-to-lever clearance is

Throttle cam-to-lever clearance:
0 1 mm (0 0.04 in)
If NG, adjust the clearance with the adjust nut.
NOTE:
Check that the cap is positioned in the groove.
S6M0099A
Check the cruise control cable installation.

If NG, install the cable securely.
3. ACCELERATOR CABLE
S6M0099A
Check the movement of accelerator cable when the

cruise control throttle is moved by hand.
If NG, check the throttle cam.
4. THROTTLE CAM
Check that the throttle cam moves smoothly.
If NG, repair the throttle cam.
CC-5


A: LOCATION
BO0002
(1)
(2)
(3)
Actuator
Cruise control command switch
(4)
(5)
(6)

Clutch switch (MT)
Stop and brake switch
CC-6
(7)

CC-7
CRUISE CONTROL MODULE I/O SIGNAL

4. Cruise Control Module I/O Signal

10
20 19 18 17 16 15 14 13 12 11
B6M1628
Content
Main light
Terminal No.
1
Motor B
Ground
Motor A
6
7
RESUME/ACCEL switch
SET/COAST switch
10
Main power supply
11
Ignition switch
12
Motor C
13
Motor clutch
14
15
Measuring conditions and I/O signals (ignition switch ON and engine idling)
Battery voltage is present when main switch is turned OFF.
0 volt is present when main switch is turned ON.
Battery voltage is present when selector lever is other than P or N position.
0 volt is present when selector lever is set to P or N position.
ON-and-OFF (0-and-battery voltage) operation is alternately repeated while
cruise control is operating.
0 volt is present when main switch is turned OFF.

Battery voltage is present when command switch is turned to RESUME/ACCEL
position.
0 volt is present when command switch is released.
Battery voltage is present when command switch is turned to SET/COAST
position.
0 volt is present when command switch is released.
Battery voltage is present when main power is turned ON.
0 volt is present when main power is turned OFF.
Battery voltage is present when ignition switch is turned ON.
0 volt is present when ignition switch is turned OFF.
0 volt is present when vehicle is stopped.
Battery voltage is present during pressing the cruise control main switch.
CC-8

Content
Brake switch
Terminal No.
16
Data link connector

Data link connector
Vehicle speed sensor (MT)
TCM (AT)
17
18
19
Stop light switch
20
Measuring conditions and I/O signals (ignition switch ON and engine idling)
Leave clutch pedal released (MT), while cruise control main switch is turned ON.
Then check that;
Battery voltage is present when brake pedal is released.
0 volt is present when brake pedal is depressed.
Additionally only in MT vehicle, keep the cruise control main switch to ON and
leave brake pedal released.
Then check that;
Battery voltage is present when clutch pedal is released.
0 volt is present when clutch pedal is depressed.
Lift-up the vehicle until all four wheels are raised off ground, and then rotate any
wheel manually.
Approx. 5 and 0 volt pulse signals are alternately input to cruise control module.
Turn ignition switch to OFF.
Then check that;
Battery voltage is present when brake pedal is depressed.
0 volt is present when brake pedal is released.
NOTE:
Voltage at terminals 5, 7, 13 and 14 cannot be checked unless vehicle is driving by cruise control operation.
CC-9

B: SCHEMATIC
<Ref. to WI-102, SCHEMATIC, Cruise Control System.>
CC-10

2. CRUISE CANCEL CONDITIONS DIAGNOSIS
A: OPERATION
1. GENERAL
The on-board diagnosis function of the cruise control system uses an external Subaru Select Monitor.
The on-board diagnosis function operates in two
categories, which are used depending on the type
of problems;
1) Cruise cancel conditions diagnosis:
(1) This category of diagnosis requires actual
vehicle driving in order to determine the cause,
(as when cruise speed is cancelled during driving although cruise cancel condition is not entered).
(2) Cruise control module memory stores the
cancel condition (Code No.) which occurred during driving. When there are plural cancel conditions (Code No.), they are shown on the Subaru
Select Monitor.
CAUTION:
The cruise control memory stores not only
the cruise cancel which occurred (although
cancel operation is not entered by the driver),
but also the cancel condition input by the
driver.
The content of memory is cleared when ignition switch or cruise main switch is turned OFF.
2) Real-time diagnosis:
The real-time diagnosis function is used to determine whether or not the input signal system is in
good order, according to signal emitted from
switches, sensors, etc.
(1) Vehicle cannot be driven at cruise speed because problem occurs in the cruise control system or its associated circuits.
(2) Monitor the signal conditions from switches
and sensors.
S2M0285

Monitor.
<Ref. to CC-4, SPECIAL TOOLS, PREPARATION
TOOL, General Description.>
S2M0286A

connector.
(1) Data link connector is located in the lower
portion of the instrument panel (on the driver's
side).
BO0129

connector.
5) Start the engine and turn the cruise control main
switch to ON.
CC-11

3. REAL-TIME DIAGNOSIS
6) Turn the Subaru Select Monitor switch to ON.
S2M0288A
7) On the Main Menu display screen, select the {All

System Diagnosis} and press [YES] key.
NOTE:
The diagnostic trouble code (DTC) is also shown in
the {Each System Check} mode. This mode is
called up on the Cruise Control Diagnosis screen
by selecting the item {Cancel Code(s) Display}.
8) Drive the vehicle at least 30 km/h (19 MPH) with
cruise speed set.
9) If the cruise speed is canceled itself (without doing any cancel operations), a diagnostic trouble
code (DTC) will appear on select monitor display.
CAUTION:
A diagnostic trouble code (DTC) will also appear when cruise cancel is effected by driver.
Do not confuse.
Have a co-worker ride in the vehicle to assist
in diagnosis during driving.
NOTE:
Diagnostic trouble code (DTC) will be cleared by
turning the ignition switch or cruise control main
switch to OFF.
1) Connect the select monitor.

2) Turn the ignition switch and cruise control main
switch to ON.
3) Turn the Subaru Select Monitor switch to ON.
5) On the System Selection Menu display screen,
select the {Cruise Control} and press [YES] key.
7) On the Cruise Control Diagnosis display screen,
select the {Current Data Display & Save} and press
[YES] key.
8) Make sure that normal indication is displayed
when controls are operated as indicated below:
Depress/release the brake pedal. (Stop light
switch and brake switch turn ON.)
Turn ON the SET/COAST switch.
Turn ON the RESUME/ACCEL switch.
Depress/release the clutch pedal. (MT)
Set the selector lever to P or N. (AT)
NOTE:
(DTC).
<Ref. to CC-28, List of Diagnostic Trouble Code
(DTC).>
CC-12
DIAGNOSTICS CHART WITH SYMPTOM

6. Diagnostics Chart with Symptom

A: SYMPTOM CHART
Symptom
Cruise control main switch is
not turned ON.
Cruise control cannot be set.
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.
Repair area
(1) Check the power supply.
(2) Check the cruise control
main switch.
(1) Check the SET/COAST
switch.
(2) Check the stop light
switch and brake switch.
(3) Check the clutch switch
(MT).
(4) Check the inhibitor switch
(AT).
(5) Check the vehicle speed
sensor.
(6) Check the motor drive
system.
(7) Check the motor clutch
drive system.
(1) Check the vehicle speed
sensor.
system.
drive system.
(1) Check the RESUME/
ACCEL switch.
system.
drive system.
(1) Check the SET/COAST
switch.
system.
drive system.
(1) Check the CANCEL
switch.
system.
drive system.
(1) Check the stop light
switch and brake switch.
system.
drive system.
CC-13
Reference
<Ref. to CC-16, CHECK POWER SUPPLY, Diagnostics
Chart with Symptom.>
<Ref. to CC-18, CHECK CRUISE CONTROL MAIN
SWITCH, Diagnostics Chart with Symptom.>
<Ref. to CC-20, CHECK CRUISE CONTROL COMMAND SWITCH, Diagnostics Chart with Symptom.>
<Ref. to CC-22, CHECK STOP LIGHT SWITCH AND
BRAKE SWITCH, Diagnostics Chart with Symptom.>
<Ref. to CC-24, CHECK CLUTCH SWITCH (MT), Diagnostics Chart with Symptom.>
<Ref. to CC-26, CHECK INHIBITOR SWITCH (AT),
Diagnostics Chart with Symptom.>
<Ref. to CC-30, DTC 22 VEHICLE SPEED SENSOR,
Diagnostics Chart with Trouble Code.>
<Ref. to CC-34, DTC 35 AND 36 ACTUATOR MOTOR,
<Ref. to CC-36, DTC 37 ACTUATOR MOTOR CLUTCH,
<Ref. to CC-30, DTC 22 VEHICLE SPEED SENSOR,
<Ref. to CC-22, CHECK STOP LIGHT SWITCH AND
BRAKE SWITCH, Diagnostics Chart with Symptom.>

Symptom
after clutch pedal has been
depressed (MT).
Repair area
(1) Check the clutch switch.
system.
drive system.
CC-14
Reference
<Ref. to CC-24, CHECK CLUTCH SWITCH (MT), Diagnostics Chart with Symptom.>

CC-15

B: CHECK POWER SUPPLY

TROUBLE SYMPTOM:
Cruise control can be set normally, but indicator does not come on. (When main switch is pressed.)
WIRING DIAGRAM:
IGNITION
SWITCH
BATTERY
F/B No.18
SBF-4
CRUISE CONTROL
MAIN SWITCH
B94
B161
B94
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
12
15
11
B161
BO0461
CC-16

Step
CHECK POWER SUPPLY.
2)Disconnect the cruise control module harness connector.
1)Turn the ignition switch OFF.
connector terminal and chassis ground.
Check
Yes

?
CC-17
No
Check the fuse
No. 18 (in fuse &
relay box).
Check the harness for open or
short between
cruise control
module and fuse &
relay box.
Power supply and Repair the harground circuit are ness.
OK.

C: CHECK CRUISE CONTROL MAIN SWITCH

TROUBLE SYMPTOM:
Cruise control main switch is not turned ON and cruise control cannot be set.
NOTE:
When the main relay (built-in cruise control module) operates, the main switch circuit is in normal condition.
The main relay operation can be checked by hearing the operation sound.
This operation sound will be heard when the ignition switch and cruise control main switch is turned to ON.
WIRING DIAGRAM:
IGNITION
SWITCH
BATTERY
F/B No.18
SBF-4
CRUISE CONTROL
MAIN SWITCH
B94
B161
B94
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
12
15
11
B161
BO0461
CC-18

Step
CHECK CRUISE CONTROL MAIN SWITCH
CIRCUIT.
2)Disconnect the cruise control main switch
harness connector.
CHECK CRUISE CONTROL MAIN SWITCH
CIRCUIT.
1)Turn the ignition switch OFF.
3)Measure the resistance between cruise control module harness connector terminal and
cruise control main switch harness connector
terminal.
(B94) No. 15 (B161) No. 5:
(B94) No. 1 (B161) No. 6:
(B94) No. 11 (B161) No. 1:
CHECK CRUISE CONTROL MAIN SWITCH.
Remove and check the cruise control main
switch. <Ref. to CC-5, Cruise Control Main
Switch.>
Check
Yes
No
Check the fuse
No. 18 (in fuse &
relay box).
short between
cruise control main
switch and fuse &
relay box.

?
Go to step 3.
Is the cruise control main

switch OK?
Replace the cruise Replace the cruise

control module.
control main
switch.
CC-19
Repair the harness.

D: CHECK CRUISE CONTROL COMMAND SWITCH

TROUBLE SYMPTOM:
Cruise control cannot be set. (Cancelled immediately.)
WIRING DIAGRAM:
BATTERY
M/B No.6
HORN SWITCH
SET/
COAST
SWITCH
CRUISE CONTROL
COMMAND SWITCH
HORN RELAY
CANCEL
SWITCH
RESUME/
ACCEL
SWITCH
S1
HORN
B144
STEERING
ROLL CONNECTOR
10
B68
B94
S1
B68
B144
B94
1 2 3
1
2
3 4 5
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
BO0462
CC-20

Step
CHECK SET/COAST SWITCH CIRCUIT.
3)Measure the voltage between harness connector terminal and chassis ground when SET/
COAST switch is pressed and not pressed.
CHECK RESUME/ACCEL SWITCH CIRCUIT.
Measure the voltage between harness connector terminal and chassis ground when
RESUME/ACCEL switch is pressed and not
pressed.
CHECK CANCEL SWITCH CIRCUIT.
Measure the voltage between harness connector terminal and chassis ground when CANCEL switch is pressed and not pressed.
CHECK POWER SUPPLY FOR COMMAND
SWITCH.
Check the horn operation.
CHECK CRUISE CONTROL COMMAND

SWITCH.
Remove and check the cruise control command switch. <Ref. to CC-6, Cruise Control
Command Switch.>
Check
Yes
Is the voltage 0 V when SET/ Go to step 2.
COAST switch is not pressed?
when SET/COAST switch is
pressed?
No
Go to step 4.
Is the voltage 0 V when

Go to step 3.
RESUME/ACCEL switch is not
pressed? Is the voltage more
than 10 V when RESUME/
ACCEL switch is pressed?
Go to step 4.
Is the voltage 0 V when CANCEL switch is not pressed? Is

the voltage more than 10 V
when CANCEL switch is
pressed?
Cruise control
command switch
circuit is OK.
Go to step 4.
Does the horn sound?
Go to step 5.
Check the fuse

No. 6 (in main fuse
box).
Check the horn
relay. <Ref. to
COM-3, HORN
RELAY, INSPECTION, Horn System.>
short between
cruise control
command switch
and fuse & relay
box.
Is the cruise control command Check the harness Replace the cruise
switch OK?
between cruise
control command
control command switch.
switch and cruise
control module.
CC-21

E: CHECK STOP LIGHT SWITCH AND BRAKE SWITCH

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-1
F/B No.16
SBF-2
STOP LIGHT SWITCH

AND BRAKE SWITCH
STOP LIGHT
SWITCH
CLUTCH
SWITCH (MT)
2
1
2
MT
AT
BRAKE
SWITCH
B107
1
AT
3
B65
20
: AT MODEL
16
AT
11
MT
B94
MT : MT MODEL
CRUISE
CONTROL
MODULE
B107
B65
B94
1 2
1 2
3 4
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
BO0132
CC-22

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.
1)Turn the cruise control main switch and ignition switch to OFF.
stop light switch and brake switch harness
connector terminal.
(B94) No. 20 (B65) No. 3:
(B94) No. 16 (B65) No. 1:
CHECK STOP LIGHT SWITCH AND BRAKE
SWITCH.
Remove and check the stop light switch and
brake switch. <Ref. to CC-7, Stop and Brake
Switch.>

?
Go to step 4.
Are the stop light switch and

brake switch OK?
Stop light switch

and brake switch
circuit are OK.
CC-23
No
Check the fuse
No. 16 (in fuse &
relay box).
short between
stop light/brake
switch and fuse &
relay box.

short between
stop light/brake
switch and cruise
control module
(AT).
Check the clutch
switch and circuit
(MT).
Repair the harness.
Replace the stop

light switch and
brake switch.

F: CHECK CLUTCH SWITCH (MT)

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-1
F/B No.16
SBF-2
STOP LIGHT SWITCH

AND BRAKE SWITCH
STOP LIGHT
SWITCH
CLUTCH
SWITCH (MT)
2
1
2
MT
AT
BRAKE
SWITCH
B107
1
AT
3
B65
20
: AT MODEL
16
AT
11
MT
B94
MT : MT MODEL
CRUISE
CONTROL
MODULE
B107
B65
B94
1 2
1 2
3 4
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
BO0132
CC-24

Step
CHECK CLUTCH SWITCH CIRCUIT.
2)Disconnect the clutch switch harness connector.
CHECK CLUTCH SWITCH CIRCUIT.
1)Turn the cruise control main switch and ignition switch OFF.
2)Disconnect the stop light switch and brake
switch harness connector.
3)Measure the resistance between clutch
switch harness connector terminal and stop
light switch and brake switch harness connector terminal.
(B107) No. 1 (B65) No. 4:
CHECK CLUTCH SWITCH.
Remove and check the clutch switch. <Ref. to
CC-8, Clutch Switch.>
Check
Yes
No
Check the harness
for open or short
between clutch
switch and cruise
control module.

?
Go to step 3.
Repair the harness.
Is the clutch switch OK?
Clutch switch circuit is OK.
Replace the clutch

switch.
CC-25

G: CHECK INHIBITOR SWITCH (AT)

TROUBLE SYMPTOM:
WIRING DIAGRAM:
CRUISE
CONTROL
MODULE
12
11
B94
B12
12
7
T3
T7
B14
STARTER
MOTOR
INHIBITOR
SWITCH(AT)
B12
T7
B94
1 2 3 4
5 6 7 8
9 10 11 12
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
BO0133
CC-26

Step
2)Disconnect the inhibitor switch harness connector.
(T7) No. 12 (+) Chassis ground ():
1)Turn the cruise control main switch and ignition switch to OFF.
2)Disconnect the starter motor harness connector.
3)Measure the resistance between inhibitor
switch harness connector terminal and chassis
ground.
(T7) No. 7 (B14) No. 1:
Remove and check the inhibitor switch. <Ref.
to CC-9, Inhibitor Switch.>
Check
Yes
No
Check the harness
for open or short
between inhibitor
switch and cruise
control module.

?
Go to step 3.
Is the inhibitor switch OK?
Inhibitor switch cir- Replace the inhibicuit is OK.

tor switch.
CC-27
Repair the harness.

7. List of Diagnostic Trouble Code (DTC)

A: LIST
DTC
21
Item
Inner relay is seized.
Cruise control module inner relay is seized when main
switch is OFF.
22
Vehicle speed signal changes more than 10 km/h (6

MPH) within 350 ms.
24
Cruise control module is

abnormal.
Two vehicle speed values stored in cruise control module memory are not the same.
25

abnormal.
Two output values stored in cruise control module memory are not the same.
28
Wiring harness opened.
Open wiring harness circuit is detected via control module relay when main switch is ON.
35
Motor drive system is

abnormal.
Motor output circuit is open or shorted.

Motor drive circuit is open or shorted.
36
Trouble of motor turning

speed
Motor turning speed is low.
37
Motor clutch drive system

is abnormal.
Motor clutch output circuit is open or shorted.

Motor clutch drive circuit is open or shorted.
38
Motor drive shaft does not

engage properly.
Motor drive gear engagement is not properly adjusted.
39
Motor is overloaded.
Current flows through motor more frequently than under

normal conditions.
2A

abnormal.
Cruise control module self-diagnosis function senses

abnormality.
CC-28
Reference
<Ref. to CC-29, DTC 21,
24, 25 AND 2A CRUISE
CONTROL MODULE
BUILT-IN RELAY, CPU
RAM, Diagnostics Chart
with Trouble Code.>
<Ref. to CC-30, DTC 22
VEHICLE SPEED SENSOR, Diagnostics Chart
with Trouble Code.>
CONTROL MODULE
BUILT-IN RELAY, CPU
with Trouble Code.>
CONTROL MODULE
BUILT-IN RELAY, CPU
with Trouble Code.>
WIRING HARNESS
OPENED., Diagnostics
Chart with Trouble Code.>
AND 36 ACTUATOR
MOTOR, Diagnostics
AND 36 ACTUATOR
MOTOR, Diagnostics
ACTUATOR MOTOR
CLUTCH, Diagnostics
MOTOR DRIVE SHAFT
DOES NOT ENGAGE
PROPERLY., Diagnostics
MOTOR IS OVERLOADED., Diagnostics
CONTROL MODULE
BUILT-IN RELAY, CPU
with Trouble Code.>
DIAGNOSTICS CHART WITH TROUBLE CODE

8. Diagnostics Chart with Trouble Code

A: DTC 21, 24, 25 AND 2A CRUISE
CONTROL MODULE BUILT-IN RELAY, CPU RAM
DIAGNOSIS:
Poor welding of built-in relay of cruise control
module.
Failure of built-in CPU RAM of cruise control
module.
TROUBLE SYMPTOM:
Cruise control is canceled and memorized cruise
speed is also canceled.
Once cruise control is canceled, cruise control
cannot be set until the ignition switch and cruise
control main switch turns OFF, and then turns ON
again.
NOTE:
Check input/output signal and vehicle speed signal
with select monitor. When signals are in good condition, failure is in cruise control module. (Check
the power supply and ground conditions of cruise
control module.)
CC-29

B: DTC 22 VEHICLE SPEED SENSOR

DIAGNOSIS:
Disconnection or short circuit of vehicle speed sensor system.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
IGNITION
SWITCH
BATTERY
F/B No.18
SBF-4
3
TRANSMISSION
CONTROL
C17
MODULE
AT
MT
VEHICLE SPEED
SENSOR(MT)
2
B56
AT
: AT MODEL
MT
: MT MODEL
B17
B22
16
NA : NON-TURBO MODEL
E3
B94
19
TB : TURBO MODEL
CRUISE
CONTROL
MODULE
E
GE
B17
NA
1 2 3
B17
1 2
3 4
TB
B94
B22
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
1 2 3 4
10 11 12 13
19 20 21
B56
5 6
14 15
7
16
22
8
17
23
9
18
24
BO0463
CC-30

1
2
Step
AND VEHICLE SPEED SENSOR.
2)Disconnect the harness connector from vehicle speed sensor.
4)Measure the voltage between vehicle speed
CHECK HARNESS BETWEEN CRUISE CONTROL MODULE AND VEHICLE SPEED SENSOR.
2)Disconnect the harness connector from
cruise control module.
speed sensor harness connector terminal and
cruise control module harness connector terminal.
(B17) No. 1 (B94) No. 19:
SPEED SENSOR AND ENGINE GROUND.
speed sensor harness connector terminal and
engine ground.
CHECK VEHICLE SPEED SENSOR.
1)Connect the harness connector to vehicle
speed sensor.
2)Lift-up the vehicle and support with safety
stands.
Check
Yes
Is the transmission type MT? Go to step 2.
No
Go to step 6.
Check the harness
for open or short
between fuse and
vehicle speed sensor.

?
Go to step 4.
Repair the harness.

?
Go to step 5.
Repair the harness.
Is the voltage less than 1V

more than 4 V?
Replace the cruise Replace the vehicontrol module.

cle speed sensor.
<Ref. to CC-4,
Cruise Control
Module.>
Warning:
Be careful not to be caught up by the running wheels.
km/h (12 MPH).
4)Measure the voltage between cruise control
module harness connector terminal and chassis ground.
CC-31

Step
Check
CHECK HARNESS BETWEEN CRUISE CON- Is the resistance less than 10
TROL MODULE AND TRANSMISSION CON- ?
TROL MODULE.
transmission control module and cruise control
module.
transmission control module harness connector terminal.
CAUTION:
To measure the voltage and/or resistance,
use a tapered pin with a diameter of less
than 0.64 mm (0.025 in). Do not insert the pin
more than 2 mm (0.08 in).
(B94) No. 19 (B56) No. 17:
CHECK TRANSMISSION CONTROL MOD- Is the voltage less than 1 V
ULE.
more than 4 V?
1)Connect the harness connector to transmission control module.
2)Lift-up the vehicle and support with safety
stands.
Warning:
Be careful not to be caught by the running
wheels.
3)Drive the vehicle faster than 10 km/h (6
MPH).
4)Measure the voltage between transmission
and chassis ground.
CAUTION:
To measure the voltage and/or resistance,
use a tapered pin with a diameter of less
than 0.64 mm (0.025 in). Do not insert the pin
more than 2 mm (0.08 in).
CC-32
Yes
Go to step 7.
No
Repair the harness.
Replace the cruise

control module.
<Ref. to CC-4,
Cruise Control
Module.>
Replace the transmission control

module. <Ref. to
AT-46, Transmission Control Module (TCM).>

C: DTC 28 WIRING HARNESS OPENED.

1
Step
CHECK BATTERY.
Measure the battery specific gravity of electrolyte.
CHECK FUSES, CONNECTORS AND HARNESSES.
Check the condition of the main and other
fuses, and harnesses and connectors. Also
check for proper grounding.
Check
Is the battery specific gravity
more than 1.250?
Yes
Go to step 2.
Is there anything unusual

Repair or replace
about the appearance of main the faulty parts.
fuse, fuse, harness, connector
and grounding?
CC-33
No
Charge or replace
the battery. Go to
step 2.
End of inspection.

D: DTC 35 AND 36 ACTUATOR MOTOR

DIAGNOSIS:
Open or poor contact of cruise control actuator motor.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
14
13
11
CRUISE CONTROL
MODULE
B94
B7
CRUISE CONTROL
ACTUATOR
B7
B94
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
B6M1616
CC-34

Step
CHECK POWER SUPPLY.
cruise control actuator.
Terminals
1)Turn the ignition switch and cruise control
main switch to OFF.
2)Measure the resistance between cruise control actuator harness connector terminal and
chassis ground.
Terminals
MEASURE RESISTANCE OF ACTUATOR.
Measure the resistance of cruise control actuator motor.
Terminals
No. 4 No. 1:
No. 4 No. 2:
No. 4 No. 5:
CHECK HARNESS BETWEEN ACTUATOR
AND CRUISE CONTROL MODULE.
cruise control actuator harness connector terminal.
(B7) No. 1 (B94) No. 7:
Measure the resistance between cruise control
module harness connector terminal and cruise
control actuator harness connector terminal .
(B7) No. 5 (B94) No. 5:
Check
Yes

?
Go to step 3.
No
Check the harness
for open or short
between cruise
control module
and cruise control
actuator.
Repair the harness.
Is the resistance approximately Go to step 4.

5 ?
Replace the cruise

control actuator.
<Ref. to CC-3,
Actuator.>

?
Go to step 5.
Repair the harness.

?
Replace the cruise Repair the harcontrol module.

ness.
<Ref. to CC-4,
Cruise Control
Module.>
CC-35

E: DTC 37 ACTUATOR MOTOR CLUTCH

DIAGNOSIS:
Open or poor contact of cruise control actuator motor clutch.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
14
13
11
CRUISE CONTROL
MODULE
B94
B7
CRUISE CONTROL
ACTUATOR
B7
B94
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
B6M1616
CC-36

Step
CHECK POWER SUPPLY.
Terminals
1)Turn the ignition switch and cruise control
main switch to OFF.
2)Measure the resistance between cruise control actuator harness connector terminal and
chassis ground.
Terminals
MEASURE RESISTANCE OF ACTUATOR
CLUTCH.
Measure the resistance of cruise control actuator clutch.
Terminals
No. 3 No. 6:
cruise control actuator harness connector terminal.
(B7) No. 2 (B94) No. 13:
Measure the resistance between cruise control
module harness connector terminal and cruise
control actuator harness connector terminal.
(B7) No. 3 (B94) No. 14:
Check
Yes

?
Go to step 3.
Is the resistance approx. 39 ? Go to step 4.
No
Check the harness
for open or short
between cruise
control module
and cruise control
actuator.
Repair the harness.
Replace the cruise

control actuator.
<Ref. to CC-3,
Actuator.>

?
Go to step 5.

?
Replace the cruise Repair the harcontrol module.

ness.
<Ref. to CC-4,
Cruise Control
Module.>
CC-37
Repair the harness.

F: DTC 38 MOTOR DRIVE SHAFT DOES NOT ENGAGE PROPERLY.

1
Step
CHECK ACTUATOR MOTOR.
3)Remove the cruise control actuator from
mounting bracket.
4)Pull the cable by hand to check for looseness or status of inner gear engagement.
Check
Are foreign particles caught in
the inner gear or does inner
gear engage and disengage
improperly?
Yes
Replace the cruise
control actuator.
<Ref. to CC-3,
Actuator.>
No
Check the cruise
control cable
adjustment.<Ref.
to CC-5, CABLE
FREE PLAY, General Description.>
Yes
Replace the cruise
control module.
<Ref. to CC-4,
Cruise Control
Module.>
No
Check the power
supply circuit.
<Ref. to CC-16,
CHECK POWER
SUPPLY, Diagnostics Chart with
Symptom.>
G: DTC 39 MOTOR IS OVERLOADED.

1
Step
Check
CHECK THE OPERATING CURRENT TO AC- Is the current more than 10A?
TUATOR MOTOR.
link connector.
2)Try to drive the vehicle while operating the
cruise control system.
3)Check the operation current to the cruise
control actuator motor.
CC-38
WIRING SYSTEM SECTION

WIRING SYSTEM
WI

of SUBARU vehicles.

approval.
G1840GE7
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
Basic Diagnostics Procedure ......................................................................3
Working Precautions .................................................................................15
Super Multiple Junction (SMJ) ..................................................................16
Power Supply Routing...............................................................................18
Ground Distribution ...................................................................................33
Airbag System...........................................................................................52
Air Conditioning System............................................................................59
Anti-lock Brake System .............................................................................72
A/T Control System ...................................................................................79
Audio System ............................................................................................90
Charging System.......................................................................................95
Combination Meter....................................................................................98
Cruise Control System ............................................................................102
Door Lock System...................................................................................105
Engine Coolant Temperature Gauge System .........................................110
Engine Electrical System ........................................................................113
Fuel Gauge System ................................................................................172
Full-Time Dual-Range System ................................................................175
Front Accessory Power Supply System ..................................................178
Headlight Beam Leveler System.............................................................179
Horn System ...........................................................................................180
Immobilizer System.................................................................................181
Keyless Entry System .............................................................................186
Back-up Light System .............................................................................193
Clearance Light and Illumination Light System .......................................194
Front Fog Light System...........................................................................204
Headlight System ....................................................................................208
In Compartment Light System.................................................................211
Stop Light System ...................................................................................216
Turn Signal Light and Hazard Light System............................................217
Oil Pressure Warning Light System ........................................................222
Outside Temperature Display System ....................................................225
Parking Brake and Brake Fluid Level Warning System ..........................228
Power Window System ...........................................................................231
Radiator Fan System ..............................................................................240
Rear Fog Light System ...........................................................................243
Rear Window Defogger System..............................................................247
Remote Controlled Rearview Mirror System...........................................250
Seat Belt Warning System ......................................................................253
Starter System ........................................................................................256
Sunroof System.......................................................................................259
Wiper and Washer System (Front)..........................................................260
Wiper and Washer System (Rear) ..........................................................263
WIRING SYSTEM
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
Overall Systems ......................................................................................266

Front Wiring Harness ..............................................................................268
Bulkhead Wiring Harness (In Engine Room) ..........................................272
Bulkhead Wiring Harness (In Compartment) ..........................................280
Engine Wiring Harness and Transmission Cord .....................................286
Instrument Panel Wiring Harness ...........................................................292
Rear Wiring Harness, Bulkhead Wiring Harness, Roof Cord and Fuel Tank Cord...........296
Door Cord................................................................................................300
Rear Wiring Harness and Trunk Lid Cord ...............................................304
Rear Wiring Harness and Rear Gate Cord .............................................306
WI-2
BASIC DIAGNOSTICS PROCEDURE

WIRING SYSTEM
1. Basic Diagnostics Procedure
B: BASIC INSPECTION
A: BASIC PROCEDURES
1. VOLTAGE MEASUREMENT
1. GENERAL
1) Using a voltmeter, connect the negative lead to a

good ground point or negative battery terminal and
the positive lead to the connector or component terminal.
2) Contact the positive probe of the voltmeter on
connector (A).
The voltmeter will indicate a voltage.
3) Shift the positive probe to connector (B). The
voltmeter will indicate no voltage.
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 symptom.
3. PROBABLE CAUSE OF TROUBLE

Look at the wiring diagram and check system's circuit. Then check the switch, relay, fuse, ground,
etc.
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 problems are encountered, check the
component parts.
5. CONFIRMATION OF SYSTEM OPERATION
H6M0510A
4) With 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.
5) The circuit is in good order. If a problem such as
a lamp failing to light occurs, use the procedures
outlined above to track down malfunction.
After repairing, ensure that the system operates

properly.
WI-3

WIRING SYSTEM
2. CIRCUIT CONTINUITY CHECKS

1) Disconnect the battery cable or connector so
there is no voltage between 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 the diode continuity. When contacting the negative lead to diode
positive side and positive lead to negative side,
there should be continuity.
When contacting the two leads in reverse, there
should be no continuity.
3. HOW TO DETERMINE AN OPEN CIRCUIT

1) Voltmeter Method:
An open circuit is determined by measuring the
voltage between respective connectors and ground
using a voltmeter, starting with the connector closest to 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
previous connector is open.
G6M0208
G6M0207
3) Symbol indicates that continuity exists

between two points or terminals. For example,
when a switch position is 3, continuity exists
among terminals 1, 3 and 6, as shown in table below.
2) Ohmmeter method:
Disconnect all connectors affected, and check the
continuity in wiring between adjacent connectors.
When the ohmmeter indicates infinite, the wiring
is open.
G6M0209
B6M0749
WI-4

WIRING SYSTEM
4. HOW TO DETERMINE A SHORT CIRCUIT

1) Test lamp method:
Connect a test lamp (rated at approximately 3
watts) in place of the blown fuse and allow current
to flow through the circuit. Disconnect one connector at a time from the circuit, starting with the one located farthest from power supply. If the test lamp
goes out when a connector is disconnected, the
wiring between that connection and next connector
(farther from the power supply) is shorted.
G6M0210
2) Ohmmeter method:
Disconnect all affected connectors, and check the
continuity between each connector and ground.
When the ohmmeter indicates continuity between a
particular connector and ground, that the connector
is shorted.
G6M0211
WI-5

WIRING SYSTEM
C: HOW TO READ WIRING DIAGRAMS

1. WIRING DIAGRAM
The wiring diagram of each system is illustrated so that you can understand the path through which electric
current flows from 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 front.
G6M0193
The number of poles or pins, presence of a lock, and pin number of each terminal are indicated in the
sketch of each connector. In the sketch, the highest pole number refers to the number of poles which connector has. For example, the sketch of connector shown in the figure indicates the connector has 9 poles.
Connector used in vehicle
Connector shown in wiring diagram

Symbol
Sketch
Number of poles
Numbered in order from upper

right to lower left.
G6M0194
G6M0196
Numbered in order from upper

left to lower right.
G6M0195
G6M0197
WI-6
G6M0198

WIRING SYSTEM
When one set of connectors is viewed from the

front side, the pole numbers of one connector are
symmetrical to those of other. When these two connectors are connected as a unit, the poles which
have the same number are joined.
The following color codes are used to indicate

the colors of the wires used.
G6M0199
Electrical wiring harness:

The connectors are numbered along with the number of poles, external colors, and mating connections in accompanying list.
The sketch of each connector in the wiring diagram usually shows (A) side of the connector. The
relationship between wire color, terminal number
and connector is described in figure.
Color code
L
B
Y
G
R
W
Br
Lg
Gr
P
Or
Lb
V
SA
SB
Color
Blue
Black
Yellow
Green
Red
White
Brown
Light green
Gray
Pink
Orange
Light Blue
Violet
Sealed (Inner)
Sealed (Outer)
NOTE:
A wire which runs in one direction from a connector
terminal sometimes may have a different color from
that which runs in the other direction from that terminal.
B6M1585A
In wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of
these connectors are omitted intentionally.
B6M1586A
WI-7
MG-098

WIRING SYSTEM
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 stripe marking by its second letter.
Each unit is directly grounded to the body or indirectly grounds through a harness ground terminal.
Different symbols are used in the wiring diagram to
identify the two grounding systems.
G6M0202
B6M1587A
The table lists the nominal sectional areas and

allowable currents of wires.
The ground points shown in the wiring diagram

refer to the following:
CAUTION:
When replacing or repairing a wire, be sure to
use the same size and type of wire which was
originally used.
NOTE:
All wiring harnesses are provided with a ground
point which should be securely connected.
NOTE:
The allowable current in the table indicates tolerable amperage of each wire at an ambient temperature of 40C (104F).
The allowable current changes with ambient
temperature. Also, it changes if a bundle of more
than two wires is used.
Nominal
sectional
area
No. of
strands/
strand
diameter
mm2
0.3
0.5
0.75
0.85
1.25
2
3
5
8
Outside
diameter of
finished
wiring
Allowable
current
Amps/
40C (104F)
B6M1420A
mm
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
1.8
2.2 (or 2.0)
2.6 (or 2.4)
2.4 (or 2.2)
2.7 (or 2.5)
3.1 (or 2.9)
3.8 (or 3.6)
4.6 (or 4.4)
5.5
7
12
16
16
21
28
38
51
67
WI-8

WIRING SYSTEM
Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more
contacts.
The wiring diagram shows the relay mode when energizing circuit is OFF.
B6M0748
WI-9

WIRING SYSTEM
Each connector number shown in the wiring diagram corresponds to that in wiring harness. The location of each connector in actual vehicle is
determined by reading the first character of the
connector (for example, a F for F8, i for i16, etc.)
and type of wiring harness.
The first character of each connector number refers
to the area or system of the vehicle.
Symbol
F
B
E
T
Wiring harness and cord

Front wiring harness
Bulkhead wiring harness
Engine wiring harness
Transmission cord, Rear oxygen sensor cord
Door cord LH & RH,
Rear door cord LH & RH, Rear gate cord
Instrument panel wiring harness
Rear wiring harness,
Fuel tank cord,
Roof cord, ORVR cord
D
i
R
F94
F25
F35
B
F39
F24
F22
F23
F78
F34
F79
F47
F58
F17
GB-2
F21
F96
Each connector number

shown in wiring diagram
corresponds to that in
the vehicle.
FRONT FOG
LIGHT LH
WB
F21
FRONT FOG
LIGHT RH
WB
1
2
B
F6
B196
F6
(BLACK)
1 2
F21
(BLACK)
1 2
BO0258
WI-10

WIRING SYSTEM
D: SYMBOLS IN WIRING DIAGRAMS

A number of symbols are used in each wiring diagram to easily identify parts or circuits.
WIRE TRACING
ON EXTENDED
WIRING DIAGRAMS
P-SUP-02
P-SUP-02
SBF-6 30A
FUSE No. & RATING
No.1 20A
No.2 15A
No.8 15A
BW
M
L
K
J
I
H
G
F
E
D4 LgB
BG
LOW
B:
YL
LB
HIGH
P-SUP-04
P-SUP-03
P-SUP-03
P-SUP-04
P-SUP-03
P-SUP-04
No.5 10A
H1
SMJ
i5
B62
RL
P-SUP-04
D7
A: B51
F45
P-SUP-04
FUSE &
RELAY
BOX (F/B)
LB
HEADLIGHT LH
BG G7
MB-5
HEADLIGHT
RELAY
WR G4
LW
FB-16
F/B FUSE NO. 11
(IG)
GR
MB-11
M/B FUSE NO. 9
RL

MB-10
M/B FUSE NO. 8
P-SUP-04
D11 Or
5
G
F38
P-SUP-04
SMJ
H/L(2L)-01
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
3
LY
RY
HL
17
17
YB
16
16
13
13
LY
CLASSIFICATION
OF SPECIFICATIONS
LIGHTING SWITCH
OFF
HC
OR : WITHOUT REAR DEFOGGER

WR : WITH REAR DEFOGGER
TC
B71
EL
C: B52
YB
RY
REF. TO FOG(H6)-01
(GRAY)
A: B51
1 2
3
4 5 6 7 8
SD : SEDAN
SD
P
WG
B112
17
R3
P
B99
SD
WG : WAGON
WG
G: F41
1
2 3
4 5 6 7
REF. TO FOG(H4)-01
DIODE
DIODE
FB-34
HU
FB-35
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
CLASSIFICATION
OF SPECIFICATIONS
F40
G: F41
FB-37
SYMBOLS OF
WIRE
CONNECTION
AND CROSSING
F36
POWER SUPPLY
ROUTING
MB-10
MB-11
2
RL
F68
R
7
LW
F39
LR
3
LR
CONNECTOR-1
R
No.9 15A
HEADLIGHT
RELAY
LH
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
B112
F7
(BLACK)
F44
1 2
F23
(BLACK)
1 2 3 4
5 6 7 8
R4
GROUND
PARKING BRAKE
SWITCH
R1
P
B97
CONNECTOR
SKETCH
B6M1640A
REF. TO GND-02
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 fuse box (main fuse box, fuse and joint
box).
The sketch of the connector indicates 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 (as
when two pages are needed for clear indication).
Each connector is indicated by a symbol.

Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form.
For example, terminal number C2 refers to No.
2 terminal of connector (C: F41) shown in the connector sketch.
WI-11

WIRING SYSTEM
6. CONNECTOR SKETCH
Each connector sketch clearly identifies the
shape and color of a connector as well as terminal
locations. Non-colored connectors are indicated in
natural color.
When more than two types of connector number
are indicated in a connector sketch, it means that
the same type connectors are used.
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
B6M1588
11.POWER SUPPLY ROUTING

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 POWER SUPPLY ROUTING
in the wiring diagram.
Accordingly, using the POWER SUPPLY ROUTING and wiring diagrams permits service personnel
to understand the entire electrical arrangement of a
system.
12.CLASSIFICATION BY SPECIFICATION
When the wiring diagrams differ according to vehicle specifications, the specification difference is described by using abbreviations.
WI-12

WIRING SYSTEM
E: CONNECTOR SYMBOL IN WIRING HARNESS

Main symbols of connector (in wiring harness) are indicated in below.
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
BO0257
WI-13

WIRING SYSTEM
F: ABBREVIATION IN WIRING DIAGRAMS

Abbreviation
ABS
ACC
A/C
AD
AT
AU
+B
DN
E
F/B
FL1.5
IG
Illumi.
LH
Lo
M
M/B
MG
Mi
OP
PASS
RH
SBF
ST
SW
UP
WASH
Full name
Antilock Brake System
Accessory
Air Conditioning
Auto Down
Automatic Transmission
Auto Up
Battery
Down
Ground
Fuse & Joint Box
Fusible link 1.5 mm2
Ignition
Illumination
Left Hand
Low
Motor
Main Fuse Box
Magnet
Middle
Optional Parts
Passing
Right Hand
Slow Blow Fuse
Starter
Switch
Up
Washer
WI-14
WORKING PRECAUTIONS
WIRING SYSTEM
2. Working Precautions
A: PRECAUTIONS WHEN WORKING
WITH THE PARTS MOUNTED ON
THE VEHICLE
1) When working under a vehicle which is jackedup, always be sure to use safety stands.
2) The parking brake must always be applied during working. Also, in automatic transmission vehicles, keep the select lever set to P (Parking) range.
3) Be sure the workshop is properly ventilated
when running the engine. Further, be careful not to
touch the belt or fan while the engine is operating.
4) Be careful not to touch hot metal parts, especially the radiator and exhaust system immediately after the engine has been shut off.
5) Some connectors are provided with a lock. One

type of such a connector is disconnected by pushing the lock, and the other, by moving the lock up.
In either type the lock shape must be identified before attempting to disconnect the connector.
To connect, insert the connector until it snaps and
confirm that it is tightly connected.
B: PRECAUTIONS IN TROUBLE DIAGNOSIS AND REPAIR OF ELECTRIC PARTS

1) The battery cable must be disconnected from
battery's () terminal, and the ignition switch must
be set to 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
body end parts or edges and bolts or screws.
3) When installing the parts, be careful not to catch
them on the wiring harness.
4) When disconnecting a connector, do not pull the
wires, but pull while holding the connector body.
G6M0213
6) When checking continuity between connector

terminals, or measuring the 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 accessible from the wiring side), contact test probes
on the terminal side being careful not to bend or
damage terminals.
G6M0212
G6M0214
7) Sensors, relays, electrical unit, etc., are sensitive to strong impacts.

Handle them with care so that they are not dropped
or mishandled.
WI-15
SUPER MULTIPLE JUNCTION (SMJ)

WIRING SYSTEM
3. Super Multiple Junction (SMJ)

A: HOW TO USE SUPER MULTIPLE JUNCTION (SMJ)
The SMJ indicated in wiring diagrams is shown in a simplified form.
B: TERMINAL ARRANGEMENT
Bulkhead Wiring Harness

B209
40 Poles
A1 K2 A3
B1 L2
C1 M2 C3
D1 N2
E1
F1
G1 Q2
H1 R2
I1 S2
J1 T2
Front Wiring Harness

F76
K4 A5
L4 B5
M4 C5
N4 D5
E5
40 Poles
A5 K4 A3
B5 L4
C5 M4 C3
D5 N4
E5
F5
Q4 G5
H3 R4 H5
S4 I5
J3 T4 J5
F5
G5 Q4
H5 R4
I5 S4
J5 T4
K2
L2
M2
N2
Q2
H3 R2
S2
J3 T2
A1
B1
C1
D1
E1
F1
G1
H1
I1
J1
BO0259
C: INSTALLATION
G6M1285A
Tightening torque:
T: 4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
NOTE:
Align the cutout portion of one connector with
that of other before tightening the connecting bolt.
Do not tighten the bolt excessively since this may
deform the connectors.
WI-16
SUPER MULTIPLE JUNCTION (SMJ)

WIRING SYSTEM
D: EXPLANATION OF SMJ SHOWN IN THE WIRING DIAGRAM
B6M1563A
WI-17
POWER SUPPLY ROUTING

WIRING SYSTEM
4. Power Supply Routing

A: SCHEMATIC
WI-18

WIRING SYSTEM
P-SUP(L)-01
P-SUP(L)-01
1. LHD MODEL
MAIN FUSE BOX (M/B)

MAIN FAN
20A
SUB
A/C
FAN
RELAY
RELAY-2
SUB FAN
20A
SBF-7 SBF
-8
FWD SWITCH
MAIN
SUB
MAIN
FAN
FAN
FAN
RELAY-1 RELAY-2 RELAY-1
SBF SBF
-5
-6
No. 1
No. 6
Horn
relay
No. 5
No. 4
No. 3
SBF-2 SBF-3
SBF-1
SBF-4
No. 9
No. 8
No. 7
No. 2
H/L
relay
RH
H/L
relay
LH
FUSE & RELAY BOX (F/B)
No. 13
No. 14
No. 7
No. 1
No. 15
No. 8
No. 2
No. 16 No. 9
No. 17 No. 10
No. 3
No. 18 No. 11
No. 5
No. 19 No. 12
No. 6
No. 4
GL01-21A
WI-19

WIRING SYSTEM
WI-20

P-SUP(L)-03
P-SUP(L)-03
WIRING SYSTEM
SBF-4 50A
SBF-3 50A
F36
F38
W
BW
No.1 20A
3
No.2 15A
2
F68
LR
No.5 15A
1
4
WR
F37
WL
No.7 20A
SBF-2 50A
SBF-5 30A
1
BR
RG
BL
F39
HORN
RELAY
P-SUP(L)-02
No.4 10A
P-SUP(L)-02
YR
No.6 15A
P-SUP(L)-02
SBF-6 30A
MAIN FUSE BOX (M/B)
F36
F68
1 2 3
1 2
3 4
(BLACK)
F37
1 2 3
4 5 6
(BLACK)
F39
P-SUP(L)-05
P-SUP(L)-05
P-SUP(L)-05
P-SUP(L)-05
P-SUP(L)-04
P-SUP(L)-04
P-SUP(L)-05
P-SUP(L)-04
MB-13
MB-12
MB-11
MB-10
MB-9
MB-8
MB-7
MB-6
MB-5
MB-4
E
F
G
H
I
J
K
L
(BLACK)
1 2 3 4
5 6 7 8
GL01-21C
WI-21

P-SUP(L)-04
FB-3
P-SUP(L)-05
E8
R
F8
A3
F9 WR
LR
BG
A2 LgB
P-SUP(L)-03
F4
P-SUP(L)-03
I
L
J
D11 Or
P-SUP(L)-03
FB-2
FB-1
P-SUP(L)-04
WIRING SYSTEM
C: B52
REAR
DEFOGGER
RELAY
No.6 15A
TAIL &
ILLUMINATION
RELAY
No.11 15A
B: B271
No.17 15A
A: B51
No.18 15A
No.5 10A
No.12 10A
FUSE &
RELAY
BOX (F/B)
D: B152
E: B158
F:
F40
R
FB-23
A4
GY
FB-22
C4
GR D5
FB-21
A5
GOr C1
FB-20
B7
GOr G2
FB-19
GB G3
GB C5
FB-17
B1
L
FB-16
B4
RL
FB-15
D1
WR E5
BW D2
FB-13
FB-14
BR D12
FB-12
C7
V
FB-11
B2
V
A1
C6
LR
FB-9
B3
LR
FB-8
A6
RY D10
FB-7
G1
RY
D7
LR
A: B51 (BLUE)
(GRAY)
F:
1 2
3
4 5 6 7 8
1
5
F40
3
2
6 7 8
4
9
1
6
1
2 3
4 5 6 7
B: B271 (BLUE)
D: B152
E: B158 (GRAY)
(BROWN)
2
7
3
8
4 5
9 10
FB-18
FB-10
B99
C: B52
G: F41
BG G7
13
FB-6
R3
FB-4
R79
FB-5
TRAILER
CONNECTOR
10 LR
LgB G4
D4
G: F41
R79
1 2 3 4 5
6 7 8 9 10
B99
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3
4 5
6 7 8 9 10 11 12
GL01-21D
WI-22
IGNITION SWITCH
OFF ACC ON ST
P-SUP(L)-03
F46
B
ACC
IG
WB
ST
B108
P-SUP(L)-05
P-SUP(L)-05
WIRING SYSTEM
B72
P-SUP(L)-03
WL
WL
F45
B62
IGNITION RELAY
P-SUP(L)-04
P-SUP(L)-03
F
G
H
P-SUP(L)-03
P-SUP(L)-03
WL
10
13
11
GW
B157
E1
B11
F6 BW
F2
F3
Y
E7
E9
REF. TO GND-02
FUSE &
RELAY
BOX (F/B)
B: B271
No.13 10A
No.3 15A
No.1 15A
No.2 15A
No.7 15A
No.8 20A
No.16 20A
No.19 20A
No.10 10A
No.4 20A
No.9 15A
No.15 30A
No.14 10A
A: B51
C: B52
D: B152
E: B158
F40
G: F41
F46
(BLACK)
1
2
B: B271 (BLUE)
D: B152
1 2 3
4 5
6 7 8 9 10 11 12
B72 (BLUE)
1 2
3 4
C: B52
G: F41
A: B51 (BLUE)
(GRAY)
F:
1 2
3
4 5 6 7 8
1
5
F40
3
2
6 7 8
ST
FB-36
FB-35
FB-34
FB-33
FB-32
FB-31
FB-30
FB-29
FB-28
FB-27
FB-26
FB-25
FB-24
P-SUP(L)-02
E: B158 (GRAY)
(BROWN)
4
9
IG
D3
A8
RW E6
RW F7
D9
RL
WB D8
G5
RY
RW D6
E3
LY
RW E10
C2
LR
B8
B6
YR
B9
YG
C3
E2
YB
WG F1
WR E4
F:
1
6
2
7
3
8
4 5
9 10
1
2 3
4 5 6 7
F45
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B157
1 2
3 4
5 6
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
7 8
WI-23
GL01-21E

WIRING SYSTEM
No.
MB-1
MB-2
MB-3
MB-4
MB-5
MB-6
MB-7
MB-8
MB-9
MB-12
MB-13
SBF-8
IG
ST
FB-1
FB-2
FB-3
FB-4
FB-5
FB-6
FB-7
FB-8
FB-9
Load
Air conditioning relay holder
Combination meter
Headlight RH
Headlight LH
Horn
Cruise control sub switch
Horn switch
Hazard switch
Key warning switch
Diode (With rear fog light model)
Lighting switch
Data link connector
Fuel pump relay
Immobilizer control module
Main relay
Power window circuit breaker
Relay holder
ABS control module
Hazard switch
Power window relay
Starter motor (MT)
Hazard switch
Rear turn signal light RH
Trailer connector
Turn signal switch
Hazard switch
Rear turn signal light LH
Trailer connector
Turn signal switch
Parking switch
Front turn signal light RH
Side turn signal light RH
Front turn signal light LH
Side turn signal light LH
Front clearance light LH
Front clearance light RH
Headlight leveler LH
Headlight leveler RH
License plate light
Tail light LH
Tail light RH
Trailer connector
Auto A/C control module
Combination meter
Door lock timer
Luggage room light (Wagon)
Radio
Room light
Spot light
Trunk room light (Sedan)
No.
FB-10
FB-11
FB-12
FB-13
FB-14
FB-15
FB-16
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
FB-31
FB-32
FB-33
FB-34
WI-24
Load
Bright switch
Combination meter
Front fog light relay
Front fog light switch
Headlight leveling switch
Illumination light
Rear fog light relay
Rear fog light switch
Parking switch
Lighting switch
Parking switch
Mirror heater relay
Rear defogger
Rear defogger timer
ABS relay
Back-up light switch (MT)
Check connector
Cruise control actuator
Seat belt timer
Main relay
Sub fan relay
Thermal protector
AUTO A/C control module
Blower motor relay
Rear defogger timer
Manual A/C switch
Fuel pump relay
Rear washer motor
Rear wiper intermittent module
Rear wiper motor
Front washer motor
Front wiper motor
Front wiper switch
Radio
Front accessory power supply socket
Remote controlled rearview mirror switch
Mirror heater relay
Stop light switch
ABS control module
Blower motor relay

WIRING SYSTEM
No.
FB-35
FB-36
Load
Door lock timer
Combination meter
WI-25

WIRING SYSTEM
2. RHD MODEL
WI-26

WIRING SYSTEM
WI-27

P-SUP(R)-03
P-SUP(R)-03
WIRING SYSTEM
SBF-4 50A
SBF-3 50A
2
B143
B145
W
BW
No.1 20A
3
No.2 15A
2
B186
LR
No.5 15A
1
4
W
B144
WL
No.7 20A
SBF-2 50A
SBF-5 30A
1
BR
RG
BL
F39
HORN
RELAY
P-SUP(R)-02
No.4 10A
P-SUP(R)-02
YR
No.6 15A
P-SUP(R)-02
SBF-6 30A
MAIN FUSE BOX (M/B)
B143
1 2 3
B186 (BLACK)
1 2
3 4
B144 (BLACK)
1 2 3
4 5 6
F39
P-SUP(R)-05
P-SUP(R)-05
P-SUP(R)-05
P-SUP(R)-05
P-SUP(R)-04
P-SUP(R)-04
P-SUP(R)-05
P-SUP(R)-04
MB-13
MB-12
MB-11
MB-10
MB-9
MB-8
MB-7
MB-6
MB-5
MB-4
E
F
G
H
I
J
K
L
(BLACK)
1 2 3 4
5 6 7 8
GR01-21C
WI-28

P-SUP(R)-04
G
P-SUP(R)-05
E8
R
F8
F9
A3
LR
BG
A2 LgB
P-SUP(R)-03
F4
P-SUP(R)-03
I
L
J
D11 Or
P-SUP(R)-03
FB-3
FB-2
FB-1
P-SUP(R)-04
WIRING SYSTEM
C: B52
No.6 15A
REAR
DEFOGGER
RELAY
No.11 15A
TAIL &
ILLUMINATION
RELAY
No.17 15A
A: B51
B: B271
No.18 15A
No.5 10A
No.12 10A
FUSE &
RELAY
BOX (F/B)
D: B152
E: B158
F: B159
Or
FB-23
A4
R
FB-22
C4
GR D5
FB-21
A5
GOr B7
FB-20
C1
GOr G2
FB-19
GB G3
GB C5
FB-17
B1
B4
L
FB-16
D1
RL
FB-13
FB-15
BR D12
BW D2
FB-12
WR E5
A1
V
FB-11
FB-14
B2
V
FB-10
C7
C6
B3
LR
WR D10
FB-7
A6
BG G7
WR G1
D7
LR
A: B51 (BLUE)
(GRAY)
F: B159 (BROWN)
1 2
3
4 5 6 7 8
1
5
2
3
6 7 8
4
9
1
6
1
2 3
4 5 6 7
B: B271 (BLUE)
D: B152
E: B158 (GRAY)
2
7
3
8
4 5
9 10
FB-18
FB-8
B99
C: B52
G: F41
FB-6
13
R3
FB-4
R79
FB-5
TRAILER
CONNECTOR
10 LR
LgB G4
D4
G: F41
R79
1 2 3 4 5
6 7 8 9 10
B99
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
GR01-21D
WI-29

IGNITION SWITCH
OFF ACC ON ST
P-SUP(R)-03
B
ACC
IG
WB
ST
P-SUP(R)-05
P-SUP(R)-05
WIRING SYSTEM
B72
P-SUP(R)-03
IGNITION RELAY
P-SUP(R)-04
P-SUP(R)-03
F
G
H
P-SUP(R)-03
P-SUP(R)-03
WL
38
36
34
GW 37
B157
E1
B11
F6 BW
F2
F3
Y
E7
E9
REF. TO GND-07
FUSE &
RELAY
BOX (F/B)
B: B271
No.13 10A
No.3 15A
No.1 15A
No.2 15A
No.7 15A
No.8 20A
No.16 20A
No.19 20A
No.10 10A
No.4 20A
No.9 15A
No.15 30A
No.14 10A
A: B51
C: B52
D: B152
G: F41
B72 (BLUE)
1 2
3 4
C: B52
G: F41
A: B51 (BLUE)
(GRAY)
1 2
3
4 5 6 7 8
F: B159 (BROWN)
1
5
1 2 3
4 5
6 7 8 9 10 11 12
2
3
6 7 8
4
9
ST
FB-36
E: B158 (GRAY)
1
6
2
7
3
8
4 5
9 10
1
2 3
4 5 6 7
B: B271 (BLUE)
D: B152
FB-35
FB-34
FB-33
FB-32
FB-31
FB-30
FB-29
FB-28
FB-27
FB-26
FB-25
P-SUP(R)-02
IG
D3
A8
F7
GR
GW E6
D9
RL
WB D8
G5
RY
RW D6
E3
F: E159
LY
B6
YR
RW E10
C3
YR
C2
B9
YG
LR
E2
YB
B8
E4
YL
F1
E: B158
B157
1 2
3 4
5 6
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
7 8
RELAY BLOCK (BLACK)
GR01-21E
WI-30

WIRING SYSTEM
No.
MB-1
MB-2
MB-3
MB-4
MB-5
MB-6
MB-7
MB-8
MB-9
MB-10
MB-12
MB-13
SBF-8
IG
ST
FB-1
FB-2
FB-3
FB-4
FB-5
FB-6
FB-7
Load
Air conditioning relay holder
Combination meter
Headlight RH
Headlight LH
Horn
Cruise control sub switch
Horn switch
Hazard switch
Key warning switch
Diode (With rear fog light model)
Lighting switch
Data link connector
Fuel pump relay
Main relay
Auto A/C Control module
Combination meter
Door lock timer
Luggage room light (Wagon)
Radio
Room light
Spot light
Trunk room light (Sedan)
Power window circuit breaker
Relay holder
ABS control module
Hazard switch
Starter motor (MT)
Hazard switch
Rear turn signal light RH
Trailer connector
Turn signal switch
Hazard switch
Rear turn signal light LH
Trailer connector
Turn signal switch
Parking switch
Front turn signal light RH
Front turn signal light LH
Front clearance light LH
Front clearance light RH
Headlight leveler LH
Headlight leveler RH
License plate light
Tail light LH
Tail light RH
Trailer connector
No.
FB-10
FB-11
FB-12
FB-13
FB-14
FB-15
FB-16
FB-17
FB-18
FB-19
FB-20
FB-21
FB-22
FB-23
FB-25
FB-26
FB-27
FB-28
FB-29
FB-30
FB-31
FB-32
FB-33
WI-31
Load
Bright switch
Combination meter
Headlight leveling switch
Illumination control module
Illumination light
Parking switch
Lighting switch
Parking switch
Mirror heater relay
Rear defogger
Rear defogger timer
ABS relay
Check connector
Power window relay
Rear defogger timer
Main relay
Pressure switch
Sub fan relay
AUTO A/C control module
Blower motor relay
Manual A/C switch
Fuel pump relay
Rear washer motor
Rear wiper motor
Front washer motor
Front wiper motor
Front wiper switch
Radio
Front accessory power supply socket
Remote controlled rearview mirror switch
Mirror heater relay
Stop light switch
ABS control module

WIRING SYSTEM
No.
FB-34
FB-35
FB-36
Load
Blower motor relay
Door lock timer
Combination meter
WI-32
GROUND DISTRIBUTION
WIRING SYSTEM
5. Ground Distribution
A: SCHEMATIC
WI-33
GROUND DISTRIBUTION
WIRING SYSTEM
POWER WINDOW
MAIN SWITCH
5
B
19
WL
B132
B62
WL
FRONT DOOR LOCK

ACUTUATOR (DRIVER SIDE)
BR 2
D7
F45
MAIN FAN MOTOR

(TURBO ENGINE MODEL)
1
B
REARVIEW MIRROR
(DRIVER SIDE)
HEADLIGHT LEVELER RH
WL 1
F59
DOOR LOCK SWITCH

BR 1
B
D5
1
SUB FAN MOTOR

1
B
HEADLIGHT LEVELER LH
WL 1
MAIN FAN MOTOR

(NON-TURBO ENGINE MODEL)
D1
B30
KEYLESS ENTRY
CONTROL MODULE
B
6
FRONT CLEARANCE
LIGHT LH
B
2
POWER WINDOW RELAY

16
B
F22
F17
SUB FAN MOTOR
1
D8
F58
F16
13
F17
D72
BR
GND-01
HEADLIGHT LEVELING SWITCH
GND-01
1. LHD MODEL (GENERAL)
FRONT CLEARANCE
LIGHT RH
B
2
14
B176
FRONT FOG LIGHT SWITCH

B
5
B
2
DOOR LOCK TIMER

4
B
F4
F16
B42
B92
B160
SIDE TURN SIGNAL
LIGHT LH
B
1
FRONT FOG LIGHT LH

2
B
REAR FOG LIGHT SWITCH

B
3
B
6
F54
F21
B195
FWD SWITCH
29 B
11
F45
WL
F67
GND-02
B62

TE : TURBO ENGINE MODEL
GB-1
GB-2
F16
(BLACK) : NA
F21 (BLACK)
F17
(BLACK) : NA
1 2
2 1
(GRAY)
D8
F54
1 2
F4
(GRAY)
F22
(GRAY)
1 2 3
F16
(BLACK) : TE
F58
(BLACK)
F17
(BLACK) : TE
F59
(BLACK)
3 2 1
1 2 3
B160 (GRAY)
D72 (GRAY)
B132
1
2
3 4 5 6
1 2
3 4
1 2 3 4
D7
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1
2
3 4 5 6
B176
1 2 3 4 5
11 12 13 14
15
2
4
5 6 9 13 14 17 21 22 25
15
18
26
7
10
23
8 11 12 16 19 20 24 27 28
B92
D5
1 2 3 4
5 6 7 8
3
2 1
8 7 6 5 4
F45
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
6 7 8 9 10
16 17 18
B42
F67
1
B195
29
30
D1
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
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK (BLACK)
WI-34
GG04-21A
GROUND DISTRIBUTION
WIRING SYSTEM
GND-02
B132
REAR DEFOGGER TIMER
1
B
AT SELECT LEVER
B
3
RADIO
7
B
B116
FRONT DOOR SWITCH (DRIVER SIDE)
B120
2
B
B70
B296
B267
B8
TURN&HAZARD MODULE
B
2
COMBINATION SWITCH (LIGHTING)

16 B
B71
B12
FRONT ACCESSORY
POWER SUPPLY SOCKET
B
3
B
4
B284
BRAKE FLUID LEVEL

WARNING SWITCH
2
B
B119
ABS RELAY
3
B
B16
MIRROR HEATER RELAY

B 31
B264
GLOVE BOX
ILLUMINATION LIGHT
1
B
B171
AUTO A/C
CONTROL MODULE
B B20
B B12
CHECK CONNECTOR
8
B
B79
B208
POWER MODE AND

SNOW MODE SWITCH
B
4
B
6
B157
B46
MAIN RELAY
B
1
B268
B47
MODE ACTUATOR
B
2
AWD-LO SWITCH
1
B
B29
B133
KICK DOWN SWITCH
B
1
FUEL PUMP RELAY

B
3
FRONT DOOR SWITH

(PASSENGER SIDE)
3
B
B283
IGNITION RELAY
11 B
B293
INHIBITOR SWITCH (AT)

4
B
B32
REMOTE CONTROLLED
REARVIEW MIRROR SWITCH
2
B
AIR MIX ACTUATOR

B
2
FRONT WIPER MOTOR

4
B
B77
SEAT BELT TIMER

3
B
B129
GND-03
GND-03
B44
A
B
GND-01
B
B
COMBINATION METER
B A6
OrW A9
B B27
CLOCK
A:
i10
B
2
24 B
15 OrW
i2
B37
MANUAL A/C SWITCH

B
1
3
B
B
6
GB-5
B16
B29
1
2
B208
B129
1
2
B133
1
2
3 4 5 6
1 2 3
4 5 6
B77
B268
B46
B132
1 2
3
B267
B293
B119
i59
1
2
3
B44
1 2 3 4
5 6 7 8
B168
B264 (RED)
1 2
3 4
B284
1 2 3 4 5
6 7 8 9 10
3 4
1 2
5 6 7 8 9 10
B71
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B:
i11
1
9
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
2
10
GB-4
i22
B32 (BLACK)
i22
B120
i11
HAZARD SWITCH
OrW 2
B168
1 2
B116
B:
i59
3 4 5 6
11 12 13 14 15
8
17
1
10
2
11
A:
i10
(GREEN)
7
16
8 9
17 18
B157
1 2 3
4 5
B12
1 2 3 4
5 6 7 8
9 10 11 12
2
4
6
B79 (GRAY)
1
8
2 3 4 5
9 10 11 12
6 7
13 14
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B171
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK (BLACK)
WI-35
B47 (BROWN)
1
3
5
B283
i2
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
1 2 3 4 5 6 7 8 9 10
3 4 5 6
12 13 14 15
B8
B296
1 2 3 4
B70
7
16
GND-02

B
1
GG04-21B
GROUND DISTRIBUTION
GND-03
REARVIEW MIRROR
(PASSENGER SIDE)
4
GND-03
WIRING SYSTEM
FUEL PUMP ASSEMBLY

1 BW
R58
B
BW
D15
R57
3
D11
R15
B101
ROOM LIGHT
3
B
SEAT BELT SWITCH

1
B
FRONT FOG LIGHT LH

BY 2
R52
R8
B306
SIDE TURN SIGNAL
LIGHT RH
BY 1
SPOT LIGHT
2
B
R56
REAR DOOR SWITCH LH

3
B
R22
B305
B
ABS CONTROL
MODULE
BW 23
R50
B90

B
5
B301
R122
REAR DOOR SWITCH RH

3
B
FAN CONTROL AMP.

4
B
R16
B275
HI-MOUNTED STOP
LIGHT (SEDAN)
1
B
ABS CONDENSOR
2
B
R19
B304
REAR DEFOGGER
CHOKE COIL (SEDAN)
BLOWER FAN SWITCH

1
B
B169
R130
B97
GND-04
R1
BY
BW
B
B
GND-02
GND-02
3
4
1
2
B198
GB-6
B304
B305
B306
R8
R56
R130
R19
1 2
1 2
1
2
1 2
1
2
1
2
B169
R58
1 2 3
4 5 6
B97
1 2 3 4
5 6 7 8
GB-7
GB-9
D15
R122
3
2 1
8 7 6 5 4
3 4
1 2
5 6 7 8 9 10
R16
R52
B90
B198
R15
R22
1 2 3
B275
1 2 3 4 5
1
2
3 4 5 6
1
2
3
D11
1 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-36
1 2
3 4
B301 (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
GG04-21C
GROUND DISTRIBUTION
GND-04
AB6
B
B120
B121
REAR COMBINATION
LIGHT RH (WAGON)
28
SRS HARNESS
27
RADIO
11
RADIO
BW
GND-04
WIRING SYSTEM
TRAILER CONNECTOR
8
B
R26
R79
REAR COMBINATION
LIGHT LH (WAGON)
2
LICENCE PLATE LIGHT
R28
TRUNK ROOM LIGHT

SWITCH (SEDAN)
REAR COMBINATION
LIGHT RH (SEDAN)
4
B
R26
REAR WIPER
INTERMITTENT MODULE
(WAGON)
B
2
R28
R27
WG : WAGON
SD : SEDAN
R27
REAR COMBINATION
LIGHT LH (SEDAN)
4
B
R116
BW
E
B
D
B
GND-03
R63
GB-8
GR
GB-4
GB-5
R63
2 1
2 1
R26 : SD
R26 : WG
R116
R28 : SD
R28 : WG
1 2 3 4
5 6 7 8
1 2 3
4 5 6
2
1
6 5 4 3
GND-05
AB6 (YELLOW)
R79
B120
1 2 3 4 5
6 7 8 9 10
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 28
GG04-21D
WI-37
GROUND DISTRIBUTION
WG : WAGON
SD : SEDAN
GND-05
GND-05
WIRING SYSTEM
REAR DEFOGGER
(WITHOUT CHOKE COIL)
B
D48

B
1
REAR GATE LATCH SWITCH

2
B
D46
D39
REAR DEFOGGER
(WITH CHOKE COIL)
REAR WIPER MOTOR

3
B
D43
HIGH-MOUNTED STOP
LIGHT (REAR SPOILER)
D74
R66
D35
1
R60
R24
WG
R39
GND-04
SD
D39
D46
R24
1
2
D74
1 2
R66
2 1
1
2
D43
D35
1 2
3 4
GG04-21E
WI-38
GROUND DISTRIBUTION
WIRING SYSTEM
POWER WINDOW
MAIN SWITCH
1
B
D7
F45
B
1
F17
D5
F16
FRONT CLEARANCE
LIGHT LH
B
2
POWER WINDOW RELAY

33 B
FRONT FOG LIGHT LH

2
B

B
5
B
2
B92
B160
ABS CONDENSER
B
2
F21
F97

3
B
6
B
SIDE TURN SIGNAL

LIGHT RH
1
B
FRONT FOG LIGHT RH

2
B
B195
F51
F6
ABS CONTROL MODULE
23 B
AIR MIX
ACTUATOR
B
2
MODE ACTUATOR
2
B
F49
B293
B77
FWD SWITCH
29 B
F44
F67
14
B176
DOOR LOCK TIMER

4
B
F4
F16
B42
FRONT CLEARANCE
LIGHT RH
B
2
KEYLESS ENTRY
CONTROL MODULE
B
6
B94
F22
SUB FAN MOTOR

D8
D1
B30
CRUISE CONTROL
MODULE
6
B
F58
F17
DOOR LOCK SWITCH

BR 1
B
1
MAIN FAN MOTOR

1
F59
SUB FAN MOTOR

1
B
D72
REARVIEW MIRROR
(DRIVER SIDE)
BR
MAIN FAN MOTOR

1
B
13
11
B62
B132
FRONT DOOR LOCK

ACTUATOR (DRIVER SIDE)
BR 2
GND-06
GND-06
2. RHD MODEL (GENERAL)
GND-07
B61

TE : TURBO ENGINE MODEL
GB-1
F97
(BLACK)
1
2
GB-2
D8
(GRAY)
F16
(BLACK) : NA
F6
(BLACK)
F17
(BLACK) : NA
F21 (BLACK)
F51
F4
(GRAY)
F16
(BLACK) : TE
B77
F58
(BLACK)
1 2
F22
(GRAY)
F17
(BLACK) : TE
B293
F59
(BLACK)
1
2
3
1 2 3
1 2 3
2 1
3 2 1
1 2
D72 (GRAY)
1 2
3 4
B160 (GRAY)
B132
1 2 3 4
1
2
3 4 5 6
D5
F44
B92
D7
1
2
3 4 5 6
3
2 1
8 7 6 5 4
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
B94 (BLACK)
B176
F45
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
1 2 3 4 5
11 12 13 14
15
6 7 8 9 10
16 17 18
D1
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
B195
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
F49
F67
1
5 6 9 13 14 17 21 22 25
29
7
10
15
18
23
26
8 11 12 16 19 20 24 27 28 30
(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
B42
1
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK (BLACK)
GG04-21F
WI-39
GROUND DISTRIBUTION
WIRING SYSTEM
A:
i10
i2
DIAGNOSIS CONNECTOR
B
B
21
GND-07
GND-07
COMBINATION METER
B
A6 B
B37
B81
REAR DEFOGGER TIMER
1
B
AT SELECT LEVER
B
3
RADIO
7
B
B120
B296
B116

2
B
FRONT DOOR SWITCH (DRIVER SIDE)

3
B
FRONT WIPER MOTOR

4
B
B267
B70
TURN&HAZARD MODULE
B
2
COMBINATION SWITCH (LIGHTING)

16 B
B71
GND-08
B8
CRUISE CONTROL ACTUATOR
B
6
B32
REMOTE CONTROLLED
REARVIEW MIRROR SWITCH
2
B
B7
FRONT ACCESSORY
POWER SUPPLY SOCKET
B
3
B
4
B284

4
B
B12
B119
ABS RELAY
3
B
BRAKE FLUID LEVEL

WARNING SWITCH
2
B
MIRROR HEATER RELAY

B 14
B171
B264
B16
B283
B79
B157
FUEL PUMP RELAY

B
3
B46
B208
POWER MODE AND

SNOW MODE SWITCH
B
4
B
6
IGNITION RELAY
34 B
B148
GLOVE BOX
ILLUMINATION LIGHT
1
B

B B20
B B12
CHECK CONNECTOR
8
B
SIDE TURN SIGNAL LIGHT LH

B
1
FRONT DOOR SWITCH

(PASSENGER SIDE)
3
B
MAIN RELAY
B
1
B268
B133
KICK DOWN SWITCH

1
B

B
1
B129
B47
AWD-LO SWITCH
1
B
B29
B132
C
B
B90
ROOM LIGHT
B
3
GND-08
GND-06
R52
R50
SPOT LIGHT
2
B
R56
GB-4
B16 (GRAY)
B129
B29
B208
1
2
1
2
1 2
B132
B8
1 2 3 4
1 2 3
4 5
(BLACK)
i10
2
11
1 2
B7
(GREEN)
1 2 3 4 5 6 7 8 9 10
3 4 5 6
12 13 14 15
7
16
8 9
17 18
B32 (BLACK)
B267
1 2
3
B268
B47 (BROWN)
(BLACK)
1
3
5
2
4
6
1 2 3 4
5 6 7 8
9 10 11 12
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B116
R52
1 2 3
1
2
3
B133 (BLUE)
1
2
3 4 5 6
B12
B283 (GRAY)
B70
1
10
1 2
1 2 3
4 5 6
A:
B284
1 2 3 4 5
6 7 8 9 10
R56
B148
GB-5
2 3 4 5
9 10 11 12
B264 (PINK)
1 2
3 4
1 2
3 4
B71
B120
1 2 3
4 5 6
7 8 9 10 11 12 13 14
6 7
13 14
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
B90
B296
1 2 3
4 5 6
B79 (GRAY)
1
8
B46 (GREEN)
B119
1
9
2
10
B171
1
7
16
8
17
B157
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK (BLACK)
WI-40
3 4 5 6
11 12 13 14 15
GG04-21G
GROUND DISTRIBUTION
GND-08
REARVIEW MIRROR
(PASSENGER SIDE)
4
GND-08
WIRING SYSTEM
FUEL PUMP ASSEMBLY

1 BW
R58
B
BW
D15
R57
3
D11
GND-07
R15
B101
SEAT BELT SWITCH

2
B
R8
REAR DOOR SWITCH LH

3
B
R22

B
5
R122
REAR DOOR SWITCH RH

3
B
R16
HI-MOUNTED STOP
LIGHT (SEDAN)
1
B
MANUAL
A/C SWITCH
B
8
B 10
FAN CONTROL AMP.

4
B
B275
R19
B168
REAR DEFOGGER
CHOKE COIL (SEDAN)
BLOWER FAN SWITCH

1
B
B169
GND-07
GB-3
R8
R19
R130
1
2
1
2
1
2
D15
3
2 1
8 7 6 5 4
B168
GND-09
R1
B97
GB-7
R16
B275
R22
1 2
3 4
1
2
3
R15 (BLACK)
1
2
3 4 5 6
B169
B97
R58
1 2 3 4
5 6 7 8
1 2 3
4 5 6
D11
R122 (BLACK)
1 2
3 4
5 6 7 8 9 10
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
WI-41
GG04-21H
GROUND DISTRIBUTION
GND-09
AB6
B
B120
B
B121
REAR COMBINATION
LIGHT RH (WAGON)
28
SRS HARNESS
27
RADIO
11
RADIO
BY
GND-09
WIRING SYSTEM
TRAILER CONNECTOR
8
B
R26
R79
REAR COMBINATION
LIGHT LH (WAGON)
2
LICENCE PLATE LIGHT
R28
TRUNK ROOM LIGHT

SWITCH (SEDAN)
REAR COMBINATION
LIGHT RH (SEDAN)
4
B
R26
WG : WAGON
SD : SEDAN
REAR WIPER
INTERMITTENT MODULE
(WAGON)
B
2
R28
R27
R27
REAR COMBINATION
LIGHT LH (SEDAN)
4
B
R116
BY
E
B
D
B
GND-08
R63
GB-8
GR
GB-4
GB-5
R63
2 1
2 1
R26 : SD
R26 : WG
R116
R28 : SD
R28 : WG
1 2 3 4
5 6 7 8
1 2 3
4 5 6
1
2
6 5 4 3
GND-10
AB6 (YELLOW)
R79
B120
1 2 3 4 5
6 7 8 9 10
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 28
GG04-21I
WI-42
GROUND DISTRIBUTION
GND-10
GND-10
WIRING SYSTEM
WG : WAGON
SD : SEDAN
REAR GATE LATCH SWITCH

2
B
REAR DEFOGGER
B
D48
D46

B
1
REAR WIPER MOTOR

3
B
D43
R66
D39
HIGH-MOUNTED STOP
LIGHT (REAR SPOILER)
R60
1
D35
WG
R24
R39
GND-09
SD
D39
D46
R24
R66
1 2
1
2
1
2
2 1
D43
D35
1 2
3 4
GG04-21J
WI-43
GROUND DISTRIBUTION
WIRING SYSTEM
B: B135
C: B136
ENGINE
CONTROL
MODULE
DATA LINK CONNECTOR

BR 12
13
B40
BR C22
BR C21
BR
BW A8
*1
A27
BR
GND-11
A: B134
BG A7
GND-11
3. LHD SOHC W/O OBD ENGINE MODEL
TEST MODE CONNECTOR

BR
B76
VEHICLE SPEED SENSOR (MT)

BR 2
B17
NEUTRAL POSITION SWITCH (MT)

BR 2
B25
FRONT OXYGEN SENSOR
GW
B18
BW
B22
6
B37
E3
BR
14
BR
16
BR
13
BG
15 BW
BW
i2
COMBINATION METER
BR C8
C:
i12
E12
BR
GW
GW
IGNITION COIL & IGNITOR

GW 3
*1
: AT MODEL : B6
MT MODEL : B25
GE
B25 (BROWN)
1 2
B76 (GREEN)
1
2
B22 (BROWN)
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
(GRAY)
B17
E12
1 2 3
1 2 3 4
B40 (GRAY)
2 1
4 3
i2
6 7 8 9 10 11
1 2 3 4 5
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
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
B18
C:
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B: B135
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
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
GG04-21K
WI-44
GROUND DISTRIBUTION
WIRING SYSTEM
B: B135
C: B136
ENGINE
CONTROL
MODULE
DATA LINK CONNECTOR

GW 12
B40
GW C22
GW C21
BL A27
*1
GW
A7
BW A8
GW 13
GND-12
A: B134
BY
GND-12
4. RHD SOHC W/O OBD ENGINE MODEL
TEST MODE CONNECTOR

GW
B76

GW 2
B17

GW 2
B25
FRONT OXYGEN SENSOR
BW
BL
B37
BW 11
14
B18
B22
E3
BR
BY
BW
13
BY
15 BW
16 GW
BW
i2
COMBINATION METER
BW C8
i12

B
3
BR
BY
BW
C:
E12
*1
: AT MODEL : B6
MT MODEL : B25
GE
B25 (BROWN)
1 2
B76 (GREEN)
1
5
9
13
2
6
10
14
1 2 3
1
2
B22 (BROWN)
3
7
11
15
4
8
12
16
B17 (BLACK)
B40 (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
1 2 3 4
B: B135
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
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
i2
E12 (DARK GRAY)
B18
2 1
4 3
C:
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
C: B136
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
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
GG04-21L
WI-45
GROUND DISTRIBUTION
WIRING SYSTEM
C: B136
D: B137
E: B84
DATA LINK CONNECTOR

BR 12
ENGINE
CONTROL
MODULE
BR
13
E1
BR A15
C18
TEST MODE CONNECTOR
BR
A7
BR
D8
D9
BL
BL
BY
C8
B40
GND-13
A: B134
BW A22
BW C17
GND-13
5. LHD TURBO ENGINE MODEL
BR
B76
BR 2
B17
SMJ
GB
BW
6
14
BY
BR
BR
BL
BL
E3
B37
B99
R3
BW
B
B
BR
BR
BR
16
F60
BL
BL
N2
F1
BR
BL
A3
BY
BY
BW
BY
13
B128
B209
F76
15 BW
C3
J3 BW
NEUTRAL POSITION SWITCH

BR 3
i2
GB
COMBINATION METER
BW C8
C:
i12
R15
R57
BY
BR
BY
BY
BW
BR
BL
BL
FUEL PUMP ASSEMBLY

B
3
IGNITION COIL No.4
2
E34
E32
E33
E31
R58
IGNITION COIL No.2

IGNITION COIL No.3
IGNITION COIL No.1
BW 3
GE
E7
B76 (GREEN)
E7
(BLACK)
1 2 3
1
2
B17
E31
E32
B128
E33 (BLACK)
1 2
3 4
E34 (BLACK)
C:
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B40 (GRAY)
1
2
3
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B99
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
F60
1
5
9
13
2
6
10
14
3
7
11
15
(BROWN)
4
8
12
16
E: B84
1 2 3 4 5 6
7 8 9 10 11 12
16 17
13 14 15
R58 (GRAY)
1 2
3 4
5 6
A: B134
6 7
1 2 3 4 5
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
B: B135
C: B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
R15 (BLACK)
1
2
3 4 5 6
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
GG04-21M
WI-46
GROUND DISTRIBUTION
WIRING SYSTEM
C: B136
D: B137
E: B84
DATA LINK CONNECTOR

GW 12
ENGINE
CONTROL
MODULE
GW 13
GW E1
GW A15
C18
B
GW A7
BW D8
BW D9
BY
C8
B40
GND-14
A: B134
BW A22
BW C17
GND-14
6. RHD TURBO ENGINE MODEL
TEST MODE CONNECTOR

GW
B76
GW 2
B17
GW 3
BW
19 GW
B99
B37
BW 11
E3
GW
B22
BY
BR
14
16 GW
BW
BY
13
3
BR
BL
BL
15 BW
B128
R3
i2
GW
COMBINATION METER
BW C8
C:
i12
R15
R57
BY
BR
BY
BY
BW
BR
BL
BL
FUEL PUMP ASSEMBLY

B
3
IGNITION COIL No.4
2
E34
E32
E33
E31
R58
IGNITION COIL No.2

IGNITION COIL No.3
IGNITION COIL No.1
BW 3
GE
B76 (GREEN)
E7
(BLACK)
E7
1 2 3
1
2
E31
B17 (BLACK)
E32
B128 (GRAY)
E33 (BLACK)
1 2
3 4
E34 (BLACK)
C:
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
A: B134
1 2 3 4 5
6 7
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
B22 (BROWN)
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
C: B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
1
2
3
B40 (BLACK)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B135
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
WI-47
R15 (BLACK)
1
2
3 4 5 6
R58 (GRAY)
1 2
3 4
5 6
E: B84
B99
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
GG04-21N
GROUND DISTRIBUTION
WIRING SYSTEM
A: B134
B: B135
C: B136
ENGINE
CONTROL
MODULE
DATA LINK CONNECTOR

BR 12
: AT MODEL : B6
MT MODEL : B25
*1
BR
13
BR C22
BR C21
A27
B
BR
*1
BY A34
BY A35
BW A8
BG A7
B40
GND-15
GND-15
7. LHD SOHC MODEL
TEST MODE CONNECTOR

BR
B76
BR 2
B17
BR 2
B37
B99
R3
BR
E3
B22
GB
14
GW
BR
BW
BR
BR
16
BY
BG
13
8
BR
i2
COMBINATION METER
BR C8
GB
15 BW
B25
C:
i12
R15
R57
GW
GW
BR
BR
FUEL PUMP ASSEMBLY

B
3
R58

GW 3
GE
B25 (BROWN)
1 2
E12
B76 (GREEN)
1 2 3
1
2
B22 (BROWN)
1
5
9
13
2
6
10
14
3
7
11
15
B17
R15 (BLACK)
E12
1 2 3 4
1
2
3 4 5 6
B40 (GRAY)
B99
i2
4
8
12
16
1 2 3 4 5 6 7 8
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
9 10 11 12 13 14 15 16
C: B136
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
R58 (GRAY)
1 2
3 4
5 6
C:
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B: B135
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
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
WI-48
GG04-21O
GROUND DISTRIBUTION
WIRING SYSTEM
B: B135
ENGINE
CONTROL
MODULE
C: B136
*1
DATA LINK CONNECTOR

GW 12
: AT MODEL : B6
MT MODEL : B25
GW 13
GW C22
GW C21
BL A27
GW
*1
BR A35
BR A34
BW A8
A7
B40
GND-16
A: B134
BY
GND-16
8. RHD SOHC MODEL
TEST MODE CONNECTOR

GW
B76
GW 2
B17
BW 2
BW
B37
B99
BW 11
E3
19 GW
B22
BW
GW
14
BL
16 GW
BR
BR
BR
15 BW
B
13
BY
B25
R3
i2
BW
COMBINATION METER
BW C8
C:
i12
R15
R57
FUEL PUMP ASSEMBLY
B
3
R58
E12
GW
GW
BR
BR

GW 3
GE
B25 (BROWN)
1 2
B76 (GREEN)
2
6
10
14
3
7
11
15
4
8
12
16
R15 (BLACK)
E12
1 2 3
1
2
B22 (BROWN)
1
5
9
13
B17 (BLACK)
1 2 3 4
B40 (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
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
(GREEN)
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
A: B134
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
i12
B: B135
9 10 11 12 13 14 15 16
C: B136
C:
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2
3 4
5 6
B99
1 2 3 4 5 6 7 8
R58 (GRAY)
1 2
3 4
5 6
7 8
9 10 11 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
GG04-21P
GROUND DISTRIBUTION
WIRING SYSTEM
GND-17
BY A19
BL A10
BW B9
B8
TRANSMISSION CONTROL MODULE
C: B56
B18
B: B55
Lg B24
BL C19
BL A21
A: B54
GND-17
9. LHD MODEL (TRANSMISSION)
SHIELD JOINT
CONNECTOR
BY
LgB
SB
BL
L
SB
BW
B
SB
6
4
5
3
1
2
9
7
8
B
15
14
L
18
17
Lg
20 LgB
19
16
BL
B53
B11
VEHICLE
SPEED
SENSOR 1
(AWD)
T4
TORQUE
CONVERTER
TURBINE
SPEED
SENSOR
VEHICLE
SPEED
SENSOR 2
AT CONTROL (TRANSMISSION)
B11 (BLACK)
B53 (BLACK)
1 2 3 4 5 6 7 8 9 10 11 12
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
A: B54
1 2 3 4 5 6 7
10 11 12 13 14 15 16
22
19 20 21
B: B55 (GRAY)
8
17
23
9
18
24
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
C: B56 (GREEN)
9
18
24
1 2 3 4 5 6
10 11 12 13 14 15
19 20 21
7 8
16 17
22 23
9
18
24
GG04-21Q
WI-50
GROUND DISTRIBUTION
WIRING SYSTEM
GND-18
GrB A19
GrR A10
B9
Gr
B8
C: B56
LG
B: B55
YL B24
BW C19
BW A21
A: B54
W B18
GND-18
10.RHD MODEL (TRANSMISSION)
SHIELD JOINT
CONNECTOR
GrB
YG
SB
GrR
B
SB
Gr
LR
SB
9
7
8
6
4
5
3
1
2
LG
LR
15
14
W
17
18
YG
YL
19
20
16 BW
B53
B11
VEHICLE
SPEED
SENSOR 1
(AWD)
T4
TORQUE
CONVERTER
TURBINE
SPEED
SENSOR
VEHICLE
SPEED
SENSOR 2
AT CONTROL (TRANSMISSION)
B11 (BLACK)
B53 (BLACK)
1 2 3 4 5 6 7 8 9 10 11 12
1 2
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
B: B55 (GRAY)
7
16
22
8 9
17 18
23 24
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
C: B56 (GREEN)
9
18
24
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7 8 9
16 17 18
22 23 24
GG04-21R
WI-51
AIRBAG SYSTEM
WIRING SYSTEM
6. Airbag System
A: SCHEMATIC
WI-52
AIRBAG SYSTEM
WIRING SYSTEM
1. LHD MODEL
A:
A/B(L)-01
A/B(L)-01
i10
B:
i11
GB
GY
RW
FB-23
FB-22
FB-17
FB-36
F/B FUSE NO. 13 F/B FUSE NO. 11 F/B FUSE NO. 6 F/B FUSE NO. 18
(IG)
(IG)
(IG)
(IG)
COMBINATION
METER
AIRBAG
INDICATOR
LIGHT
A7 GOr
GOr
B18 GR
GR
i1
AIRBAG
CIRCUIT
A6
CHECK
CONNECTOR
GB 7
23 RW
B36
8
GR
24
i2
GR
B79
B37
DIAGNOSIS
CONNECTOR
L
1
TB :TURBO ENGINE MODEL
W
B82
DIAGNOSIS
TERMINAL
BR
BR
NA
TB
N2
BR
B81
B209
SMJ
GR
GY
BR
B31
5
AB1
E3
NA
E3
B22
2
F60
16
16
BR
F76
A:
B31 (YELLOW)
B82 (BLACK)
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
1
2
3 4 5 6
B36 (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
B22 (BROWN)
F60
2 3
9 10
REF. TO GND-02
B79 (GRAY)
1
8
AB6
GE
19
GR
GY
6
BR
TB
4 5
11 12
6 7
13 14
1
5
9
13
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
2
6
10
14
3
7
11
15
B:
(BROWN)
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
4
8
12
16
i11
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
GL86-21A
WI-53
AIRBAG SYSTEM
1
2
A/B(L)-02
FRONT SUB SENSOR RH
A/B(L)-02
FRONT SUB SENSOR LH
2
1
WIRING SYSTEM
W
G
G
WR
AB13
AB16
1
2
AB12
26
15
LY
Br
20 G
9 WR
LY
Br
AB11
BW 27
28
B
YL
YB
YL
YB
YR
YG
10
11
14
13
AB6
YL
YB
1
2
AB8
AB3
AB7 (YELLOW)
AB13 (YELLOW)
(YELLOW)
AB16 (YELLOW)
1 2
BW
1
2
AB9 (YELLOW)
GB-4
AB10
AB2
AB8
GB-5
AB9
2
1
AB7
YL
YB
YR
YG
STEERING
ROLL CONNECTOR

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
AB11 (YELLOW)
1 2
GL86-21B
WI-54
AIRBAG SYSTEM
INFLATOR
(SIDE LH)
AB19 (YELLOW)
AB23 (YELLOW)
AB21 (YELLOW)
AB28 (YELLOW)
AB24 (YELLOW)
AB26 (YELLOW)
2
3
5
6
YG
YB
AB18
AB26
1
2
AB24
1
2
1
2
3
4
AB28
AB20
ELR WITH
PRETENSIONER LH
YG
YB
2
1
YR
YL
YR
YL
Gr
Y
Lg
Br
W
L
G
B
AB23
1
2
3
4
1
2
AB19
1
2
Gr
Y
Lg
Br
W
L
G
B
YG
YB
AB17
YG
YB
YR
YL
YR
YL
AB21
12
10
9
7
7
9
10
12
5
6
2
1
A/B(L)-03
A/B(L)-03
WIRING SYSTEM
AB25
SIDE AIRBAG
SENSOR LH
SIDE AIRBAG
SENSOR RH
AB17 (YELLOW)
ELR WITH
PRETENSIONER RH
INFLATOR
(SIDE RH)
AB18 (YELLOW)
1 2 3 4 5 6
1 2 3 4 5 6
7 8 9 10 11 12
7 8 9 10 11 12
1 2
GL86-21C
WI-55
AIRBAG SYSTEM
WIRING SYSTEM
2. RHD MODEL
FB-17
F/B FUSE NO. 18
(IG)
GW
Or
GB
GW
MT
B36
B:
4
i3
COMBINATION
METER
i11
GW
GW 22
B38
i10
A/B(R)-01
FB-23
F/B FUSE NO. 6
(IG)
GW
AT
AT
i1
MT
A7 GW
AIRBAG
INDICATOR
LIGHT
CHECK
CONNECTOR
GB 7
AIRBAG
CIRCUIT
B18 LgR
A6
LgR 10
LgR
21
i2
LgR
B79
B37
DIAGNOSIS
CONNECTOR
L
1
V
2
B82
DIAGNOSIS
TERMINAL
B
B
B31
3
Or
LgR
R
6
B81
Lg
RY
Or
19
AB6
LR
AB1
A:
FB-22
F/B FUSE NO. 11
(IG)
R
A/B(R)-01

FB-36
F/B FUSE NO. 13
(IG)
REF. TO GND-07
A:
B31 (YELLOW)
B82 (BLACK)
i10
(GREEN)
B79 (GRAY)
1 2 3 4 5 6 7 8 9 10
1
8
1
2
3 4 5 6
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
B:
i11
2 3
9 10
4 5
11 12
i1
(BLACK)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
6 7
13 14
(GREEN)
i3
(BLACK)
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
i2
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
GR86-21A
WI-56
AIRBAG SYSTEM
1
2
A/B(R)-02
FRONT SUB SENSOR RH
A/B(R)-02
FRONT SUB SENSOR LH
1
2
WIRING SYSTEM
AB13
G
W
G
W
L
Br
AB16
2
1
AB15
20
9
26
15
G
W
L
Br
G
W
AB14
27
BY
28
B
YL
YB
YL
YB
YR
YG
10
11
14
13
AB6
YL
YB
1
2
AB8
AB3
AB7 (YELLOW)
AB13 (YELLOW)
AB8 (YELLOW)
AB16 (YELLOW)
AB14 (YELLOW)
BY
1
2
1 2
GB-4
AB10
AB2
AB9 (YELLOW)
GB-5
AB9
2
1
AB7
YL
YB
YR
YG
STEERING
ROLL CONNECTOR

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
1 2
GR86-21B
WI-57
AIRBAG SYSTEM
AB28
INFLATOR
(SIDE LH)
AB19 (YELLOW)
AB23 (YELLOW)
AB21 (YELLOW)
AB28 (YELLOW)
AB24 (YELLOW)
AB26 (YELLOW)
2
3
YR
YL
A/B(R)-03
YR
YL
1
2
1
2
1
2
3
4
AB18
AB26
AB24
AB20
ELR WITH
PRETENSIONER LH
5
6
2
1
YG
YB
YG
YB
W
L
G
B
W
L
G
B
AB23
1
2
3
4
1
2
AB19
1
2
W
L
G
B
W
L
G
B
YG
YB
AB17
YG
YB
YR
YL
AB21
12
10
9
7
7
9
10
12
5
6
2
1
YR
YL
A/B(R)-03
WIRING SYSTEM
AB25
SIDE AIRBAG
SENSOR LH
ELR WITH
PRETENSIONER RH
SIDE AIRBAG
SENSOR RH
AB17 (YELLOW)
INFLATOR
(SIDE RH)
AB18 (YELLOW)
1 2 3 4 5 6
1 2 3 4 5 6
7 8 9 10 11 12
7 8 9 10 11 12
1 2
GR86-21C
WI-58
AIR CONDITIONING SYSTEM

WIRING SYSTEM
7. Air Conditioning System

A: SCHEMATIC
WI-59

WIRING SYSTEM
EVAPORATION
THERMO SWITCH
A/C(MLH)-01
A/C(MLH)-01
1. MANUAL A/C LHD MODEL
NA
1
BW
3
BrY
TB
LY
GOr
FB-19
F/B FUSE NO.17
(IG)
B88
AIR CONDITIONING
RELAY
10 GOr
11 BrY
12
Br
BrY 16
Br
BrY
15
F45
A/C(MLH)-02
A/C(MLH)-02
Br
B62
F31
NA
TB
NA
TB
A: B134
D: B137
PRESSURE
SWITCH
C30 GR
B27 LY
A17 Br
LY
D27 Br
1
THERMAL
PROTECTOR
A6
F79
F24
MAGNET
CLUTCH
A9 GR
BrY
GOr
1
NA
TB
A: B134 ENGINE
CONTROL
B: B135 MODULE
(NON-TURBO
C: B136 ENGINE MODEL)
ENGINE
CONTROL
MODULE
(TURBO ENGINE
MODEL)
COMPRESSOR
F79
1 2
(GRAY)
F24
B88 (BROWN)
(GRAY)
1 2
3 4
1 2 3
C: B136 : NA
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
A: B134 : TB
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 21 22 23 24
D: B137 : TB
F31
1
F45
5 6 9 13 14 17 21 22 25
15
18
26
7
10
23
8 11 12 16 19 20 24 27 28
29
30
1 2
3 4 5 6 7 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 : NA
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
A: B134 : NA
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
GL45-20A
WI-60

A/C(MLH)-02
A/C(MLH)-02
WIRING SYSTEM
FB-20
F/B FUSE NO.17
(IG)
FB-34
F/B FUSE NO.1
(IG) NO.2
GOr
RW
BLOWER FAN
MOTOR RELAY
A/C(MLH)-01 A
RW
GOr
GR
BR
B50
BLOWER FAN MOTOR
BR
BY
B87
BLOWER FAN RESISTOR
A/C(MLH)-01 B
YB
RY
BW
REF. TO ILM(L)-01
B86
BLOWER FAN SWITCH
B168
BW
RY
YB
BY
GR
B169
10 GOr
GR
BW
9
OrW
V
5
BY
ILLUMINATION
LIGHT
REF. TO GND-03
AIR CONDITIONING SWITCH

B87
B50
1
2
1 2
3 4
B86 (BROWN)
1 2 3 4
B169
1 2 3
4 5 6
B168
1 2
3 4
5 6 7 8 9 10
GL45-20B
WI-61

WIRING SYSTEM
A/C(MRH)-01
A\C(MRH)-01
2. MANUAL A/C RHD MODEL

EVAPORATION
THERMO SWITCH
1
BW
3
BrY
PB
GOr
FB-19
F/B FUSE NO.17
(IG)
B88
AIR CONDITIONING
RELAY
10 GOr
12 BrY
11
Br
BrY
BrY
Br
16
BrR
F45
A/C(MRH)-02
A/C(MRH)-02
B62
(GRAY)
1 2
F24
(GRAY)
1 2 3
C30 GR
ENGINE
B: B135 CONTROL
MODULE
C: B136
PRESSURE
SWITCH
B88 (BROWN)
B: B135
F45
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
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
1 2
3 4
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
B27 PB
GOr
A: B134
THERMAL
PROTECTOR
COMPRESSOR
F79
F79
A17 BrR
MAGNET
CLUTCH
F24
Lg
Lg
BrY
F31
A: B134
F31
1
5 6 9 13 14 17 21 22 25
7
10
15
18
23
26
8 11 12 16 19 20 24 27 28
29
30
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
GR45-20A
WI-62

A/C(MRH)-02
A/C(MRH)-02
WIRING SYSTEM
FB-20
F/B FUSE NO.17
(IG)
FB-34
F/B FUSE NO.1
(IG) NO.2
GOr
RW
BLOWER FAN
MOTOR RELAY
A/C(MRH)-01
RW
GOr
GR
BR
B50
BLOWER FAN MOTOR
BR
BW
B87
BLOWER FAN RESISTOR
BW
1
4
RY
BLOWER FAN SWITCH
GOr
B168
RY
BW
YB
BW
GR
B169
GR
BW
YB
BW
B86
REF. TO ILM(ROI)-01
REF. TO ILM(RWI)-01
A/C(MRH)-01
ILLUMINATION
LIGHT
REF. TO GND-08
AIR CONDITIONING SWITCH

B87
B50
1
2
1 2
3 4
B86 (BROWN)
1 2 3 4
B169
1 2 3
4 5 6
B168
1 2
3 4
5 6 7 8 9 10
GR45-20B
WI-63

WIRING SYSTEM
A/C(ALH)-01
A/C(ALH)-01
3. AUTO A/C LHD MODEL
FB-34
F/B FUSE NO. 1 (B)
F/B FUSE NO. 2 (B)
RW
GOr
FB-20
F/B FUSE NO. 17
(IG)
GOr

FB-19
F/B FUSE NO. 17
(IG)
TB
TB
NA
NA
BLOWER MOTOR
RELAY
AIR
CONDITIONING
RELAY
RW
10 GOr
11 BrY
BrY 16
Br
12
Br
GR
BR
BrY
15
Br
B50
L
F45
F31
BLOWER MOTOR
A: B134
D: B137
PRESSURE SWITCH
2
B62
ENGINE
CONTROL
MODULE
(TURBO
ENGINE
MODEL)
A9 GR
A6
BR
BY
B87
LY
D27 Br
TB
NA
GOr
BrY
B: B135
RL
FAN
B275 CONTROL
AMP
NA
MAGNET
CLUTCH
A: B282
B: B283
A16 RL
B11 BY
B14 GR
A8 GOr
B4
LY
F24
B3 BrY
NA
BY
GOr
1
C: B136
ENGINE
CONTROL
A17 Br
MODULE
B27 LY
(NON-TURBO
ENGINE
C30 GR
MODEL)
TB
A: B134
TB
Y
F79
AUTO A/C
CONTROL MODULE
REF. TO GND-03
COMPRESSOR
B87
F79
1
2
1 2
(GRAY)
F24
1 2 3
A: B134 : TB
6 7
1 2 3 4 5
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
(GRAY)
B275
1 2
3 4
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
5 6 9 13 14 17 21 22 25
7
10
15
18
23
26
8 11 12 16 19 20 24 27 28
A: B282 (GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B135 : NA
F45
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
29
30
B: B283 (GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
C: B136 : NA
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
26 27
28 29 30
A: B134 : NA
D: B137 : TB
F31
1
B50
1 2
3 4 5 6 7 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
GL46-21A
WI-64
LR
YG
GB
B17
AT
GB
GY C17
LR
C: B56
TRANSMISSION
CONTROL
MODULE (AT)
FB-17
F/B FUSE NO. 18
(IG)
GY
FB-27
F/B FUSE NO. 9
(ACC)
FB-9
F/B FUSE NO. 2
(B)
FB-8
M/B FUSE NO. 2
(B)
A/C(ALH)-02
VEHICLE SPEED
SENSOR (MT)
BR
A/C(ALH)-02
WIRING SYSTEM
MT
B209
SMJ
16
F60
E3
B22
E3
NA
BR
16
BR
BR
F76
BR
BR
N2
BR
NA
TB
TB
TB
NA
NA
BR
REF. TO ILM(L)-01
REF. TO R/DEF(L)-01
TB
B19 GY
B1
YG
LR
B20
B2
B10
R
A13
A14 RL
GE
A: B282
B17 : NA
1 2 3
B17 : TB
B22 (BROWN)
1 2
3 4
F60
1
5
9
13
2
6
10
14
3
7
11
15
(BROWN)
4
8
12
16
B: B283
B: B283 (GRAY)
A: B282 (GRAY)
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
C: B56 (GREEN)
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7 8
16 17
22 23
9
18
24
GL46-21B
WI-65
BP
A/C(ALH)-03
YB A11
12
22
YB
i1
YB
BP
B8
BL
R
BL
B36
I/F
I/F
i51
B256
2
F78
B12 YB
BL B17
BL
2
GR
BL
BL
BL
BP
BP
F45
GR
B62
B11 BP
GR B16
BL
BL
BP
GR
B7
B: B283
BP
B9
A: B282
21
A/C(ALH)-03
WIRING SYSTEM
-COM
LCD(OUT TEMP)
AMBIENT SENSOR
A: B282 (GRAY)
B256
F78
(BLACK)
i51
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
EVAPORATION
THERMO SWITCH
SUNLOAD
SENSOR
B: B283 (GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
F45
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
B:
i11
COMBINATION
METER
B36 (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
1 2
B:
i11
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
GL46-21C
WI-66

A/C(ALH)-04
RY A12
LW B6
A4
B12
GY B5
WG B15
B: B283
BL A15
A: B282
LgR A7
A/C(ALH)-04
WIRING SYSTEM
WG
J1 WG
NA
TB
B209
SMJ
F76
AIR MIX
ACTUATOR
MODE ACTUATOR
GY
LW
RY
E2
15 WG
WG
B21
F61
B77
B293
E2
NA
WG
10 WG
WG
TB
B293
1
2
3
E8
1 2
3
(LIGHT GRAY)
FRESH/RECIRC
ACTUATOR
B91 (BLACK)
1
2
3 4 5 6
BL
B77
B91
REF. TO GND-02
REF. TO GND-02
THERMOMETER
LgR
E8
A: B282 (GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B283 (GRAY)
F61
(BLACK)
B21 (LIGHT GRAY)
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
11 12
9 10
14 15
13
16
19 20
17 18
5
GL46-21D
WI-67

WIRING SYSTEM
A/C(ARH)-01
A/C(ARH)-01
4. AUTO A/C RHD MODEL
FB-34
F/B FUSE NO. 1 (B)
F/B FUSE NO. 2 (B)
RW
GOr
FB-20
F/B FUSE NO. 17
(IG)
GOr

FB-19
F/B FUSE NO. 17
(IG)
TB
TB
NA
NA
BLOWER MOTOR
RELAY
AIR
CONDITIONING
RELAY
10 GOr
12 BrY
Br
Br
16
BrY
BrR
GR
BR
B50
F45
F31
B62
BLOWER MOTOR
ENGINE
CONTROL
MODULE
(TURBO
ENGINE
MODEL)
A: B134
D: B137
PRESSURE SWITCH
2
2
1
A9 GR
A6
1
2
B87
PB
D27 BrR
BR
BW
TB
NA
11
BrY
RW
GOr
GOr
B: B135
NA
BW
RL
FAN
B275 CONTROL
AMP
NA
Lg
BrY
C: B136
ENGINE
CONTROL
A17 BrR
MODULE
B27 PB
(NON-TURBO
ENGINE
C30 GR
MODEL)
TB
A: B134
TB
Lg
F79
A: B282
B: B283
A16 RL
B11 BW
B14 GR
A8 GOr
MAGNET
CLUTCH
B3 BrY
B4
PB
F24
AUTO A/C
CONTROL MODULE
REF. TO GND-08
COMPRESSOR
B87
F79
1
2
1 2
(GRAY)
A: B134 : TB
6 7
1 2 3 4 5
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
D: B137 : TB
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
29 30 31
22 23 24 25 26
27 28
F24
1 2 3
(GRAY)
B50
B275
1 2
3 4
1 2
3 4
A: B282 (GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B135 : NA
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
B: B283 (GRAY)
F45
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
C: B136 : NA
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
26 27
28 29 30
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
F31
5 6 9 13 14 17 21 22 25
15
18
26
7
10
23
8 11 12 16 19 20 24 27 28
29
30
A: B134 : NA
1 2
3 4
5 6
7 8
9 10 11 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-68
GR46-21A
B17
A/C(ARH)-02
AT
GB
GY C17
GB
C: B56
TRANSMISSION
CONTROL
MODULE (AT)
1
YG
VEHICLE SPEED
SENSOR (MT)
GY
FB-17
F/B FUSE NO. 18
(IG)
FB-27
F/B FUSE NO. 9
(ACC)
MB-10
M/B FUSE NO. 2
(B)
LR
GW
A/C(ARH)-02
WIRING SYSTEM
BR
16 GW
MT
E3
: WITH ILLUMINATION CONTROL

MODEL : YL
: WITHOUT ILLUMINATION CONTROL
MODEL : B
REF. TO ILM(ROI)-01
ILM(RWI)-01
REF. TO R/DEF(R)-01
*1
B22
BR
LR
B1
B19 GY
YG
1
B20
B2
V
B10
R
A13
A14 RL
GE
A: B282
B17 (BLACK) : NA
B17 (BLACK) : TB
1 2
3 4
1 2 3
B: B283
B22 (BROWN)
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
A: B282 (GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B283
(GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
C: B56 (GREEN)
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7 8
16 17
22 23
9
18
24
GR46-21B
WI-69
24
23
B11 Or
B8
B12 W
YB
I/F
I/F
i51
1
B256
2
F78
Or
i2
YB
YB
26
GR
YB
F45
GR
25
B37
14
Or
YB
Or
YB
13
B62
A/C(ARH)-03
W A11
W
YB B17
Or
GR B16
YB
B7
B: B283
YB
Or
Or
B9
A: B282
GR
A/C(ARH)-03
WIRING SYSTEM
-COM
LCD(OUT TEMP)
AMBIENT SENSOR
F78
(BLACK)
B256
A: B282 (GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
i51
SUNLOAD
SENSOR
EVAPORATION
THERMO SWITCH
B: B283 (GRAY)
F45
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
B:
i11
COMBINATION
METER
B:
i11
(GREEN)
1 2 3 4 5 6 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
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
GR46-21C
WI-70

A/C(ARH)-04
RY A12
B12
B
LW B6
A4
L
WG B15
GY B5
B: B283
BL A15
A: B282
LgR A7
A/C(ARH)-04
WIRING SYSTEM
E2
15 WG
B21
WG
WG
10 WG
NA
TB
AIR MIX
ACTUATOR
B21
MODE ACTUATOR
GY
LW
RY
E2
B77
NA
B293
LgR
BL
NA
B91
TB
WG
TB
E8
FRESH/RECIRC
ACTUATOR
REF. TO GND-07
THERMOMETER
B77
B293
1
2
3
E8
1 2
3
(LIGHT GRAY)
B91 (BLACK)
1
2
3 4 5 6
A: B282 (GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B283 (GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B21
1 2
TB
: (BLACK)
NA
: (LIGHT GRAY)
3 4
6 7
8
11 12
9 10
14 15
13
16
19 20
17 18
5
GR46-21D
WI-71
ANTI-LOCK BRAKE SYSTEM

WIRING SYSTEM
8. Anti-lock Brake System

A: SCHEMATIC
WI-72

WIRING SYSTEM
ABS(L)-01
ABS(L)-01
1. LHD MODEL
SBF-8
SBF HOLDER
(B)
MB-13
SBF-4
(B)
FB-17
F/B FUSE NO. 18
(IG)
FB-36
F/B FUSE NO. 13
(IG)
FB-31
F/B FUSE NO.16
(B)
RY
WR
GB
RW
LY

FB-32
F/B FUSE NO. 8
(B)
WR
23
B36
A7 GOr
B108
W
B61
WR
i1
F46
F44
STOP LIGHT
SWITCH
LY
WB
RELAY HOLDER
COMBINATION
METER
10A
PARKING
BRAKE
WARNING
LIGHT
RY B19
B225
ABS RELAY
WB
GB
B
LR
2
LgY
4
Lg
i2
B37
WB
22 LgY
B301
2
21
Lg
LR
REF. TO GND-03
26
25 WR
1
2
B304
REF. TO GND-02
RY
ABS CONDENSER
i11
A ABS(L)-02
B264
24
B64
i10
WB
B
1
3
RY
ABS
INDICATOR A:
LIGHT
B:
WB
LgY B3
LgY
2
1
PUMP
MOTOR
1 2
F46
RL INLET
RL OUTLET
FR INLET
FR OUTLET
RR INLET
B64 (BLACK)
RR OUTLET
VALVE RELAY
FL OUTLET
SOLENOID
VALVE
FL INLET
ABS CONTROL MODULE
A:
i10
B302
ABS
MOTOR
GROUND
MOTOR RELAY
(BLACK)
B304 (BLACK)
1
2
B264 (RED)
1 2
3 4
B36 (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
F44
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
1 2 3 4
5 6 7 8
B:
i2
(GREEN)
i11
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
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 25 26
27 28 29 30 31
B225
1
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY HOLDER
GL82-21A
WI-73
DIAGNOSIS
CONNECTOR
F44
2
DIAGNOSIS
CONNECTOR
B81
BR
B82
BR
BR
YG
WR
3
6
LW B21
NA : NON-TURBO ENGINE
MODEL
BR
B: B55
ABS(L)-01

MB-9
SBF-5
(B)
TRANSMISSION
CONTROL
MODULE
ABS(L)-02
ABS(L)-02
WIRING SYSTEM
B61
CHECK
CONNECTOR
GB 7
BrW
LgR 10
B
B79
DATA LINK
CONNECTOR
BR 1
REF. TO GND-02
BrW
LgR
BR
12
BR
13
B40
B209
SMJ
B22
F60
E3
NA
E3
16
BR
B301
BR
F76
16
20 LgR
3
31
LW
LW
29 YG
4 WR
BrW
N2
BR
NA
TB
ABS CONTROL MODULE

BR
TB
GE
B82 (BLACK)
1
2
3 4 5 6
1 2 3 4
5 6 7 8
B: B55 (GRAY)
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
B79 (GRAY)
F44
7 8 9
16 17 18
22 23 24
B40 (GRAY)
B22 (BROWN)
F60
1
8
2 3 4 5
9 10 11 12
(BROWN)
1 2 3 4 5 6 7 8
6 7
13 14
9 10 11 12 13 14 15 16
B301
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
GL82-21B
WI-74
ABS(L)-03
ABS(L)-03
WIRING SYSTEM
SB
SB
SB
SB
SB
BW
L
G
BW 23
30
6
28
SHIELD JOINT
CONNECTOR
R
W
B
14
15
7
8
B
W
L
G
W
B
9
10
11
12
ABS CONTROL MODULE
B301
SB
FRONT
ABS
SENSOR RH
REAR
ABS
SENSOR LH
REAR
ABS
SENSOR RH
B15 (GRAY)
R72
B292
B198
(GRAY)
R73
1 2 3
1 2 3 4 5
F94
BW
R
W
B
1
2
3
2
1
FRONT
ABS
SENSOR LH
B292
B198
4
9
10
23
SB
L
G
SB
L
G
R3
R72
2
1
R73
1
2
B15
1
2
F94
B99
L
G
L
G
B
W
B
W
SB
W
B
W
B
F45
16
4
5
20
24
B62
SB
B
W
SB
W
B
B303
ABS
G SENSOR
REF. TO GND-03
B303 (GRAY)
1 2 3 4
5 6 7 8
1 2
2 1
B99
F45
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
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 25 26
27 28 29 30 31
GL82-21C
WI-75

WIRING SYSTEM
ABS(R)-01
ABS(R)-01
2. RHD MODEL
FB-36
F/B FUSE NO.13
(IG)
GB
GW
SBF-8
SBF HOLDER
(B)
FB-31
F/B FUSE NO.16
(B)
LY
FB-17
F/B FUSE NO.18
(IG)
WR
MB-13
SBF-4
(B)
RY

FB-32
F/B FUSE NO.8
(B)
AT
MT
STOP LIGHT
SWITCH
B36
4
22
B38
i3
i1
LY
WB
AT
RELAY HOLDER
10A
W
WB
B64 : OC
MT
B65 : WC
ABS
INDICATOR
A:
LIGHT
B19
P
WB
GB
B
LR
i11
WR
ABS(R)-02
ABS(R)-02
B61
B37
4
LgY
LR
B264
F44
B200
ABS CONDENSER
20
i2
2
1
3
4
i10
B:
ABS RELAY
B255
WB
PARKING
BRAKE
WARNING
LIGHT
WR
COMBINATION
METER
LgY B3
WC : WITH CRUISE
CONTROL MODEL
OC : WITHOUT CRUISE
CONTROL MODEL
F96
B225
WR
A7 GW
3
4
OC WC
1
2
2
3
F74
WB
B
1
2
F97
WB
25 WR
22 LgY
F49
2
21
LR
1
26
24
F49
RY
REF. TO GND-07
VALVE RELAY
B64 (BLACK)
F97
(BLACK)
1
2
1 2
i3
(BLACK)
F74 (BLACK)
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
RR
OUTLET
RR
INLET
RL
OUTLET
RL
INLET
FR
OUTLET
FR
INLET
FL
OUTLET
SOLENOID
VALVE
FL
INLET
ABS CONTROL MODULE
REF. TO GND-06
MOTOR RELAY
B264 (PINK)
1 2
3 4
1 2
3 4
i11
A:
F44
1 2 3 4
5 6 7 8
(GREEN)
(GREEN)
i1
(BLACK)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B225
(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
i10
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
F49
F73
ABS MOTOR GROUND
B65 (BLACK)
B:
PUMP
MOTOR
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
WI-76
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
GR82-21A
ABS(R)-02
ABS(R)-02
WIRING SYSTEM
BR
MB-9
SBF-5
(B)
ABS(R)-01
CHECK
CONNECTOR
GB 7
BrW
LgR 10
B
B: B55
DIAGNOSIS
CONNECTOR
B82
B81
B
B
YR
WL
3
6
DIAGNOSIS
CONNECTOR
REF. TO GND-07
ABS(R)-01
B79
WB B12
LW B21
TRANSMISSION
CONTROL
MODULE
DATA LINK
CONNECTOR
BR 1
BrW
LgR
GW 12
REF. TO GND-07
BrW
LgR
21
18
19
LW
YR
WL
GW 13
B40
B200
16 GW
20 LgR
29
4
3
31
LW
LW
YR
WL
BrW
F74
F49
B22
E3
BR
ABS CONTROL MODULE
GE
B82 (BLACK)
B79 (GRAY)
1
2
3 4 5 6
1
8
F74
(BLACK)
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
2 3 4 5
9 10 11 12
B40 (BLACK)
1
5
9
13
1 2 3 4 5 6 7 8
6 7
13 14
9 10 11 12 13 14 15 16
B: B55 (GRAY)
1 2 3 4
10 11 12 13
19 20 21
B22 (BROWN)
5 6
14 15
7 8 9
16 17 18
22 23 24
F49
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
GR82-21B
WI-77
ABS(R)-03
ABS(R)-03
WIRING SYSTEM
23
SHIELD JOINT
CONNECTOR
SB
F49
B
GR 30
GY 6
GOr 28
14
15
7
8
YG
YL
LG
LR
11
12
L
G
Lg
BY
9
10
ABS CONTROL MODULE
SB
SB
SB
SB
SB
5 GR
4 GY
15 GOr
14
SB
SB
GR
GY
GOr
SB
B200
B99
22
SB
11
LG
LR
LG
LR
20
21
LG
LR
13
12
SB
1
SB
SB
10
YG
YL
SB
LG
LR
LG
LR
SB
2
1
FRONT
ABS
SENSOR LH
FRONT
ABS
SENSOR RH
REAR
ABS
SENSOR LH
REAR
ABS
SENSOR RH
B292
ABS
G SENSOR
REF. TO GND-06
(GRAY)
F94
(GRAY)
R72
B292
F62
F95
(GRAY)
R73
1 2 3
1 2 3 4
5 6 7 8
1 2
2 1
F49
1
2
3
2
1
R72
1
2
R73
GR
GY
GOr
F95
1
2
F94
F74
R3
YG
YL
L
G
Lg
BY
YG
YL
8
9
YG
YL
3
2
YG
YL
F62
F74
(BLACK)
B99
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
(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
GR82-21C
WI-78
A/T CONTROL SYSTEM

WIRING SYSTEM
9. A/T Control System

A: SCHEMATIC
WI-79
A/T CONTROL SYSTEM

WIRING SYSTEM
1. LHD MODEL
AT(L)-01
AT(L)-01
RW
FB-36
F/B FUSE NO.13
(IG)
A
B
C
DIMMER CIRCUIT
AT(L)-02
AT(L)-02
C5
LB
C4
RB C10
YB
W C11
Lg C12
RL C13
GR C14
GOr A7
C3
PL
AT(L)-02
REF. TO ILM(L)-02
COMBINATION
METER
A:
i10
C:
i12
16
LB
LB
B7
15
YB
YB
B36
B6
14
RB
18
W
19
Lg
B14 Lg
3
RL
RL
B3
4
GR
B1 GR
RW 23
i1
INHIBITOR SWITCH
P
1
9
GR
LW
RL
10
LG
Lg
11
BY
RB
YB
LB
LB
T3
B12
B: B55
B5
B4
RB
T7
REF. TO GND-02
A:
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
T7
1 2 3 4 5 6
7 8 9 10 11 12
B12
1 2 3 4
5 6 7 8
9 10 11 12
C:
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B36 (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
B: B55 (GRAY)
1 2 3 4 5 6
10 11 12 13 14 15
19 20 21
7 8 9
16 17 18
22 23 24
GL41-21A
WI-80
A/T CONTROL SYSTEM

WIRING SYSTEM
AT(L)-02
AT(L)-01
AT(L)-02
A
B
AT(L)-01
I/F
DIMMER CIRCUIT
COMBINATION
METER
CUSTOM
CPU
i10
B:
i11
B5
YG
GB A2
B4
YR
A6
AT OIL
TEMP
B15
G
FWD
HOLD
B16
P
AT(L)-01
POWER
I/F
A:
REF. TO ILM(L)-01
24
13
i2
B37
POWER MODE AND

SNOW
POWER OFF
HOLD
GY
RL
B36
YG
i1
BrB
B133
KICKDOWN
SWITCH
GW
B: B55
B11 GW
B23 BrB
RL
C2
C17 GY
G
B16
C: B56
C10 YG
P
C11
B129

REF. TO GND-02
B129 (BLACK)
1
2
1 2 3
4 5 6
5 6
14 15
7
16
22
8
17
23
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
9
18
24
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
B36 (BLACK)
i2
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: B56 (GREEN)
B: B55 (GRAY)
1 2 3 4
10 11 12 13
19 20 21
A:
B133 (BLUE)
B:
i11
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
GL41-21B
WI-81
A/T CONTROL SYSTEM

WIRING SYSTEM
AT(L)-03
BR
BR
GR
YR
F45
F44
B62
BR
YR
21
YR
LY
FB-17
F/B FUSE NO.18
(IG)
MB-9
SBF-5
(B)
GB
AT(L)-03

MB-7
FB-21
FB-31
F/B FUSE NO.16 M/B FUSE NO.4 F/B FUSE NO.11
(B)
(IG)
(B)
B61
CHECK
CONNECTOR
GB 7
STOP LIGHT
SWITCH
2
1
GrB 12
LY
WB
B64
B79
DATA LINK
CONNECTOR
BR 1
GrB 10
BR
12
BR
13
BW
B40
LINE END CHECK

CONNECTOR
BW 4
NA : NON-TURBO ENGINE
MODEL
LW
16
BR
B300
B22
B64 (BLACK)
1 2
1 2 3 4 5 6
10 11 12 13 14 15
19 20 21
1 2 3
4 5 6
1 2 3 4
5 6 7 8
8 9
17 18
23 24
C24 LW
C15 GrB
A23 GR
A24 GR
C1
F44
GE
1 2 3 4 5 6 7
10 11 12 13 14 15 16
19 20 21
22
B22 (BROWN)
B79 (GRAY)
B40
4 5 6
11 12 13 14
1 2 3 4 5 6 7 8
F60
1
8
2 73
9 10
8 9
17 18
23 24
1 2 3 4
10 11 12 13
19 20 21
1
5
9
13
9 10 11 12 13 14 15 16
C: B56 (GREEN)
B: B55 (GRAY)
7
16
22
REF. TO GND-02
C: B56 TRANSMISSION CONTROL MODULE
B300
A: B54
BR
B: B55
A: B54
YR
B12 WB
E3
5 6
14 15
7
16
22
8
17
23
9
18
24
2
6
10
14
3
7
11
15
(BROWN)
4
8
12
16
F45
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
GL41-21C
WI-82
A/T CONTROL SYSTEM

WIRING SYSTEM
AT(L)-04
3
31
LW
LW
F67
WO
C15
A30
B17
B16
A31
C11
B4
B122
30
29
B301
C: B136
ABS
CONTROL
MODULE
BR
B
B: B135
FWD SWITCH (AWD)

ENGINE
CONTROL
MODULE
Sb
G
PG
RY
YR
GW
BrR
BY
RG
YR
WR
BR
E13
A: B134
RG C16
Lg C17
WO OO
3
4
1
1
SHIELD AND SENSOR

GROUND JOINT
CONNECTOR
4
3
2
AT(L)-04
THROTTLE
POSITION SENSOR
B21
Sb
Lg
BY
12
11
9
E2
WO
REF. TO GND-01
WO : WITH OBD
BR
OO : WITHOUT OBD
B62
A: B54
E13 (DARK BROWN)
1 2 3
4 5 6
5 6
14 15
7
16
22
8
17
23
9
18
24
A: B54
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
B: B55 (GRAY)
7
16
22
8 9
17 18
23 24
B: B135
F45
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 BR
Sb
G
PG
RY
YR
GW
BrR
A2
B17
C14
C5
B10
A1
C21
B21 LW
Lg
C: B56 (GREEN)
1 2 3 4
10 11 12 13
19 20 21
C: B56
B21 (LIGHT GRAY)
B122
1 2 3 4
B: B55
A3
WO
BR
17
F45
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
24 25 26
22 23
20 21
27 28
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
C: B136
1 2 3
6 7
4 5
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
28 29 30
26 27
F67
B301
1
5 6 9 13 14 17 21 22 25
29
15
18
26
7
10
23
8 11 12 16 19 20 24 27 28 30
1 2 3 4 5 6 7 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
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
GL41-21D
WI-83
A/T CONTROL SYSTEM
SHIELD
JOINT
CONNECTOR
BY
LgB
SB
BL
L
SB
BW
B
SB
AT(L)-05
BY A19
BL A10
BW B9
B8
B18
G
A11
L
LR A22
WR A20
Lg B24
C: B56
RW A5
A9
A7
B: B55
LOr A15
Or A18
RY
BL C19
WG A6
BL A21
A: B54
LgR A16
AT(L)-05
WIRING SYSTEM
6
4
5
3
1
2
9
7
8
2 1
1 2
B
15
ATF TEMPERATURE
SENSOR
SHIFT
SOLENOID 1
SHIFT
SOLENOID 2
2-4 B TIMING
SOLENOID
L/C TIMING
SOLENOID
AT1
1
AT4 (BROWN)
AT5
VEHICLE SPEED SENSOR 2
AT6
Or
Or
AT8
VEHICLE SPEED SENSOR 1 (AWD)
AT9
Gr
Gr
AT2
LINE PRESSURE
SOLENOID
LOCK-UP
SOLENOID
2-4 B SOLENOID
AWD SOLENOID
AT1 (GRAY)
14
17
18
Lg
20 LgB
19
L
11
12 WR
LR
RW
2
LgR
4
LOr
3
G
5
RY
Or
9
13
L
YR
WG
6
Br
R
AT3
AT7
B11
T4
AT4
Br
YR
BW
16
BL
B53
B11 (BLACK)
B53 (BLACK)
1 2 3 4 5 6 7 8 9 10 11 12
1 2
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
C: B56 (GREEN)
B: B55 (GRAY)
7 8 9
16 17 18
22 23 24
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
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
GL41-21E
WI-84
A/T CONTROL SYSTEM

WIRING SYSTEM
2. RHD MODEL
AT(R)-01
AT(R)-01
GW
FB-36
F/B FUSE NO.13
(IG)
A
B
C
DIMMER CIRCUIT
C4
Or
LW
RL
10
LG
*1
11
BY
RB
YL
LB
LB
T3
C5
LB
C:
i12
: TURBO ENGINE MODEL : GyL

: NON-TURBO ENGINE
MODEL : GrL
B12
B: B55
YL
LB
B6
B7
RB
B5
P
B14
*1
RL
B3
B4
Or
B1
T7
i10
LB
YL
1
9
A:
6
RB
*1
8
P
9
RL
*1
2
COMBINATION
METER
B38
INHIBITOR SWITCH
P
AT(R)-02
YL
RB C10
GrL C11
C12
P
RL C13
Or C14
10
22
GW
AT(R)-02
i3
Or
GW A7
C3
V
REF. TO ILM(ROI)-02
ILM(RWI)-02
AT(R)-02
REF. TO GND-07
A:
(GREEN)
i10
1 2 3 4 5 6 7 8 9 10
i3
(BLACK)
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
T7
B12
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4
5 6 7 8
9 10 11 12
C:
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B: B55 (GRAY)
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7 8 9
16 17 18
22 23 24
GR41-21A
WI-85
A/T CONTROL SYSTEM

WIRING SYSTEM
AT(R)-01
A
B
AT(R)-02
AT(R)-02
AT(R)-01
I/F
DIMMER CIRCUIT
COMBINATION
METER
CUSTOM
CPU
i10
B:
i11
AT OIL
TEMP
B5
A2
A6
GY
*1
YG
LOr B4
FWD
HOLD
OrL B15
LY B16
AT(R)-01
POWER
I/F
A:
: WITH ILLUMINATION
CONTROL MODULE : YL
WITHOUT ILLUMINATION
CONTROL MODULE
21
B38
i2
B37
POWER MODE AND

SNOW
POWER OFF
HOLD
YG
i3
GY
12
1
LOr
2
OrL
LY
REF. TO ILM(ROI)-01
ILM(RWI)-01
OrL
BrR
*1
B133
KICKDOWN
SWITCH
GW
B: B55
C: B56
B11 GW
B23 BrR
C17 GY
C10 YG
C2 LOr
B16 OrL
C11 LY
B129

REF. TO GND-07
B133 (BLUE)
B129
1
2
1 2 3
4 5 6
C: B56 (GREEN)
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
A:
i10
(GREEN)
i3
1 2 3 4 5 6 7 8 9 10
B:
i11
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
(BLACK)
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
B: B55 (GRAY)
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
GR41-21B
WI-86
A/T CONTROL SYSTEM

WIRING SYSTEM
AT(R)-03
FB-17
F/B FUSE NO.18
(IG)
GB
GR
YR
LY
MB-9
SBF-5
(B)
BR
AT(R)-03

MB-7
FB-21
FB-31
F/B FUSE NO.16 M/B FUSE NO.4 F/B FUSE NO.11
(B)
(IG)
(B)
STOP LIGHT
SWITCH
CHECK
CONNECTOR
GB 7
OC WC
1
2 LY
2
3 WB
LgB 12
B
B64 : OC
B79
B65 : WC
DATA LINK
CONNECTOR
BR 1
LgB 10
GW 12
GW 13
RG
WC : WITH CRUISE
CONTROL MODEL
B40
LINE END CHECK
CONNECTOR
RG 4
OC : WITHOUT CRUISE
CONTROL MODEL
RB
1 2
1 2
3 4
9 10 11 12 13 14 15 16
C24 RB
C15 LgB
A23 GR
A24 GR
C1
B65 (BLACK)
1 2 3 4 5 6 7 8
REF. TO GND-07
GE
B22
E3
C: B56 TRANSMISSION CONTROL MODULE
B64 (BLACK)
B40 (BLACK)
BR
B: B55
A: B54
YR
B12 WB
BR
16 GW
B300
1 2 3
4 5 6
1
8
A: B54
1 2 3 4 5 6 7
10 11 12 13 14 15 16
22
19 20 21
B22 (BROWN)
B79 (GRAY)
B300
2 3
9 10
4 5 6 7
11 12 13 14
B: B55 (GRAY)
8 9
17 18
23 24
1 2 3 4 5 6 7
10 11 12 13 14 15 16
19 20 21
22
8 9
17 18
23 24
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
C: B56 (GREEN)
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
GR41-21C
WI-87
A/T CONTROL SYSTEM

WIRING SYSTEM
20
19
18
12
11
3
31
LW
LW
NA
F67
WO
E2
NA TB
AT(R)-04
B9
C9
A18
A19
C14
B28
B20
C15
A30
B17
B16
A31
C11
B4
Sb
OrW
BL
VW
Br
LR
LgB
*2
*3
*
NA TB
RG C16 B19
Lg C17 B7
B83
RL
RG
E13
F49
C: B136
ABS
CONTROL
MODULE
30
29
B: B135
FWD SWITCH (AWD)

ENGINE
CONTROL
MODULE
BR
B
A: B134
TB WO OO
3
2
5
1
1
4
2
2
GOr
B94
SHIELD AND SENSOR

GROUND JOINT
CONNECTOR
CRUISE
CONTROL
MODULE
NA TB
AT(R)-04
THROTTLE
POSITION SENSOR
RL
Lg
Sb
B21
WO
WO : WITH OBD
REF. TO GND-06
OO : WITHOUT OBD
*2
: YG
: NON-TURBO ENGINE MODEL : WR
*3
: BG
: NON-TURBO ENGINE MODEL : BR
F45
B200
A: B54
E13
1 2 3
: TB
B83 : WO
E13
: NA
B: B55
C: B56
NA
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
F74 (BLACK)
6 7
1 2 3 4 5
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 21 22
C: B136 : TB
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
2
4
5 6
14 15
B: B55 (GRAY)
7 8
16 17
22 23
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
22 23
24 25 26
20 21
27 28
5 6 9 13 14 17 21 22 25
29
7
10
15
18
23
26
8 11 12 16 19 20 24 27 28 30
9
18
24
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
F49
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26
27 28 29 30 31
7
16
22
8
17
23
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
C: B56 (GREEN)
1 2 3 4
10 11 12 13
19 20 21
9
18
24
B94 (BLACK)
5 6
14 15
7
16
22
8
17
23
9
18
24
C: B136 : NA
B: B135 : TB
B: B135 : NA
F67
A: B54
1 2 3 4
10 11 12 13
19 20 21
B20 BR
B21 LW
Lg
Sb
OrW
BL
VW
Br
LR
LgB
A2
B17
C14
C5
B10
A1
C21
B21 (LIGHT GRAY)
F45
1 2 3 4
A: B134 : TB
B62
B83 (BLACK) : OO
B83 : TB
1 2 3 4 5 6
A3
B22 GOr
WO
LW
F74
15
: R
: NON-TURBO ENGINE MODEL : YR
21
*1
BR
BR
LW
NA
1 2 3
6 7
4 5
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
28 29 30
26 27
A: B134 : NA
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
GR41-21D
WI-88
A/T CONTROL SYSTEM
SHIELD
JOINT
CONNECTOR
GyB
4
SB
GyR
B
SB
GY
5
SB
2 1
1 2
C: B299 : TB
5 6
14 15
*53
*
VEHICLE SPEED SENSOR 2
ATF TEMPERATURE
SENSOR
SHIFT
SOLENOID 1
SHIFT
SOLENOID 2
A: B53 (BLACK) : NA
B11 (BLACK)
1 2 3 4 5 6 7 8 9 10 11 12
1 2
3 4
6 7
8
9 10
11 12
16
13
14 15
17 18
19 20
5
B: B55 (GRAY)
1 2 3 4
10 11 12 13
19 20 21
AT1
1 2 3 4 5 6
7 8 9
16 17 18
22 23 24
Or
AT5
VEHICLE SPEED SENSOR 1 (AWD)
AT6
1
B: B53 : TB
5 6
14 15
15
18
17
Y
AT8
2-4 B TIMING
SOLENOID
L/C TIMING
SOLENOID
LINE PRESSURE
SOLENOID
LOCK-UP
SOLENOID
2-4 B SOLENOID
AWD SOLENOID
AT4 (BROWN)
1 2 3 4
10 11 12 13
19 20 21
B53 : NA
B53 : TB
B11
AT9
Or
Y
Gr
AT2
AT1 (GRAY)
A: B54
14
*42
*
20
19
*1
11
GL
1
12 WR
RW
GB
4
WB
3
G
5
RY
YG
9
13
AT3
Br
L
AT7
A:
B:
C: B299 : TB
AT4
Gr
: B
: NON-TURBO ENGINE MODEL : LR
*5
: B
: NON-TURBO ENGINE MODEL : YG
YR
*4
TB
C3
C1
C2
B6
B4
B5
B3
B1
B2
T4
: W
: NON-TURBO ENGINE MODEL : LG
YR
*3
Br
: W
2 : TURBO ENGINE MODEL
: NON-TURBO ENGINE MODEL : YL
BW
: Gy
: NON-TURBO ENGINE MODEL : Gr
16 BW
*1
WG
NA
A9
A7
A8
A6
A4
A5
A3
A1
A2
AT(R)-05
GyB A19
B9
GY
GyR A10
B8
*3
B24
*2
W B18
A11
GL A22
WR A20
*1
C: B56
GB A16
A9
G
B: B55
WB A15
A7
RY
YG A18
BW C19
WG A6
BW A21
A: B54
RW A5
AT(R)-05
WIRING SYSTEM
7
16
22
8
17
23
C: B56 (GREEN)
9
18
24
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
GR41-21E
WI-89
AUDIO SYSTEM
WIRING SYSTEM
10.Audio System
A: SCHEMATIC
WI-90
AUDIO SYSTEM
WIRING SYSTEM
FRONT DOOR TWEETER RH
AUDIO(L)-01
REF. TO ILM(L)-01
1
3
BrW
WB 25
RY
WB
FRONT DOOR SPEAKER RH
RY
RY
WB
FRONT DOOR SPEAKER LH
D2
D4
B120
D1
D12
D14
1 2 3
4 5 6
7 8 9 10 11 12 13 14
D11
1
2
1 2
D4
1
D2
1
BrW 24
BrW
B30
D1
D12
25
G
G
1
BrW
2
G
1
D14
D11
RADIO
24
BrW
9
G
G
RY
RY
WB
WB
B120
B101
YG
YG
10
LR
LR
FB-27
F/B FUSE NO. 9
(ACC)
FB-9
M/B FUSE NO. 2
(B)
LR

FB-8
M/B FUSE NO. 2
(B)
AUDIO(L)-01
1. LHD MODEL
FRONT DOOR TWEETER LH
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
GL76-21A
WI-91
AUDIO SYSTEM
REAR DOOR
SPEAKER RH
11
REAR DOOR
SPEAKER LH
D23
R97
D21
B97
B120
D29
1 2
D27
1 2 3 4
5 6 7 8
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1
2
LY
LY
2
1
ANTENNA
AMP
D23
1
D29
R97
WR
WR
13
RB
3
RW
LY
LY
D21
RW
RW
D27
RW
3
W
R1
B121
B269
B265
3
B97
BRACKET
EARTH
RB
LY
LY
RW 12
RW
14
B120 RADIO
AUDIO(L)-02
AUDIO(L)-02
WIRING SYSTEM
GR
1 2
3 4
GL76-21B
WI-92
AUDIO SYSTEM
WIRING SYSTEM
3
BrW
2
RY
B120
WB
AUDIO(R)-01
REF. TO ILM(R)-01
*1
V
1
YG
10
YG
LR
FB-27
F/B FUSE NO. 9
(ACC)
MB-10
M/B FUSE NO. 2
(B)
LR
AUDIO(R)-01
2. RHD MODEL
RADIO
TB
NA
NA
FRONT DOOR SPEAKER LH
D2
D4
B120
D1
D12
D14
1 2 3
4 5 6
7 8 9 10 11 12 13 14
D11
1
2
1 2
BrW
D12
D14
BrW 24
BrW
D11
FRONT DOOR SPEAKER RH
B101
G
25
G
G
RY
2
D2
BrW
24
RY
D1
D4
2
TB : TURBO MODEL
NA
RY
WB
WB 25
WB
RY
WB
: WITHOUT ILLUMINATION
CONTROL MODULE : B
TB
B30
: WITH ILLUMINATION
CONTROL MODULE : YL
TB
FRONT DOOR TWEETER RH
*1
NA
TWISTED WIRE
TB
FRONT DOOR TWEETER LH
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
GR76-21A
WI-93
AUDIO SYSTEM
11
B121
WR
Or
13
BRACKET
EARTH
LY
RW 12
14
B120 RADIO
AUDIO(R)-02
AUDIO(R)-02
WIRING SYSTEM
NA
TB
NA
NA
NA
TWISTED WIRE
TB
TB
WR
4
LY
LY
3
RW
D21
RW
D27
LY
RW
R3
B269
B265
3
B99
WB 16
Or
LY
RW
TB
LY
REAR DOOR
SPEAKER RH
ANTENNA
AMP
D23
1
D29
R97
RW
WB
TB : TURBO MODEL
REAR DOOR
SPEAKER LH
GR
D23
R97
D21
B120
B99
D29
1 2
D27
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
1
2
1 2
3 4
GR76-21B
WI-94
CHARGING SYSTEM
WIRING SYSTEM
11.Charging System
A: SCHEMATIC
WI-95
CHARGING SYSTEM
WIRING SYSTEM
CHG(L)-01
CHG(L)-01
1. LHD MODEL
23 RW
RW
FB-36
F/B FUSE NO. 13
(IG)
B36
A7 GOr
i1
COMBINATION METER
A:
i10
B:
i11
BW
BW B1
CHARGE
WARNING
LIGHT
B37
BW
BW
i2
BW 13
B62
REF. TO P-SUP
F45
F25
GENERATOR
LR
BW
REF. TO P-SUP
F26
F26
B:
(GREEN)
i11
(GREEN)
1 2 3 4 5 6 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
i2
F45
A:
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
B36 (BLACK)
7 8 9 10 11
1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
GL02-20
WI-96
CHARGING SYSTEM
WIRING SYSTEM
CHG(R)-01
CHG(R)-01
2. RHD MODEL
GW
FB-36
F/B FUSE NO. 13
(IG)
GW
AT
GW
MT
B38
GW
GW 22
B36
i1
AT
A7 GW
MT
i3
COMBINATION METER
CHARGE
WARNING
LIGHT
A:
i10
B:
i11
AT : AT MODEL
BW
BW B1
MT : MT MODEL
i2
BW
BW
B37
BW 18
B62
REF. TO P-SUP
F45
F25
GENERATOR
BW
REF. TO P-SUP
F26
F26
(GREEN)
1 2 3
B:
i11
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
i1
(BLACK)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
A:
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
(BLACK)
i2
i3
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 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
F45
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
GR02-21
WI-97
COMBINATION METER
WIRING SYSTEM
12.Combination Meter
METER-01
METER-01
A: SCHEMATIC
To C:
i12
(GREEN)
C1
C7
C8
C3
C4
C13
C14
C6
To B:
i11
(GREEN)
B15
B1
B16
B7
B8
B29
B14
B30
To A:
i10
(GREEN)
A1
A2
A5
A6
A9
A10
GG64-20A
WI-98
WI-99
DOOR SWITCH
SEAT BELT SWITCH
ABS CONTROL MODULE
TRANSMISSON CONTROL MODULE
OIL PRESSURE SWITCH
GENERATOR
BRAKE FLUID LEVEL

WARNING SWTCH
PARKING BRAKE SWITCH
B6
B13
B14
B9
C6
B3
B4
B5
B2
B1
B19
IMMOBILIZER INDCATOR LIGHT
DOOR WARNING LIGHT
SEAT BELT WARNING LIGHT
MALFUNCTION INDICATOR LIGHT
ABS WARNING LIGHT
FWD INDICATOR LIGHT
AT OIL TEMP WARNING LIGHT
OIL PRESSURE WARNING LIGHT
CHARGE WARNING LIGHT
PARKING BRAKE/BRAKE FLUID LEVEL WARNING LIGHT
A10
METER-02
METER-02
COMBINATION METER
WIRING SYSTEM
A
METER-03
B
METER-04
GG64-20B
IGN
IGN
AWD-LO SWITCH
WI-100
B10
B15
B16
C5
C4
C10
C11
C12
C13
C14
AWD-LO INDICATOR LIGHT
SNOW HOLD PILOT LIGHT
POWER PILOT LIGHT
B18
A3
C7
B30
HEAD LIGHT RELAY RH
TURN SIGNAL SWITCH
METER-03
IGN
AIRBAG WARNING LIGHT
AIRBAG CIRCUIT
TURN SIGNAL INDICATOR LIGHT RH
TURN SIGNAL INDICATOR LIGHT LH
HI-BEAM
INHIBITOR
SWITCH
B29
METER-02
DIMMER SWITCH
METER-03
WIRING SYSTEM
COMBINATION METER
A
DIMMER CIRCUIT
DIMMER
CIRCUIT
C
METER-04
D
METER-04
E
METER-04
GG64-20C
WI-101
AC
AC
I/F
I/F
B12
B
E
B11
B8
I/F
I/F
CUSTOM CPU
BUZZER
OUT.TEMP
ODO METER
TRIP METER
SPEEDOMETER
AUTO A/C
CONTROL
MODULE
MT
AMBIENT SENSOR
I/F
A2
IGNITION SWITCH
VEHICLE SPEED SENSOR
AT
LOW-FUEL
WARNING LIGHT
TACHOMETER
C
F
A5
OUT TEMP
LCD BACK
LIGHT
POWER CIRCUIT
FUEL GAUGE
A7
C3
A8
TAIL & ILLUMINATION

RELAY
C2
METER-03
FUEL GAUGE MODULE
METER-02
C8
ODO/TRIP LCD
BACK LIGHT
C9
WATER TEMPERATURE GAUGE
METER-03
BRIGHT
SWITCH
THERMOMETER
A6
METER-03
A9
ILLUMINATION
LIGHT
METER-04
B
BATTERY
AT : AT MODEL
MT : MT MODEL
AC : WITH AUTO A/C MODEL
METER-04
COMBINATION METER
WIRING SYSTEM
DRIVER
DRIVER
I/F
TRIP A
B
CHANGE
TRIP
RESET SWITCH
GG64-20D

WIRING SYSTEM
13.Cruise Control System

A: SCHEMATIC
C/C-01
GB
MB-5
HORN RELAY
RG
FB-17
F/B FUSE NO.18
(IG)
LY
C/C-01

FB-31
F/B FUSE NO.16
(B)
CRUISE CONTROL SUB SWITCH
STOP LIGHT AND

BRAKE SWITCH
2
3
LY
WB
1
4
RY
1
RG
LgB
RW
(RESUME)
B68
B65
(CANCEL)
: AT : YG
MT : YR
MT
AT
*1
(SET)
CRUISE CONTROL
MAIN SWITCH
ON
AT
CLUTCH
SWITCH (MT)
1
2
YR
YG
MT
GB
GL
YG
LR
YL
OFF
B107
REF. TO ILM(RWI)-01
B161
AT : AT MODEL
C/C-02
C/C-03
RW
GL
LR
15
GB
10 LgB
12
RY
16
20 WB
YG
11
MT : MT MODEL
B94
B107 (BLUE)
B65 (BLACK)
1 2
1 2
3 4
B68 (BLACK)
1
2
3 4 5
B94 (BLACK)
B161 (BROWN)
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
GG71-21A
WI-102

WIRING SYSTEM
C/C-02
AT
LgR 17
19
GY
BR
BrW 18
B94
MB-9
SBF-5
(B)
GOr
C/C-02
C/C-01
VEHICLE SPEED
SENSOR (MT)
GB
GY
GW
MT
AT
B17
C17 GY
B: B55
C: B56
TRANSMISSION
CONTROL
MODULE (AT)
B22 GOr
16 GW
AT : AT MODEL
MT : MT MODEL
B22
E3
B17 (BLACK) : NA
1 2 3
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B94 (BLACK)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
2 3
9 10
13 GW
LgR
5
DATA LINK CONNECTOR
B79
1
8
12 GW
B17 (BLACK) : TB
1 2
3 4
B40 (BLACK)
REF. TO GND-07
BrW
BR
CHECK CONNECTOR
B
B79
8
GB
10 LgR
BrW
BR
4 5
11 12
(GRAY)
B22
1
5
9
13
6 7
13 14
B: B55 (GRAY)
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8 9
17 18
23 24
2
6
10
14
3
7
11
15
B40
GE
(BROWN)
4
8
12
16
C: B56 (GREEN)
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
GG71-21B
WI-103

WIRING SYSTEM
C/C-03
6
B
WB
14
AT
13
BY
LOr
7
RL
BG
C/C-03
B94
STARTER MOTOR
TO BATTERY TERMINAL
INHIBITOR SWITCH
R
1
12
BY
12 WB
BW
11 WR
T7
BY
LOr
BG
RL
REF. TO GND-07
CRUISE CONTROL ACTUATOR
1 2 3
4 5 6
B14
B12
REF. TO GND-06
B7
B7
WR
YG
C/C-01
T3
(BLACK)
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
B94 (BLACK)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
GG71-21C
WI-104
DOOR LOCK SYSTEM

WIRING SYSTEM
14.Door Lock System

A: SCHEMATIC
WI-105
DOOR LOCK SYSTEM

WIRING SYSTEM
D/L(LOK)-01
D/L(LOK)-01
1. LHD WITHOUT KEYLESS ENTRY MODEL

FB-35
F/B FUSE NO. 3
(B)
1
3
RG
Or
D18
15
10
D11
RG
FRONT DOOR LOCK

ACTUATOR RH
DOOR LOCK TIMER
Or
B92
LR
WB
LR
WB
FB-9
M/B FUSE NO. 2
(B)
RG
Or
B101
REAR GATE LOCK

ACTUATOR
(WAGON)
D34
RG
Or
7
6
R38
R3
WG
RG
Or
W
B
WG
B99
B30
Or
D47
5
6
2
1
D8
D1
1
2
W
Br
B265
B269
D32
3
1
REAR DOOR LOCK

ACTUATOR LH
REAR DOOR LOCK

ACTUATOR RH
D26
3
1
Or
RG
D27
Or
RG
D21
WG : WAGON
14
13
Or
RG
RG
Or
RG
2
1
DOOR LOCK
SWITCH
D8
(GRAY)
D18
D21
D47
D26
D27
1 2
D32
1 2
3 4
D34
1 2 3
4 5 6
B92
1 2 3 4
5 6 7 8
REF. TO GND-01
B99
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
D1
D11
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
1 2
3 4
GL73-22
WI-106
DOOR LOCK SYSTEM

WIRING SYSTEM
D/L(LWK)-01
D/L(LWK)-01
2. LHD WITH KEYLESS ENTRY MODEL

FB-9
M/B FUSE NO. 2
(B)
1
3
RG
Or
RG
Or
D18
15
10
D11
6
14
18
17
Or
RG
FRONT DOOR
LOCK ACTUATOR RH
KEYLESS ENTRY
CONTROL MODULE
B
B
B176
LR
16 WB
LR
WB
FB-35
F/B FUSE NO. 3
(B)
RG
Or
FRONT DOOR
LOCK ACTUATOR LH
RG
15
RG
RG
Or
10
Or
Or
B101
REAR GATE
LOCK ACTUATOR
(WAGON)
14
13
Br
Br
B30
RG
Or
D34
RG
Or
R38
RG
Or
7
6
R3
WG
RG
Or
B99
WG
Or
RG
D47
5
6
B269
1
2
1
2
B265
D21
D32
3
1
Or
RG
D26
3
1
Or
RG
D27
REAR DOOR LOCK

ACTUATOR LH
REAR DOOR LOCK

ACTUATOR RH
D18
1 2
D32
D72
D26
WG : WAGON
D47
D21
D27
(GRAY)
D72
Or
RG
2
1
D1
1 2
3 4
D34
1 2 3
4 5 6
B176
1 2 3 4 5
11 12 13 14
15
REF. TO GND-01
B99
6 7 8 9 10
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
D1
D11
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
1 2
3 4
GL73-20
WI-107
DOOR LOCK SYSTEM

WIRING SYSTEM
D/L(ROK)-01
D/L(ROK)-01
3. RHD WITHOUT KEYLESS ENTRY MODEL

FB-35
F/B FUSE NO. 3
(B)
LR
WB
LR
WB
MB-10
M/B FUSE NO. 2
(B)
1
3
RG
LgB
D18
15
10
D11
RG
FRONT DOOR LOCK

ACTUATOR LH
DOOR LOCK TIMER
LgB
B92
RG
LgB
B101
REAR GATE LOCK

ACTUATOR
(WAGON)
B97
W
B
WG
B30
LgB
RG
R1
WG
RG
LgB
B269
W
Br
14
13
D1
2
1
D8
B265
1
2
R38
8
4
RG
D34
RG
LgB
D47
5
6
LgB
RG
LgB
2
1
DOOR LOCK
SWITCH
D27
D21
LgB
RG
D32
REAR DOOR LOCK

ACTUATOR LH
REAR DOOR LOCK

ACTUATOR RH
3
1
D26
3
1
LgB
RG
WG : WAGON
D8
(GRAY)
D18
D21
D47
D26
D27
1 2
D32
1 2
3 4
D34
1 2 3
4 5 6
B92
1 2 3 4
5 6 7 8
B97
D1
1 2 3 4
5 6 7 8
D11
REF. TO GND-06
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
1 2
3 4
GR73-23
WI-108
DOOR LOCK SYSTEM

WIRING SYSTEM
D/L(RWK)-01
D/L(RWK)-01
4. RHD WITH KEYLESS ENTRY MODEL

MB-10
M/B FUSE NO. 2
(B)
RG 15
LgB 10
RG
LgB
5
17
7
W
6
14
1
3
B
B
FRONT DOOR
LOCK ACTUATOR LH
RG
KEYLESS ENTRY
CONTROL MODULE
LgB 18
B176
LR
16 WB
LR
WB
FB-35
F/B FUSE NO. 3
(B)
FRONT DOOR
LOCK ACTUATOR RH
RG
RG
LgB
LgB
D18
D11
15
RG
RG
10 LgB
LgB
Br
Br
B101
W
14
13
B30
D1
D72
REAR GATE
LOCK ACTUATOR
(WAGON)
D34
RG
LgB
R1
R38
8
4
RG
LgB
B97
WG
WG
B269
1
2
LgB
RG
D47
RG
LgB
LgB
RG
5
6
RG
LgB
D21
LgB
RG
D27
D32
3
1
D26
3
1
LgB
RG
B265
1
2
2
1
REAR DOOR LOCK

ACTUATOR LH
REAR DOOR LOCK

ACTUATOR RH
WG : WAGON
D47
D18
D21
1 2
D32
D27
D72
D26
(GRAY)
1 2
3 4
D34
1 2 3
4 5 6
1 2 3 4
5 6 7 8
D1
B176
B97
1 2 3 4 5
11 12 13 14
15
REF. TO GND-06
6 7 8 9 10
16 17 18
D11
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
1 2
3 4
GR73-22
WI-109
ENGINE COOLANT TEMPERATURE GAUGE SYSTEM

WIRING SYSTEM
15.Engine Coolant Temperature Gauge System

A: SCHEMATIC
WI-110

WIRING SYSTEM
C/T(L)-01
C/T(L)-01
1. LHD MODEL
23 RW
RW
FB-36
F/B FUSE No.13
(IG)
i1
GOr
B36
*1
A7 GOr

: BL
: NON-TURBO ENGINE MODEL : B
BR
BR
C8
i12
NA
B21
i10
C:
B37
TB
BW J3
NA
10 WG
TB
E2
A:
i2
BW
WG
18 WG
WG C9
WG
COMBINATION
METER
ENGINE
COOLANT
TEMPERATURE
GAUGE
B209
BW
F76
BW 15
F60
BL
E3
WG
WG
15 WG
F76
F61
WG
E2
J1 WG
B209
B22
E3
TB
TB
15 BW
NA
SMJ
SMJ
NA
*1
E8
THERMOMETER
E8
GE
(LIGHT GRAY)
C:
i12
(GREEN)
1 2
3
F60
i2
(BROWN) : TB
F61
A:
i10
(GREEN)
(BLACK) : TB
1 2 3 4 5 6 7 8 9 10
1
5
9
13
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
B21 (LIGHT GRAY) : NA
B22 (BROWN) : NA
1 2 3
4 5 6
7 8 9 10 11 12 13 14
2
6
10
14
3
7
11
15
4
8
12
16
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
B36 (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
GL68-21
WI-111

WIRING SYSTEM
2. RHD MODEL
C/T(R)-01
C/T(R)-01
GW
FB-36
F/B FUSE NO. 13
(IG)
AT
MT
B38
4
22
B36
i3
i1
MT
A7 GW
AT

*1
: NON-TURBO ENGINE
WITHOUT OBD MODEL : BW
: NON-TURBO ENGINE
WITH OBD MODEL : B
: TURBO ENGINE MODEL : BL
WG C9
BW C8
11 BW
TB
NA
B21
WG
15 WG
E2
B21
15 BW
TB
15 BW
NA
E2
i10
i12
B37
NA
TB
10 WG
A:
C:
i2
BW
WG
15 WG
WG
COMBINATION
METER
ENGINE
COOLANT
TEMPERATURE
GAUGE
B22
B22
E3
TB
WG
E3
E8
*1
NA
THERMOMETER
E8
(LIGHT GRAY)
A:
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
1 2
3
GE
i1
C:
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
(LIGHT GRAY) : NA
B22 (BROWN)
(BLACK)
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B21
1 2
(BLACK) : TB
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
i3
(BLACK)
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32 33
GR68-21
WI-112
ENGINE ELECTRICAL SYSTEM

WIRING SYSTEM
16.Engine Electrical System

A: SCHEMATIC
WI-113

WIRING SYSTEM
XXX-001
E/G(LOO)-01
XXX-001
E/G(LOO)-01
1. LHD SOHC W/O OBD MODEL

GR
FB-21
F/B FUSE NO. 11
(IG)
FUEL PUMP
RELAY
2
BR
GR
VW
BY
A
B
E/G(LOO)-03
E/G(LOO)-08
B46
FUEL PUMP ASSEMBLY

FUEL PUMP
2
1
RB
RB
BY
BW
BW
R57
R58
R1
BY
B97
R15
*1
B7 GR
VW
: WITH IMMOBILIZER SYSTEM : A29

WITHOUT IMMOBILIZER SYSTEM : A16
*1
BY
A: B134
B: B135
ENGINE CONTROL
MODULE
REF. TO GND-03
B46
(GREEN)
R15 (BLACK)
2
1
3 4 5 6
1 2
3 4
R58
1 2 3
4 5 6
B97
1 2 3 4
5 6 7 8
B: B135
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
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
GL10-23A
WI-114

E/G(LOO)-02
E/G(LOO)-02
WIRING SYSTEM

FB-36
F/B FUSE NO. 13
(IG)
GB
RW
FB-17
F/B FUSE NO. 18
(IG)
23
B36
A7 GOr
i1
SPEEDOMETER
TACHOMETER
I/F
MALFUNCTION
INDICATOR LIGHT
A:
I/F
C: B56
i10
B:
i11
C:
i12
TRANSMISSION
CONTROL
MODULE (AT)
AT
VEHICLE
SPEED SENSOR (MT)
GB
GY
BR
22
G
RW
GY
16
18
GW
E/G(LOO)-05
E/G(LOO)-08
E/G(LOO)-07
GW
WG
3
1
2
B17
B37
10 WG
WG
GW
i2
GW
E2
BW
23
MT
B21
E/G(LOO)-05
GY C17
I/F
A5
LG
RW C6
CUSTOM CPU
GB A2
TEMPERATURE
GAUGE
C8
WG C9
BR
OIL PRESSURE
WARNING LIGHT
GB B2
COMBINATION
METER
G
A30
B24 GY
A11 RW
E11
A: B134 B: B135
OIL PRESSURE SWITCH

A:
B17
1 2 3
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
i2
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:
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2
3
6 7
9 10
11
13
14 15
17 18
19
5
1 2 3 4
10 11 12 13
19 20 21
8
12
16
20
B: B135
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
C: B56 (GREEN)
B21 (LIGHT GRAY)
B:
i11
5 6
14 15
7 8 9
16 17 18
22 23 24
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B36 (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
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
GL10-23B
WI-115

E/G(LOO)-03
E/G(LOO)-03
WIRING SYSTEM

MB-9
SBF-5
(B)
ST
IGNITION SWITCH
(ST)
AT MODEL : WR
MT MODEL : WB
BR
WB
*2
B61
MT
AT
BR
F44

P
E/G(LOO)-01
WB 12
BY
12
WR 11
BW
B12
T3
T7
MAIN RELAY
G
H
I
J
BR
YR
BR
YL
LgW
E/G(LOO)-05
E/G(LOO)-06
E/G(LOO)-08
E/G(LOO)-09
STARTER MOTOR
B47
TO BATTERY TERMINAL
*2
B14
B47 (BROWN)
1
3
5
2
4
6
F44
1 2 3 4
5 6 7 8
B12 (BLACK)
1 2 3 4
5 6 7 8
9 10 11 12
AT
B28 WR
BR
C9
B: B135
AT
YL
C2
B28 WB
YL
C1
B19 LgW
MT
REF. TO GND-02
B26 WB
MT
AT
C: B136 ENGINE CONTROL MODULE
B: B135
T7
1 2 3 4 5 6
7 8 9 10 11 12
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
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
GL10-23C
WI-116
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
C: B136
B17 PG
B16 RY
A31 YR
C11 GW
B21
C3 BW
REF. TO ILM(L)-01
REF. TO AT(L)-04
E/G(LOO)-04
B: B135
B: B135
REF. TO R/DEF(L)-01
REF. TO R/F(NA)-01
A: B134
A12 GR
RL
A3
B27 LY
C30 GR
A17 Br
B23 RY
B22 YG
REF. TO IMB(L)-02
REF. TO A/C(ALH)-01
E/G(LOO)-04
WIRING SYSTEM
C: B136
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
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
GL10-23D
WI-117

E/G(LOO)-05
E/G(LOO)-05
WIRING SYSTEM
GB B26
MT
GrB B3
RW B20
LB B15
Or B14
B: B135 ENGINE CONTROL MODULE
NEUTRAL POSITION
SWITCH (MT)
GB
BR
1
2
B25
E/G(LOO)-03
E/G(LOO)-02
E/G(LOO)-02
T2
E/G(LOO)-08
TEST MODE
CONNECTOR
Or
B76
REF. TO GND-02
B25 (BROWN)
B75 (GREEN)
BR
BR
12
13
BR
BW
10 GrB
B300
B126
B40
DATA LINK CONNECTOR

LINE END
CHECK CONNECTOR
LINE END CONNECTOR
B79 (GRAY)
B300
1 2 3
4 5 6
RW
BW
BR
Or
LB
B125
B79
CHECK CONNECTOR
1
2
1 2
12 GrB
GB
B75
BR
1
8
2 3
9 10
4 5
11 12
6 7
13 14
B40 (GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B135
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
GL10-23E
WI-118

E/G(LOO)-06
E/G(LOO)-06
WIRING SYSTEM
(DARK BROWN)
1 2 3
1 2 3 4
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
B21 (LIGHT GRAY)
B18
2 1
4 3
1 2
3
6 7
9 10
11
13
14 15
17 18
19
5
4
8
12
16
20
Lg C17
E/G(LOO)-07
E/G(LOO)-08
E/G(LOO)-07
E/G(LOO)-07
E/G(LOO)-07
9
BR
BR
BY
Sb C15
CO ADJUSTING
RESISTOR
OXYGEN SENSOR
E13
4
B28
B18
E13
YR
Sb
GY
BW
YR
E2
B28
Lg
11
Sb
12
YR
WR
B21
WR
C12
E/G(LOO)-03
C7
SB C23
A: B134 B: B135 C: B136 ENGINE CONTROL MODULE
THROTTLE POSITION
SENSOR
B: B135
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
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
GL10-23F
WI-119

E/G(LOO)-07
C: B136
*4
R
W A6
G A20
B A5
R A19
*3
W
SB B10
C4
B: B135
BY C14
Br C13
C5
PL
B8
G
RG C16
A: B134
SB C25
E/G(LOO)-07
WIRING SYSTEM
SHIELD AND
SENSOR GROUND
JOINT CONNECTOR
5
: WITH
IMMOBILIZER
MODEL : B2
WITHOUT
IMMOBILIZER
MODEL: B1
:
WITH
4
IMMOBILIZER
MODEL: B1
WITHOUT
IMMOBILIZER
MODEL : B2
*3
RG
BY
GY
17
19
18
20
2
4
1
3
Y
Or
B
W
GL
LB
L
RY
E8
E14
E10 (LIGHT GRAY)
E15 (BLACK)
1 2
3
E20 (BLACK)
1
3
4
6
2
5
CAMSHAFT
POSITION SENSOR
IDLE AIR CONTROL

SOLENOID VALVE
(BLACK)
1 2 3
4 5 6
1 2
B: B135
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
E/G(LOO)-08
E/G(LOO)-08
E/G(LOO)-09
E7
B21 (LIGHT GRAY)
B83
1 2 3 4
5 6 7 8
GL
LB
L
RY
Y
Y
R
G
CRANKSHAFT
POSITION SENSOR
E7
1 2 3 4
B
W
E15
1
2
2
3
1
(LIGHT GRAY)
E10
E14
PRESSURE SENSOR
KNOCK
ENGINE COOLANT
AND INTAKE AIR
TEMPERATURE SENSOR SENSOR
TEMPERATURE SENSOR
AND THERMOMETER
W
G
B
R
16
PL
W
B
13
BY
E8
2
1
3
4
E20
Y
Or
1
2
E/G(LOO)-06
PL
E/G(LOO)-06
Br
BR
YR
R
E/G(LOO)-02
BR
WG
BY
E2
Br
14
B21
Br
S
PL
E/G(LOO)-06
15
E/G(LOO)-06
BY
B83
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
A: B134
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
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
GL10-23G
WI-120

E/G(LOO)-08
WL A2
GW A26
YL A25
A27
BR B25
MT
BR C22
BR C21
BG A7
BW A8
OrB B13
A: B134 B: B135
E/G(LOO)-08
WIRING SYSTEM
YR
R
R
WR
WR
L
L
: EXCEPT 1.6L
MODEL
WL
GW
RG
GR
YW
YL
14
RG
YW
E/G(LOO)-07
GW
GR
: 1.6L MODEL
POWER STEERING OIL

PRESSURE SWITCH
E4
(BLUE)
E12
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
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
2
6
4
7
1 2
3 4
6 7
8
11 12
9 10
14
13
15
16
19 20
17 18
5
4
1
B21 (LIGHT GRAY)
E4
1
2
* *
3
3
BW
B22 (BROWN)
E12
IGNITION COIL
AND IGNITOR
GE
( 5)
1 2 3 4
1 2
BW
GW
E19
GW
GR
E/G(LOO)-07
GW
E3
BR
E2
16
B22
B21
BR
BR
E/G(LOO)-06
BG
13
E/G(LOO)-02
15 BW
E/G(LOO)-05
*6
*7
E/G(LOO)-03
( 5 ) : 1.6L : GRAY
EXCEPT 1.6L :
DARK GRAY
OrB
E/G(LOO)-01
PURGE CONTROL
SOLENOID VALVE
B: B135
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
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
GL10-23H
WI-121

E/G(LOO)-09
E/G(LOO)-09
WIRING SYSTEM
PL A13
PB A14
PG A15
PL
PB
PG
A4
P
P
A: B134 ENGINE CONTROL MODULE
12
11
GB
B22
E3
E5
(LIGHT GRAY)
E6
(LIGHT GRAY)
E16 (LIGHT GRAY)

(LIGHT GRAY)
2
6
10
14
3
7
11
15
4
8
12
16
GB
FUEL INJECTOR
NO. 3
E17
2
E6
1
GOr
Y
2
FUEL INJECTOR
NO. 2
FUEL INJECTOR
NO. 4
A: B134
B22 (BROWN)
1
5
9
13
FUEL INJECTOR
NO. 1
E16
Lg
E5
E17
GOr
10
Lg
Br
E/G(LOO)-07
Br
YL
E/G(LOO)-03
1 2
3 4
5 6
7 8
9 10 11 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
GL10-23I
WI-122

WIRING SYSTEM
2. LHD SOHC MODEL
WI-123

WIRING SYSTEM
WI-124

E/G(LWO)-03
E/G(LWO)-03
WIRING SYSTEM

MB-9
SBF-5
(B)
ST
IGNITION SWITCH
(ST)
AT MODEL : WR
MT MODEL : WB
BR
WB
*2
B61
MT
AT
BR
F44

P
E/G(LWO)-01
WB 12
BY
12
WR 11
BW
B12
T3
T7
MAIN RELAY
6
BR
YR
BR
YL
LgW
H
I
E/G(LWO)-05
E/G(LWO)-09
E/G(LWO)-06
STARTER MOTOR
B47
TO BATTERY TERMINAL
*2
B14
B47 (BROWN)
1
3
5
2
4
6
C: B136
F44
B12
T7
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
AT
B28 WR
BR
C9
B: B135
AT
YL
C2
B28 WB
YL
C1
B19 LgW
MT
REF. TO GND-02
B26 WB
MT
AT
B: B135
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
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
GL10-25C
WI-125
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
C: B136
B17 PG
B16 RY
A31 YR
C11 GW
B4 BrR
B21
C3 BW
REF. TO ILM(L)-01
REF. TO AT(L)-04
E/G(LWO)-04
B: B135
B: B135
REF. TO R/DEF(L)-01
REF. TO R/F(NA)-01
A: B134
A12 GR
A3
RL
C30 GR
B27 LY
A17 Br
B23 RY
B22 YB
REF. TO IMB(L)-02
REF. TO A/C(ALH)-01
E/G(LWO)-04
WIRING SYSTEM
C: B136
A: B134
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
GL10-25D
WI-126

E/G(LWO)-05
E/G(LWO)-05
WIRING SYSTEM
GB B26
MT
GrB B3
Or B14
RW B20
NEUTRAL POSITION
SWITCH (MT)
GB
BR
1
2
B25
E/G(LWO)-03
E/G(LWO)-02
E/G(LWO)-02
T2
E/G(LWO)-08
TEST MODE
CONNECTOR
RL
BR
B75
CHECK CONNECTOR
B25 (BROWN)
B75 (GREEN)
1
2
1 2
B79 (GRAY)
B300
1 2 3
4 5 6
1
8
2 3 4 5
9 10 11 12
6 7
13 14
BR
13
BR
12
BR
BW
LINE END CHECK

CONNECTOR
10 GrB
4
LINE END CONNECTOR
B300
6
B126
1
B125
RW
BW
RL
Or
Or
B79
4
12 GrB
REF. TO GND-02
GB
B76
B40
DATA LINK CONNECTOR
B40 (GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B135
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
GL10-25E
WI-127

E/G(LWO)-06
Lg C17
RG C16
Sb C15
YL C29
C6
C20
SB C23
C7
C19
BrB A22
BrB A23
SB C24
W C18
BrW A21
A: B134
E/G(LWO)-06
WIRING SYSTEM
SHIELD AND
SENSOR GROUND
JOINT CONNECTOR
BW
RG
BW
YW
SB
L
BY
1 2 3
2 1
4 3
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
B18
B122
1 2 3
4 5 6
1 2 3
4 5 6
BY
9
E/G(LWO)-07
E/G(LWO)-07
E13
B2
ATMOSPHERIC
PRESSURE SENSOR
E2
BR
Lg
11
B21
BR
YR
Sb
YL
WR
12
E13
YR
B19
B18
(DARK BROWN)
B2
C: B136
BrB
YR
2
REAR OXYGEN SENSOR
YW
YR
BrW
1
B19
WR
E/G(LWO)-03
Sb
B122
THROTTLE POSITION
SENSOR
B21 (LIGHT GRAY)

1 2
3
6 7
9 10
11
13
14 15
17 18
19
5
4
8
12
16
20
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
GL10-25F
WI-128
E/G(LWO)-02
E/G(LWO)-06
E/G(LWO)-07
*B84
R
G
W A6
G A20
B A5
R A19
*3
: WITH IMMOBILIZER
SYSTEM : B2
WITHOUT
IMMOBILIZER
SYSTEM : B1
*4
: WITH IMMOBILIZER
SYSTEM : B1
WITHOUT
IMMOBILIZER
SYSTEM : B2
R
G
W
G
B
R
*B93
W
B
W
B
2
4
1
3
18
20
B21
E2
GL
LB
L
RY
B
W
Y
Or
PL
17
19
W
16
13
BY
SB B10
C: B136
C4
SB C25
B: B135
BY
BY C14
Br C13
Br
14
Br
15
PL
PL
C5
A: B134
E/G(LWO)-07
WIRING SYSTEM
N E/G(LWO)-08
O E/G(LWO)-08
E/G(LWO)-06 M
(LIGHT GRAY)
E8
(BLACK)
1 2
3
E14
E15
(LIGHT GRAY)
E20
E7
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
1
3
4
6
2
5
B21 (LIGHT GRAY)
(BLACK)
1 2 3
4 5 6
1 2
3
6 7
9 10
11
13
14 15
17 18
19
5
4
8
12
16
20
A: B134
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
E7
CAMSHAFT
IDLE AIR CONTROL
POSITION SENSOR SOLENOID VALVE
1 2
B: B135
E/G(LWO)-08
GL
LB
L
RY
Y
Y
B
W
Y
Or
CRANKSHAFT
POSITION SENSOR
(BLACK)
1 2 3 4
E15
1
2
2
3
1
PRESSURE SENSOR
KNOCK
ENGINE COOLANT
AND INTAKE AIR
TEMPERATURE SENSOR
AND THERMOMETER
E10
E10
E14
1
2
E8
2
1
3
4
E20
PL
BR
WG
BY
Br
BR
YR
R
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
GL10-25G
WI-129
E4
(BLACK)
(PURPLE)
E/G(LWO)-08
WL A2
YG A24
WL
YG
GW
YL
GR
WR
4
YW
RG
14
GW
E12
1 2 3 4
1 2
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
B22 (BROWN)
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
1 2
3 4
6 7
8
11 12
9 10
14 15
13
16
19 20
17 18
WR
E4
E42
AIR ASSIST INJECTOR PURGE CONTROL

SOLENOID VALVE
SOLENOID VALVE
B: B135
B21 (LIGHT GRAY)
E12
2.0L 1.6L
IGNITION COIL
AND IGNITOR
GE
: ( 3)
RG
GW
GW
GW
BR
3
POWER STEERING OIL
PRESSURE SWITCH
E42
GW A26
A27
B
YL A25
*2
BR C22
BY A35
BY A34
BG A7
BR C21
BR
16
BR
BY
8
BR
BW
BW
E19
YW
E/G(LWO)-07
E3
Q E/G(LWO)-09
E/G(LWO)-07
AT MODEL : B6
MT MODEL : B25
B22
GR
E/G(LWO)-07
E2
B
GR
B21
BR
F
BG
E/G(LWO)-02
13
15 BW
E/G(LWO)-05
*2
OrB
E/G(LWO)-01
BW A8
OrB B13
A: B134 B: B135
BR
E/G(LWO)-08
WIRING SYSTEM
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
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
( 3) 1.6L: (GRAY)
2.0L: (DARK GRAY)
GL10-25H
WI-130

E/G(LWO)-09
E/G(LWO)-09
WIRING SYSTEM
PL A13
PB A14
PG A15
PL
PB
PG
A4
P
P
12
11
GB
GOr
10
Lg
Br
B22
E3
FUEL INJECTOR
NO. 1
E5
(LIGHT GRAY)
E6
(LIGHT GRAY)
E16
(LIGHT GRAY)
E17
(LIGHT GRAY)
B22 (BROWN)
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
GB
FUEL INJECTOR
NO. 3
E17
2
E6
1
GOr
FUEL INJECTOR
NO. 2
E16
2
E5
Lg
E/G(LWO)-08
Br
YL
E/G(LWO)-03
FUEL INJECTOR
NO. 4
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
1 2
GL10-25I
WI-131

WIRING SYSTEM
E/G(LTB)-01
E/G(LTB)-01
3. LHD DOHC TURBO MODEL

GR
FB-21
F/B FUSE NO. 11
(IG)
FUEL PUMP
RELAY
REF. TO GND-02
LR
GR
BY
A
B
E/G(LTB)-03
E/G(LTB)-02
E/G(LTB)-10
B46

10
BY
LgR
VW
FUEL PUMP ASSEMBLY
BW
BOr
BY
R1
BY
B97
R122
FUEL PUMP
BR
BR
BOr
LgR
20 LgR
BW
VW
19
VW
GB
GB
BR
BrW
BrW
BrW
11 BrW
L
BrW
B99
R59
A: B134
B: B135
A14 GR
2
1
R3
R15
A13 LgR
FUEL SUB
LEVEL SENSOR
R57
C16 VW
R58
B25 BrW
FUEL LEVEL SENSOR
C: B136
ENGINE CONTROL
MODULE
REF. TO GND-03
B46
R59
1 2
1 2
3 4
C: B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
(GREEN)
R15 (BLACK)
1
2
3 4 5 6
R58
1 2 3
4 5 6
B97
R122
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 11 12 13 14 15
16 17
18 19 20 21 22
B: B135
B99
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
A: B134
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
GL10-24A
WI-132

WIRING SYSTEM
WI-133

E/G(LTB)-03
E/G(LTB)-03
WIRING SYSTEM

MB-9
SBF-5
(B)
BR
BR
BR
WB
ST
IGNITION SWITCH
(ST)
2
BR
LR
F44
B61
E/G(LTB)-01
MAIN RELAY
6
BR
YR
LR
YL
LgW
I
J
E/G(LTB)-05
E/G(LTB)-06
E/G(LTB)-06
STARTER MOTOR
B47
TO BATTERY TERMINAL
WB
B14
A: B134
B47 (BROWN)
1
3
5
2
4
6
F44
1 2 3 4
5 6 7 8
A16 WB
YL
D3
D10 BR
YL
D2
A2 LgW
REF. TO GND-02
D: B137
A: B134
1 2 3 4 5
6 7
8 9 10 11 12 13 14 15
16 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 26
27 28
29 30 31
GL10-24C
WI-134
6 7
1 2 3 4 5
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
D: B137
A17 BW
A3
D28 GR
B: B135
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
REF. TO ILM(L)-01
E/G(LTB)-04
A: B134
B: B135
REF. TO R/DEF(L)-01
REF. TO R/F(TB)-01
A: B134
D17 RL
A9 GR
LY
A6
D27 Br
RY
B5
B14 YB
REF. TO IMB(L)-02
REF. TO A/C (ALH)-01
E/G(LTB)-04
WIRING SYSTEM
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
GL10-24D
WI-135

E/G(LTB)-05
E/G(LTB)-05
WIRING SYSTEM
GB A8
LgB A21
YG A20
Or
A5
RW A10
NEUTRAL POSITION
SWITCH
GB
BR
1
3
B128
E/G(LTB)-02
E/G(LTB)-02
E/G(LTB)-10
BR
E/G(LTB)-03
T9
B76
B75
B75 (GREEN)
1
2
CHECK CONNECTOR
B300
1 2
3 4
1 2 3
4 5 6
B79 (GRAY)
1
8
2 3
9 10
4 5
11 12
6 7
13 14
BR
BR
12
13
BR
1
10 LgB
6
3
4
1
B128
B300
LINE END CHECK
CONNECTOR
LINE END CONNECTOR
YB
B126
B125
BW
YG
YB
BW
RW
RL
Or
Or
B79
4
12 LgB
7
REF. TO GND-02
GB
TEST MODE
CONNECTOR
B40
DATA LINK CONNECTOR
B40 (GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
A: B134
1 2 3 4 5
6 7
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
GL10-24E
WI-136

E/G(LTB)-06
RG B19
W B17
SB B26
RW C13
W D19
D5
D29
B
SB D18
D4
E: B84
WB B16
E8
PL E13
SB
E7
BG
Br B27
BW D24
B: B135 C: B136 D: B137
E/G(LTB)-06
WIRING SYSTEM
SHIELD AND
SENSOR GROUND
JOINT CONNECTOR
BW
RG
GR
SB
Lg
SB
LR
1
B83
B127 (BLUE)
B279
B18
1 2
1 2
1 2
4 5
B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
C: B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
FRONT OXYGEN
EXHAUST GAS
TEMPERATURE SENSOR (A/F) SENSOR
2
4
B3
B83
1 2 3 4 5
1 2 3
4 5 6
B: B135
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
LR
YR
RW
B19
1
B18
1
B279
B19
1
3
Lg
GR
YL
AIR FLOW
SENSOR
WASTEGATE
SOLENOID
E:
B3
1
B127
E/G(LTB)-11
YR
WB
PL
E/G(LTB)-03
Br
E/G(LTB)-09
BG
YL
BW
E/G(LTB)-03
REAR OXYGEN
SENSOR
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
GL10-24F
WI-137

E/G(LTB)-07
E/G(LTB)-07
WIRING SYSTEM
B4
W
SB B22
B
B
SB B21
R
R
B1
G
G
B10
W
W
B2
B11
RL
RL
E14
2
E15
2
E10
1
3
Or
E1
Or
WL
WL
OrL
OrL
B20
GE
CRANKSHAFT
POSITION SENSOR
E10 (LIGHT GRAY)
E14 (GRAY)
E15 (LIGHT GRAY)
B20 (LIGHT GRAY)

1 2 3 4
5
6
7
8
9 10
CAMSHAFT
POSITION SENSOR
KNOCK
SENSOR
B: B135
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
1 2
GL10-24G
WI-138
(BLACK)
E55 (BLACK)
E7
1 2 3
E/G(LTB)-08
C10
K4
G5
GY
(BLACK)
E/G(LTB)-11
E/G(LTB)-10
BW
12
W
W
GY
6
GL
WL
TGV RH
E7
E55
E51
1
OIL PRESSURE SWITCH
GL
5
WL
E19
TGV LH
1 2
K2
LG
LG
L
L
YL
RY
E2
E11
YG
B5
L
LG
LY
A5
LY
LY
8
L
YL
RY
F61
14 GW
F76
B209
SMJ
E51
YG E5
E4
LG
LY E10
T2 OrB
OrB
11 OrB
GW
I1
GW
E/G(LTB)-02
E11
E: B84
OrB B24
B: B135 C: B136
E/G(LTB)-08
WIRING SYSTEM
IDLE AIR CONTROL

SOLENOID VALVE
POWER STEERING OIL

PRESSURE SWITCH
E:
(BLACK)
B84
F61
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
3 4
6 7
8
11 12
9 10
14 15
13
16
19 20
17 18
1 2
C: B136
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: B135
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
GL10-24H
WI-139

E/G(LTB)-09
E/G(LTB)-09
WIRING SYSTEM
ENGINE COOLANT
TEMPERATURE SENSOR
AND THERMOMETER
1 2
3
(LIGHT GRAY)
E13
(BLACK)
E21
(BLACK)
E50
(BLACK)
E54
(BLACK)
(BLACK)
1 2
3 4
6 7
8
11 12
9 10
14 15
13
16
19 20
17 18
5
BrR B23
B1 BrR
BrY B13
BrR
BrR
BrY
PRESSURE
SENSOR
WR
BG
TGV ANGLE
SENSOR LH
E54
E50
E21
BG
WR
10 BrY
YR
YR
Or
Or
BG
THROTTLE
POSITION
SENSOR
F61
L2 BrY
YB
F5
VW
VW
16
Sb
20
R
R
BG
E13
E8
E8
YB B8
B9
Sb
A1
Sb
S2
Lg
Lg
19
YG
YG
BG
BG
Sb
Lg
Q2
RG
RG
18
Lg
BY
BY
E2
J1 WG
G1
WG
BY
F61
17
F76
15 WG
B209
SMJ
WG
E/G(LTB)-02
WG
E/G(LTB)-06
B7
BY B18
TGV ANGLE
SENSOR RH
B: B135
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
1 2 3
GL10-24I
WI-140

E/G(LTB)-10
E1
BR
A7
BR A15
C18
B
BR
BR
F1
B
N2
16
14
BY
BR
BY
BR
BR
BY
C3
BY
BY
13
BL
BR
C8
BY
BY
BW A22
BW C17
J3 BW
BW
BL
BW
3
BR
BR
15 BW
BL
BL
YG
WY
GY
GY
LY
RY
IGNITION COIL
NO.1
F60
E31
E32
E33
(BLACK)
E34
(BLACK)
1
5
9
13
2
6
10
14
3
7
11
15
(BROWN)
4
8
12
16
IGNITION COIL
NO.2
E:
B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
A: B134
6 7
1 2 3 4 5
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
BL
E34
IGNITION COIL
NO.3
BL
BY
RY
BY
RY
E33
E32
E31
WY
BY
RY
LY
BY
E/G(LTB)-08
RY
E3
F60
BY
D8
BL
BL
A3
BL
YG
E5
YG
E1
YR
D9

YG C21
E: B84
YR C22
YB
N4
YB
YB
GR
F76
D: B137
YR
C24
Y
B209
SMJ
D5
E/G(LTB)-01
E/G(LTB)-05
H3 GR
GR
E/G(LTB)-02
C: B136
YB C23
A: B134
YR
E/G(LTB)-10
WIRING SYSTEM
IGNITION COIL
NO.4
C: B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
GE
D: B137
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
29 30 31
22 23 24 25 26
27 28
1
2
3
GL10-24J
WI-141

E/G(LTB)-11
E/G(LTB)-11
WIRING SYSTEM
(BLACK)
E5
(DARK GRAY)
E6
(DARK GRAY)
E16
(DARK GRAY)
E17
(DARK GRAY)
D1
P
PL
PB
PG
PL
PB
PG
C4
C6
PG
PG
YW
LW
12
PB
PB
10
11
PL
PL
I5
S4
T4
P
P
J5
1
R
GW
R
1 2 3 4
5 6 7 8
F60
1
5
9
13
2
6
10
14
3
7
11
15
(BROWN)
4
8
12
16
SMJ
F76
F60
E3
C: B136
3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
FUEL INJECTOR
NO. 3
E17
2
E6
1
FUEL INJECTOR
NO. 2
YW
LW
FUEL INJECTOR
NO. 1
F44
E16
2
E5
1
LgY
E4
1
1 2
B209
PURGE
CONTROL
SOLENOID
VALVE
E4
GW
LgY
YL
WL
YL
WL
F44
B61
E/G(LTB)-08
C5
WL D16
YL
E/G(LTB)-06
Q4 WL
C: B136 D: B137 ENGINE CONTROL MODULE
FUEL INJECTOR
NO. 4
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
1 2
GL10-24K
WI-142

WIRING SYSTEM
E/G(ROO)-01
E/G(ROO)-01
4. RHD SOHC W/O OBD MODEL
FB-21
F/B FUSE NO. 11
(IG)
BR
GR

MB-9
SBF-5
(B)
FUEL PUMP
RELAY
2
BR
GR
LgB
BW
A
B
E/G(ROO)-03
E/G(ROO)-08
B46
FUEL PUMP ASSEMBLY

FUEL PUMP
2
RB
RB
BW
BW
BW
BW
B97
R15
: WITH IMMOBILIZER SYSTEM : A29

WITHOUT IMMOBILIZER SYSTEM : A16
*1
*1
B7 GR
LgB
R57
R1
R58
BW
A: B134
B: B135
ENGINE CONTROL
MODULE
REF. TO GND-08
B46
(GREEN)
R15 (BLACK)
1
2
3 4 5 6
1 2
3 4
R58
1 2 3
4 5 6
B97
1 2 3 4
5 6 7 8
B: B135
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
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
GR10-23A
WI-143

WIRING SYSTEM
WI-144

E/G(ROO)-03
E/G(ROO)-03
WIRING SYSTEM

ST
IGNITION SWITCH
(ST)
AT MODEL : WR
MT MODEL : WB
WB
*2
AT
MT
P
E/G(ROO)-01
WB 12
WR 11
B12
T3
BY
12
BW
T7
MAIN RELAY
6
BR
YR
BR
YL
Lg
G
H
I
J
E/G(ROO)-05
E/G(ROO)-06
E/G(ROO)-08
E/G(ROO)-09
STARTER MOTOR
B47
TO BATTERY TERMINAL
*2
B14
B47 (BROWN)
1
3
5
2
4
6
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
C: B136
AT
B28 WR
BR
C9
B: B135
AT
YL
C2
B28 WB
YL
C1
B19 Lg
MT
REF. TO GND-07
B26 WB
MT
AT
B: B135
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
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
GR10-23C
WI-145

E/G(ROO)-04
B: B135
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: B135
C: B136
B17 BL
REF. TO AT(R)-04
A31 Br
B16 VW
C11 LR
B21
C3 BW
REF. TO ILM(ROI)-01
ILM(RWI)-01
REF. TO R/DEF(R)-01
REF. TO R/F(NA)-01
A: B134
A12 GR
A3 WL
B27 PB
C30 GR
A17 BrR
B23 YG
B22 RY
REF. TO IMB(R)-02
REF. TO A/C(ARH)-01
E/G(ROO)-04
WIRING SYSTEM
C: B136
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
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
GR10-23D
WI-146

E/G(ROO)-05
E/G(ROO)-05
WIRING SYSTEM
GR B26
MT
LgB B3
RL B20
Or B14
RB B15
NEUTRAL POSITION
SWITCH (MT)
GR
GW
1
2
B25
E/G(ROO)-03
E/G(ROO)-02
E/G(ROO)-02
T2
E/G(ROO)-08
TEST MODE
CONNECTOR
Or
GW
B76
REF. TO GND-07
B25 (BROWN)
B75 (GREEN)
B79 (GRAY)
B300
1 2 3
4 5 6
1
8
2 3
9 10
4 5
11 12
6 7
13 14
13 GW
10 LgB
BR
RG
12 GW
1
4
LINE END CHECK
CONNECTOR
LINE END CONNECTOR
B125
B300
RL
RG
GW
RB
Or
CHECK CONNECTOR
1
2
1 2
B79
B126
B
8
12 LgB
GB
B75
B40
DATA LINK CONNECTOR
B40 (BLACK)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B135
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
GR10-23E
WI-147

E/G(ROO)-06
E/G(ROO)-06
WIRING SYSTEM
RG C16
LgW B8
Lg C17
Sb C15
YR C12
C7
SB C23
B: B135 C: B136 ENGINE CONTROL MODULE
SHIELD AND
SENSOR GROUND
JOINT CONNECTOR
RG
RL
BR
LgW 6
B
(DARK BROWN)
E13
1 2 3
2 1
4 3
1 2 3 4
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
E/G(ROO)-07
E/G(ROO)-08
E/G(ROO)-07
E/G(ROO)-07
9
BR
BR
11
RL
E/G(ROO)-07
THROTTLE POSITION
SENSOR
B21 (LIGHT GRAY)
B83
1 2 3 4 5 6
E13
CO ADJUSTING
RESISTOR
B18
B: B135
B28
OXYGEN SENSOR
B28
YR
Sb
YR
BR
BW
YR
E2
B18
Lg
12
YR
WR
B21
WR
E/G(ROO)-03
Sb
B83
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
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
GR10-23F
WI-148

E/G(ROO)-07
A6
A20
A5
A19
*4
R
LW
WB
BL
BR
*3
W
C4
C: B136
SB B10
B: B135
SB C25
BY C14
C5
Br C13
A: B134
E/G(ROO)-07
WIRING SYSTEM
: WITH
IMMOBILIZER
SYSTEM : B2
WITHOUT
IMMOBILIZER
SYSTEM : B1
4 : WITH
IMMOBILIZER
SYSTEM : B1
WITHOUT
IMMOBILIZER
SYSTEM : B2
*3
16
17
19
18
20
2
4
1
3
PL
Y
Or
B
W
GL
LB
L
RY
E8
E10 (LIGHT GRAY)

E15
(BLACK)
1 2
3
E20
(BLACK)
IDLE AIR CONTROL

SOLENOID VALVE
(BLACK)
1 2 3
4 5 6
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
B21
E/G(ROO)-08
E/G(ROO)-08
E/G(ROO)-09
GL
LB
L
RY
Y
Y
1
3
4
6
2
5
CAMSHAFT
POSITION SENSOR
1 2
B: B135
B
W
CRANKSHAFT
POSITION SENSOR
E7
1 2 3 4
R
G
E15
2
3
1
(LIGHT GRAY)
E10
E14
PRESSURE SENSOR
KNOCK
ENGINE COOLANT
AND INTAKE AIR
TEMPERATURE SENSOR
AND THERMOMETER
E14
LW
WB
BL
BR
13
BY
E8
2
1
3
4
E20
1
2
Y
Or
E/G(ROO)-06
1
2
PL
E/G(ROO)-06
Br
BR
YR
R
E/G(ROO)-02
BR
WG
BY
E2
W
B
Br
14
B21
Br
E/G(ROO)-06
15
E/G(ROO)-06
BY
E7
(LIGHT GRAY)
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
A: B134
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
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
GR10-23G
WI-149

E/G(ROO)-08
WL A2
LgW A26
YL A25
*5
GW
GW C22
GW C21
BY A7
WL
YR
3
WR
L
L
WR
RG
6 LgW
GR
YW
YL
BL
14
RG
YW
E/G(ROO)-07
GW
GR
POWER STEERING OIL

PRESSURE SWITCH
E4
(BLUE)
1 2
E12
1 2 3 4
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
B22 (BROWN)
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B21 (LIGHT GRAY)

1 2
3 4
6 7
8
11 12
9 10
14 15
13
16
19 20
17 18
5
E12
E4
2
4
*7 *6
IGNITION COIL
AND IGNITOR
GE
( 8)
BW
BW
GW
E19
GW
GR
E/G(ROO)-07
GW
E3
16 GW
E2
BR
B22
B21
BR
N
BY
E/G(ROO)-06
13
15 BW
E/G(ROO)-02
E/G(ROO)-05
MODEL : B6
*5 : AT
MT MODEL : B25
*6 : 1.6L MODEL
*7 : EXCEPT 1.6L MODEL
( 8 ) 1.6L
* EXCEPT 1.6L :: (GRAY)
(DARK GRAY)
OrB
E/G(ROO)-03
E/G(ROO)-01
BW A8
OrB B13
A: B134 B: B135
BL A27
E/G(ROO)-08
WIRING SYSTEM
PURGE CONTROL
SOLENOID VALVE
B: B135
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
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
GR10-23H
WI-150

E/G(ROO)-09
E/G(ROO)-09
WIRING SYSTEM
PL A13
PB A14
PG A15
PL
PB
PG
A4
P
P
12
11
GB
GOr
10
Lg
Br
B22
E3
FUEL INJECTOR
NO. 1
E5
(LIGHT GRAY)
E6
(LIGHT GRAY)
E16
(LIGHT GRAY)
E17
(LIGHT GRAY)
2
6
10
14
3
7
11
15
4
8
12
16
GB
FUEL INJECTOR
NO. 3
E17
2
E6
1
GOr
FUEL INJECTOR
NO. 2
FUEL INJECTOR
NO. 4
A: B134
B22 (BROWN)
1
5
9
13
E16
1
E5
Lg
E/G(ROO)-07
Br
YL
E/G(ROO)-03
1 2
3 4
5 6
7 8
9 10 11 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
GR10-23I
WI-151

WIRING SYSTEM
E/G(RWO)-01
XXX-001
XXX-001
E/G(RWO)-01
5. RHD SOHC MODEL
: EXCEPT 2.5L MODEL : BrB

2.5L MODEL : L
: EXCEPT 2.5L MODEL : BrB
2.5L MODEL : BrW
GR
*2
*3
FB-21
F/B FUSE NO. 11
(IG)
BR

MB-9
SBF-5
(B)
E25 : EXCEPT 2.5L MODEL

25 : 2.5L MODEL
FUEL PUMP
RELAY
2
BR
GR
LgB
BW
A E/G(RWO)-03
B E/G(RWO)-08
B46
FUEL PUMP ASSEMBLY

R1
FUEL PUMP
RB
RB
BW
BW
BW
R58
FUEL SUB
LEVEL SENSOR
E25
BrW
*
25
E25
25
FUEL LEVEL SENSOR
R57
B97
BW
GW
GW
19 GW
BrW
BrW
R3
R15
BW
C E/G(RWO)-02
BrW
B99
A: B134
B: B135
B7 GR
A29 LgB
C27 BrW
R59
C: B136
ENGINE CONTROL
MODULE
REF. TO GND-08
B46
R59
(GREEN)
1 2
3 4
1 2
B: B135
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
R15 (BLACK)
1
2
3 4 5 6
R58
1 2 3
4 5 6
B97
B99
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
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
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
GR10-25A
WI-152

WIRING SYSTEM
WI-153

E/G(RWO)-03
E/G(RWO)-03
WIRING SYSTEM

ST
IGNITION SWITCH
(ST)
AT MODEL : WR
MT MODEL : WB
WB
*1
MT
AT
E/G(RWO)-01

P
WB 12
WR 11
B12
T3
BY
12
BW
T7
MAIN RELAY
6
BR
YR
BR
YL
Lg
H E/G(RWO)-05
I E/G(RWO)-06
J
E/G(RWO)-09
STARTER MOTOR
B47
TO BATTERY TERMINAL
*1
MT
AT
B47 (BROWN)
1
3
5
2
4
6
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
C: B136
AT
B28 WR
BR
C9
B: B135
AT
YL
C2
B28 WB
YL
C1
B19 Lg
MT
REF. TO GND-07
B26 WB
B14
B: B135
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
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
GR10-25C
WI-154
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
C: B136
B17 BL
B16 VW
C11 LR
A31 Br
B4 LgB
B21
C3 BW
REF. TO ILM(R)-01
REF. TO AT(R)-04
E/G(RWO)-04
B: B135
B: B135
REF. TO R/DEF(R)-01
REF. TO R/F(NA)-01
A: B134
A12 GR
A3 WL
C30 GR
B27 PB
A17 BrR
B23 YG
B22 RY
REF. TO IMB(R)-02
REF. TO A/C(ARH)-01
E/G(RWO)-04
WIRING SYSTEM
C: B136
A: B134
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
GR10-25D
WI-155

E/G(RWO)-05
E/G(RWO)-05
WIRING SYSTEM
GR B26
MT
LgB B3
RL B20
Or B14
NEUTRAL POSITION
SWITCH (MT)
GR
BW
1
2
B25
T2
E/G(RWO)-03
E/G(RWO)-08
E/G(RWO)-02
E/G(RWO)-08
E/G(RWO)-02
TEST MODE
CONNECTOR
RB
GW
B76
B25 (BROWN)
B75 (GREEN)
1
8
2 3 4 5
9 10 11 12
13 GW
10 LgB
12 GW
B40
DATA LINK CONNECTOR
B79 (GRAY)
B300
1 2 3
4 5 6
LINE END CHECK

CONNECTOR
B300
1
4
LINE END CONNECTOR
BR
B126
B125
RG
RL
RG
RB
Or
Or
CHECK CONNECTOR
1
2
1 2
B79
4
12 LgB
7
REF. TO GND-07
GB
B75
6 7
13 14
B40 (BLACK)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B135
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
GR10-25E
WI-156

E/G(RWO)-06
Lg C17
RG C16
Sb C15
GW C29
C6
C20
SB C23
C7
C19
WG A22
WG A23
SB C24
C18
L
BW A21
A: B134
E/G(RWO)-06
WIRING SYSTEM
SHIELD AND
SENSOR GROUND
JOINT CONNECTOR
BW
RG
BW
GY
SB
Gr
RL
9
BR
RL
11
Lg
12
B21
YR
WR
E/G(LWO)-03
Sb
B83
E2
M E/G(RWO)-07
B19
1 2 3
2 1
4 3
C: B136
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
E13 (DARK BROWN)
1 2 3
4 5 6
1 2 3 4
BR
YR
E13
3
ATMOSPHERIC
PRESSURE SENSOR
THROTTLE POSITION
SENSOR
B21 (LIGHT GRAY)
B18
B83
WR
Sb
Gr
1
2
B2
B2
2
B18
B19
REAR OXYGEN SENSOR
GW
YR
WG
GY
YR
BW
N E/G(RWO)-07
1 2
3
6 7
9 10
11
13
14 15
17 18
19
5
4
8
12
16
20
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
GR10-25F
WI-157
E/G(RWO)-02
E/G(RWO)-06
E/G(RWO)-06
E/G(RWO)-07
LW
WB
BL
BR
LW
WB
BL
BR
SB B10
R
B
R
B
B1
B8
B2
B9
W
G
B21
2
4
1
3
E2
GL
LB
L
RY
B
W
Y
Or
18
19
17
20
W
G
C4
Y
Y
PL
BY
A6
A20
A5
A19
C: B136
16
BY C14
BY
B: B135
13
Br C13
Br
14
Br
15
C5
G
G
A: B134
SB C25
E/G(RWO)-07
WIRING SYSTEM
O E/G(RWO)-08
P E/G(RWO)-08
(LIGHT GRAY)
E8
(BLACK)
1 2
3
E14
E15
E20
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
GL
LB
L
RY
Y
Y
1
2
1
3
4
6
2
5
CAMSHAFT
POSITION SENSOR
IDLE AIR CONTROL

SOLENOID VALVE
(BLACK)
1 2 3 4
E7
1 2 3
4 5 6
1 2
B: B135
B
W
Y
Or
CRANKSHAFT
POSITION SENSOR
2
3
1
(LIGHT GRAY)
E15
E14
PRESSURE SENSOR
KNOCK
ENGINE COOLANT
AND INTAKE AIR
TEMPERATURE SENSOR
AND THERMOMETER
E10
E10
1
2
E8
2
1
3
4
E20
PL
BR
WG
BY
Br
BR
YR
R
Q E/G(RWO)-08
C: B136
E7
(BLACK)
B21 (LIGHT GRAY)

1 2
5
6
9 10
13
14
17 18
3 4
7
8
11 12
15
16
19 20
A: B134
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
21 22
28 29 30
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
GR10-25G
WI-158
E4
(BLACK)
(PURPLE)
E/G(RWO)-08
WL A2
PL A24
LgW A26
WL
PL
6 LgW
E3
WR
YL
GR
5
RG
YW
GW
14
BL
16 GW
BR
E12
1 2 3 4
1 2
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
B22 (BROWN)
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B21 (LIGHT GRAY)

1 2
3 4
6 7
8
11 12
9 10
14 15
13
16
19 20
17 18
5
WR
E12
E4
E42
* *
2
4
IGNITION COIL
AND IGNITOR
GE
: ( 5)
RG
GW
GW
GW
BR
3
POWER STEERING OIL
PRESSURE SWITCH
E42
YL A25
BL A27
*2
GW C22
BR A35
GW C21
BY A7
BR A34
BR
BW
BW
E19
YW
E/G(RWO)-07
E/G(RWO)-07
B22
R E/G(RWO)-09
GR
E/G(RWO)-07
E2
B
GR
B21
BR
E/G(RWO)-05
1.6L : (DARK GRAY)
BR
BY
E/G(RWO)-02
13
15 BW
E/G(RWO)-05
MODEL : B6
*2 : AT
MT MODEL : B25
*3 : 1.6L MODEL
1.6L
*4 : EXCEPT
MODEL
( 5 ) 1.6L : (GRAY)
* EXCEPT
OrB
E/G(RWO)-01
BW A8
OrB B13
A: B134 B: B135
GW
E/G(RWO)-08
WIRING SYSTEM
AIR ASSIST INJECTOR PURGE CONTROL

SOLENOID VALVE
SOLENOID VALVE
B: B135
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
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
GR10-25H
WI-159

E/G(RWO)-09
E/G(RWO)-09
WIRING SYSTEM
PL A13
PB A14
PG A15
PL
PB
PG
A4
P
P
12
11
GB
GOr
10
Lg
Br
B22
E3
FUEL INJECTOR
NO. 1
E5
(LIGHT GRAY)
E6
(LIGHT GRAY)
E16
(LIGHT GRAY)
E17
(LIGHT GRAY)
B22 (BROWN)
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
GB
FUEL INJECTOR
NO. 3
E17
2
E6
1
GOr
FUEL INJECTOR
NO. 2
E16
1
E5
Lg
E/G(RWO)-08
Br
YL
E/G(RWO)-03
FUEL INJECTOR
NO. 4
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
1 2
GR10-25I
WI-160

WIRING SYSTEM
E/G(RTB)-01
E/G(RTB)-01
6. RHD DOHC TURBO MODEL
GR
FB-21
F/B FUSE NO. 11
(IG)
BR

MB-9
SBF-5
(B)
FUEL PUMP
RELAY
REF. TO GND-07
BR
GR
BW
A
B
E/G(RTB)-03
E/G(RTB)-02
E/G(RTB)-10
B46

BW
10 BW
FUEL PUMP ASSEMBLY
LgR
LgB
BW
BY
R1
BW
B97
R122
FUEL PUMP
RB
RB
BY
LgR
15 LgR
BW
BW
BW
LgB
14 LgB
GW
GW
19 GW
BrB
BrW
BrW
L
BrB
B99
R59
A: B134
B: B135
A14 GR
2
1
R3
R15
A13 LgR
FUEL SUB
LEVEL SENSOR
R57
C16 LgB
R58
BrW
B25 BrW
FUEL LEVEL SENSOR
C: B136
ENGINE CONTROL
MODULE
REF. TO GND-08
B46
R59
1 2
(GREEN)
1 2
3 4
B99
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
R15 (BLACK)
2
1
3 4 5 6
R58
1 2 3
4 5 6
R122
1 2 3 4
5 6 7 8
3 4
1 2
5 6 7 8 9 10
C: B136
A: B134
6 7
1 2 3 4 5
8 9 10 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
22 23 24
17 18 19 20 21
B: B135
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
GR10-24A
WI-161

WIRING SYSTEM
WI-162

E/G(RTB)-03
E/G(RTB)-03
WIRING SYSTEM

ST
IGNITION SWITCH
(ST)
*1
WB
AT MODEL : WR
MT MODEL : WB
MT
AT

P
E/G(RTB)-01
WB 12
BY
12
WR 11
BW
B12
T3
T7
MAIN RELAY
6
BR
YR
BR
YL
Lg
I
J
E/G(RTB)-05
E/G(RTB)-06
E/G(RTB)-06
STARTER MOTOR
B47
AT
TO BATTERY TERMINAL
MT
*1
A: B134
B47 (BROWN)
1
3
5
2
4
6
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
D: B137
AT
AT
MT
A16 WR
A16 WB
YL
D3
D10 BR
Lg
YL
A2
D2
REF. TO GND-07
A8 WB
B14
A: B134
6 7
1 2 3 4 5
8 9 10 11 12 13 14 15
16 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 26
27 28
29 30 31
GR10-24C
WI-163
D: B137
A17 BW
A3
D28 GR
B: B135
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
REF. TO ILM(ROI)-01
ILM(RWI)-01
E/G(RTB)-04
6 7
1 2 3 4 5
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
B: B135
REF. TO R/DEF(R)-01
REF. TO R/F(TB)-01
A: B134
A: B134
D17 WL
A9 GR
PB
A6
D27 BrR
YG
B5
B14 RY
REF. TO IMB(R)-02
REF. TO A/C(ARH)-01
E/G(RTB)-04
WIRING SYSTEM
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
GR10-24D
WI-164

E/G(RTB)-05
E/G(RTB)-05
WIRING SYSTEM
MT
GR A8
LgB A21
RG A20
Or
A5
RL A10
NEUTRAL POSITION
SWITCH
GR
GW
1
3
B128
E/G(RTB)-02
E/G(RTB)-02
E/G(RTB)-10
GW
E/G(RTB)-03
T9
B76
B75
B75 (GREEN)
1
2
CHECK CONNECTOR
B128 (GRAY)
1 2
3 4
B79 (GRAY)
1
8
2 3
9 10
4 5
11 12
6 7
13 14
RL
BR
RG
RW
B40 (BLACK)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B300
4
12 GW
13 GW
BR
1
BR
10 LgB
6
1 2 3
4 5 6
B40
DATA LINK CONNECTOR
LINE END CONNECTOR
B300
B126
B125
RW
RB
Or
Or
B79
4
12 LgB
7
REF. TO GND-07
GB
TEST MODE
CONNECTOR
LINE END CHECK

CONNECTOR
A: B134
1 2 3 4 5
6 7
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
GR10-24E
WI-165

E/G(RTB)-06
SB B26
RG B19
B17
L
RW C13
D19
B
SB D18
D5
W D29
D4
BR
E8
E: B84
W B16
E13
G
SB
BG
E7
LW B27
BW D24
B: B135 C: B136 D: B137
BR
E/G(RTB)-06
WIRING SYSTEM
B259
B260
SHIELD AND
SENSOR GROUND
JOINT CONNECTOR
BW
RG
BR
SB
RY
RW
SB
RL
B83
B259
B279
1 2
B18
1
3
2
4
1 2
E: B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
C: B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
1
3
B3
B83
1 2 3 4 5
1 2 3 4 5 6
B: B135
RW
RW
YR
B19
2
B18
B279
FRONT OXYGEN
EXHAUST GAS
TEMPERATURE SENSOR (A/F) SENSOR
B19
2
4
RY
LW
YL
AIR FLOW
SENSOR
WASTEGATE
SOLENOID
B127
B3
1
B127
E/G(RTB)-11
YR
BR
E/G(RTB)-03
BR
E/G(RTB)-09
BG
YL
BW
E/G(RTB)-03
REAR OXYGEN
SENSOR
D: B137
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 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
GR10-24F
WI-166

E/G(RTB)-07
E/G(RTB)-07
WIRING SYSTEM
B4
Y
SB B22
SB B21
B1
R
B10
B
B
B2
B11
W
W
RL
RL
E14
2
E15
2
E10
1
3
Or
E1
Or
WL
WL
OrL
OrL
B20
GE
CRANKSHAFT
POSITION SENSOR
E10 (LIGHT GRAY)
E14 (GRAY)
E15 (LIGHT GRAY)
B20 (LIGHT GRAY)

1 2 3 4
6
7
5
8
9 10
CAMSHAFT
POSITION SENSOR
KNOCK
SENSOR
B: B135
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
1 2
GR10-24G
WI-167
OrB B24
LR E10
LY E11
E4
Y
YG E5
BR C10
LR
LY
YG
BR
12
B21
E2
GL
WL
YL
RY
14 WR
E/G(RTB)-02
E: B84
11 OrB
B: B135 C: B136
E/G(RTB)-08
E/G(RTB)-08
WIRING SYSTEM
O E/G(RTB)-11
E51 (BLACK)
E7
E55 (BLACK)
1 2 3
1 2
(BROWN)
BW
GL
TGV RH
E/G(RTB)-10
E7
E55
E51
TGV LH
OIL PRESSURE SWITCH
WL
L
E19
E11
YL
RY
IDLE AIR CONTROL

SOLENOID VALVE
POWER STEERING OIL

PRESSURE SWITCH
E: B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
B21 (BLACK)
1 2
3 4
6 7
8
10
11 12
9
14 15
13
16
19 20
17 18
5
C: B136
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: B135
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
GR10-24H
WI-168

E/G(RTB)-09
E/G(RTB)-09
WIRING SYSTEM
B9
Sb
YB B8
RB B13
YL B23
Sb
ENGINE COOLANT
TEMPERATURE SENSOR
AND THERMOMETER
1 2
3
(LIGHT GRAY)
E21
E50
(BLACK)
E54
(BLACK)
YB
RB
YL
B21 (BLACK)
1 2
3 4
6 7
8
10
11 12
9
14 15
13
16
19 20
17 18
5
WR
BG
YR
PRESSURE
SENSOR
TGV ANGLE
SENSOR LH
E54
E50
E21
E2
BG
WR
10
B21
YR
16
Or
BG
R
R
THROTTLE
POSITION
SENSOR
E13 (BLACK)
(BLACK)
E13
E8
E8
Or
20
B7
Lg
Lg
BG
BG
BG
YG
H
H
YG
WG
WG
19
RL
18
E/G(RTB)-02
17
15 WG
E/G(RTB)-06
BY
BY B18
TGV ANGLE
SENSOR RH
B: B135
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
1 2 3
GR10-24I
WI-169

E/G(RTB)-10
GW E1
GW A15
C18
GW A7
B
B
14
BY
BR
BY
BR
16 GW
C8
BY
BY
13
BL
BY
BW A22
BL
BW
BW C17
15 BW
BW D8
BW D9
BW
3
BR
BR
YG C21
YG
7
WY
YR C22
YR
YB C23
GY
GY
4
RY
RY
B22
E3
IGNITION COIL
NO.1
B22 (BROWN)
E31
E32
E33
(BLACK)
E34
(BLACK)
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
E:
B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15
16 17
BY
BL
E34
IGNITION COIL
NO.3
BL
BY
RY
BY
RY
IGNITION COIL
NO.2
E33
E32
E31
WY
LY
RY
BY
BY
E/R(RTB)-08
LY
E/R(RTB)-01
E: B84
YB
C24
D: B137
E/R(RTB)-05
GR
E/R(RTB)-02
C: B136
A: B134
E/G(RTB)-10
WIRING SYSTEM
IGNITION COIL
NO.4
A: B134
6 7
1 2 3 4 5
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
GE
C: B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 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
1
2
3
GR10-24J
WI-170

E/G(RTB)-11
E/G(RTB)-11
WIRING SYSTEM
PB
PG
PB
PG
C4
C5
PL
PL
C6
12
YW
11
10
LW
YL
1
R
GW
GW
2
LgY
B22
E3
PURGE
CONTROL
SOLENOID
VALVE
E5
(DARK GRAY)
E6
(DARK GRAY)
E16
(DARK GRAY)
E17
(DARK GRAY)
E4
1 2
(BLACK)
2
6
10
14
3
7
11
15
4
8
12
16
C: B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
FUEL INJECTOR
NO. 3
E17
2
E6
FUEL INJECTOR
NO. 2
YW
LW
E16
FUEL INJECTOR
NO. 1
B22 (BROWN)
1
5
9
13
E5
2
E4
1
R
1
LgY
E/G(RTB)-08
WL
E/G(RTB)-06
D1
WL D16
C: B136 D: B137 ENGINE CONTROL MODULE
FUEL INJECTOR
NO. 4
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
1 2
GR10-24K
WI-171
FUEL GAUGE SYSTEM

WIRING SYSTEM
17.Fuel Gauge System

A: SCHEMATIC
WI-172
FUEL GAUGE SYSTEM

WIRING SYSTEM
1. LHD MODEL
F/G(L)-01
F/G(L)-01
23 RW
RW
FB-36
F/B FUSE NO. 13
(IG)
B36
A7 GOr
i1
LOW-FUEL
WARNING
LIGHT
I/F
CUSTOM
CPU

DRIVER
COMBINATION
METER
FUEL
GAUGE
I/F
A:
i10
C:
i12
24
B
FUEL SUB
LEVEL SENSOR
(TURBO ENGINE
MODEL)
BrW C2
BrW
ET2 : EXCEPT TURBO AND

2.5L ENGINE MODEL
B: B135
BrW B25
i2
T25 : TURBO AND 2.5L ENGINE MODEL
BrW
A6
EN : NON-TURBO ENGINE MODEL

FOR EUROPE
B37
TB
C: B136
BrW
L
T25
TB
BrW
11 BrW
BrW
EN
T25
TB
R59
BR
ET2
TB
B209
R58
R57
GB
3
R3
R15
BR
F60
F76
BR
E3
SMJ
NA
BR
B99
B22
16
BR
NA
E3
BR
1
B
16
3
5
BR
BR
N2
ENGINE
CONTROL
MODULE
(NON-TURBO
ENGINE MODEL
FOR EUROPE)
TB
FUEL LEVEL
SENSOR
R59
BrW C27
ET2
1
4
*1
ENGINE
CONTROL
MODULE
(TURBO
ENGINE
MODEL)
REF. TO GND-02
GE
: NON- TURBO ENGINE MODEL : BrW

: L
TURBO ENGINE MODEL
R15 (BLACK)
2
1
3 4 5 6
B36 (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
A:
R58
1 2 3
4 5 6
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
C:
i12
(GREEN)
B22 (BROWN)
F60 (BROWN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1
5
9
13
B: B135
B99
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
2
6
10
14
3
7
11
15
4
8
12
16
C: B136
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
GL61-21
WI-173
FUEL GAUGE SYSTEM

WIRING SYSTEM
F/G(R)-01
F/G(R)-01
2. RHD MODEL
GW
FB-36
F/B FUSE NO. 13
(IG)
GW
AT
GW
MT
B38
GW 22
B36
GW
i1
AT
MT
A7 GW
AT : AT MODEL
i3
MT : MT MODEL
LOW-FUEL
WARNING
LIGHT

EN : NON-TURBO ENGINE MODEL
FOR EUROPE
I/F
CUSTOM
CPU
DRIVER
COMBINATION
METER
FUEL
GAUGE
I/F
A:
i10
C:
i12
BrW
ET2 : EXCEPT TURBO AND 2.5L

ENGINE MODEL
ENGINE
CONTROL
MODULE
(TURBO
ENGINE
MODEL)
BrW B25
i2
21
FUEL SUB
LEVEL SENSOR
(TURBO ENGINE
MODEL)
B: B135
BrW C2
A6
T25 : TURBO AND 2.5L ENGINE MODEL
B37
TB
C: B136
BrW
L
T25
BrW
BrW
GW
19 GW
FUEL LEVEL
SENSOR
ENGINE
CONTROL
MODULE
(NON-TURBO
ENGINE MODEL
FOR EUROPE)
BrW C27
ET2
R58
R57
R15
R3
GW 16
B99
B22
BR
E3
BR
*B1
3
5
REF. TO GND-07
GE
: NON-TURBO ENGINE MODEL : BrW

: L
TURBO ENGINE MODEL
R15 (BLACK)
R59
1
EN
T25
R59
*1
BrW
ET2
1
4
2
1
3 4 5 6
i3
(BLACK)
B99
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
A:
R58
1 2 3
4 5 6
i10
(GREEN)
C:
1 2 3 4 5 6 7 8 9 10
(BLACK)
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B: B135
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
i1
i12
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
B22 (BROWN)
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
GR61-21
WI-174
FULL-TIME DUAL-RANGE SYSTEM

WIRING SYSTEM
18.Full-Time Dual-Range System

A: SCHEMATIC
WI-175

WIRING SYSTEM
1. LHD MODEL
D/R(L)-01
D/R(L)-01
B36
i1
GOr
23 RW
RW
FB-36
F/B FUSE NO. 13
(IG)
COMBINATION METER
A:
i10
B:
i11
DIMMER
CIRCUIT
GOr A7
AWD-LO
INDICATOR LIGHT
WB
19 WB
WB B10
i2
B37
AWD-LO
SWITCH
WB
B
T8
B29
2
1
REF. TO GND-02
A:
B29
1 2
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
B:
i11
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B36 (BLACK)
7 8 9 10 11
1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
GL38-20
WI-176

WIRING SYSTEM
2. RHD MODEL
D/R(R)-01
D/R(R)-01
GW
FB-36
F/B FUSE NO. 13
(IG)
AT
MT
B38
4
22
B36
i3
i1
AT
MT
COMBINATION METER
DIMMER
CIRCUIT
GW A7
AWD-LO
INDICATOR LIGHT
WB
B36
10 WB
i1
WB B10
A:
i10
B:
i11
AWD-LO
SWITCH
WB
B
T8
B29
2
1
REF. TO GND-07
B29
1 2
A:
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
i1
(BLACK)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
i3
(BLACK)
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
B:
i11
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
GR38-21
WI-177
FRONT ACCESSORY POWER SUPPLY SYSTEM

WIRING SYSTEM
19.Front Accessory Power Supply System
YR
FB-28
F/B FUSE NO. 4
(ACC)
FAPS-01
FAPS-01
A: SCHEMATIC
FRONT ACCESSORY
POWER SUPPLY SOCKET
YR
REF. TO ILM(L)-01
ILM(ROI)-01
ILM(RWI)-01
B119
: WITH ILLUMINATION
: YL
CONTROL MODEL
WITHOUT ILLUMINATION
CONTROL MODEL
:B
*2
: LHD MODEL :
REF. TO GND-02
RHD MODEL :
REF.TO GND-07
B
*1
*2
B119
1 2
3 4
GG97-21
WI-178
HEADLIGHT BEAM LEVELER SYSTEM

WIRING SYSTEM
20.Headlight Beam Leveler System
HLBL-01
HLBL-01
A: SCHEMATIC
FB-11
TAIL & ILLUMINATION RELAY
V
*1
FB-6
FB FUSE NO.5

V
1 : LHD MODEL : RY
RHD MODEL : WR
2 : LHD MODEL : LR
RHD MODEL : RG
3 : LHD MODEL : WL
RHD MODEL : B
B132
F45
B
12
11
B62
19
LHD RHD
5 : LHD MODEL :
REF. TO GND-02
RHD MODEL :
REF.TO GND-07
*23
*
*23
*B
*23
*
: LHD MODEL :
REF. TO GND-01
RHD MODEL :
REF.TO GND-06
*4
LHD RHD
2
2
*5
3
2
1
*12
*3
*
*12
*3
*
2
1
F59
F58
*4
F58
(BLACK)
B132
F45
F59
(BLACK)
1 2 3 4
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
: RHD
F45
: LHD
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
GG83-21
WI-179
HORN SYSTEM
WIRING SYSTEM
21.Horn System
HORN-01
HORN-01
A: SCHEMATIC
MB-4
HORN RELAY
MB-5
HORN RELAY
BL
RG
LHD
RHD
LHD : LHD MODEL
F45
B62
LHD
RG
10
RG
RHD : RHD MODEL
RG
BL
BL
RHD
B68
F47
1
F5
HORN
HORN
B68 (BLACK)
2
1
3 4 5
HORN SWITCH
F45
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
GG74-20
WI-180
IMMOBILIZER SYSTEM
WIRING SYSTEM
22.Immobilizer System
A: SCHEMATIC
WI-181
IMMOBILIZER SYSTEM
WIRING SYSTEM
1. LHD MODEL
FB-21
F/B FUSE NO. 11
(IG)
MB-6
M/B FUSE NO. 6
(B)
LR
BR
GR
W
W
B36
23
20
IMB(L)-01
MB-9
SBF-5
(B)
LR
IMB(L)-01

FB-9
M/B FUSE NO. 2
(B)
LR
i1
TB
NA
F45
A10 LR
B62
KEY WARNING
SWITCH
COMBINATION
METER
IMMOBILIZER
INDICATOR
LIGHT
A:
i10
B:
i11
WR
BrR B6
B74
RY B23
NA
BR
i2
2
F44
TB
YB B14
B61
NA
B37
BR
BrR
17 BrR
YB B22
ENGINE
B: B135 CONTROL
MODULE
NA
RY
RY
YB
1
GR
12
BR
11
WR
BR
10
BrR
9
TB
B5
ENGINE
B: B135 CONTROL
MODULE
TB
B74 (BLACK)
F44
1
2
1 2 3 4
5 6 7 8
F45
i2
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:
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
B: B135 : TB
B: B135 : NA
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
B36 (BLACK)
B141
1 2 3
4 5
6 7 8 9 10 11 12
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
7 8 9 10 11
1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
B:
i11
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
GL91-21A
WI-182
IMMOBILIZER SYSTEM
B142
ANTENNA
B141
DIODE
(WAGON)
REAR DOOR
SWITCH RH
Y
24
B268
B99
YR
Y
B
FRONT DOOR
SWITCH RH
1
3
R30
REAR GATE LATCH
SWITCH (WAGON)
R3
1
3
Y
B
WG
YR
YR
R38
YB
B
R16
D46
N2 BR
F76
Y
B
TB
NA
BR
B209
E3
B22
3
D35
E3
R39
NA
16
16
BR
F60
BR
SMJ
R22
BR
1
3
1
2
D34
BR
REAR DOOR
SWITCH LH
3
BR
BR
IMB(L)-02
IMB(L)-02
WIRING SYSTEM
WG : WAGON
BR
TB
GE
REF. TO GND-05

REF. TO GND-03
REF. TO GND-02
R30
D46
B142
B268
D35
D34
B141
1 2
1
2
1 2
R16
1 2
3 4
1 2 3
4 5 6
1 2 3
4 5
6 7 8 9 10 11 12
B99
R22
1
2
3
B22 (BROWN)
F60
1
5
9
13
2
6
10
14
3
7
11
15
(BROWN)
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
GL91-21B
WI-183
IMMOBILIZER SYSTEM
WIRING SYSTEM
2. RHD MODEL
FB-21
F/B FUSE NO. 11
(IG)
MB-6
M/B FUSE NO. 6
(B)
BR
GR
AT
IMB(R)-01
MB-9
SBF-5
(B)
LR
IMB(R)-01

MB-10
M/B FUSE NO. 2
(B)
TB
NA
MT
B38
3
21
B36
i3
i1
AT
MT
A10 LR
KEY WARNING
SWITCH
COMBINATION
METER
IMMOBILIZER
INDICATOR
LIGHT
A:
i10
B:
i11
WR
B74
BrR B6
RY B23
B: B135
ENGINE
CONTROL
MODULE
NA
B: B135
ENGINE
CONTROL
MODULE
TB
TB
YG
B5
i2
NA
B37
YG
RY B14
RY
WR
GR
12
BR
BR
11
TB
10
BrR
9
BrR
22
BrR
NA
YG B22
A:
B74 (BLACK)
1
2
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
B: B135 : TB
7 8 9
1 2 3 4 5 6
10 11 12 13 14 15 16 17 18 19
23 24 25 26 27 28
20 21 22
B:
(BLACK)
B141
i1
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
i11
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
i3
(BLACK)
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
B: B135 : NA
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
i2
5 6 7 8
1 2 3 4
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
GR91-21A
WI-184
IMMOBILIZER SYSTEM
B142
B141
ANTENNA
GW
GW
IMB(R)-02
IMB(R)-02
WIRING SYSTEM
DIODE
(WAGON)
1
Y
B268
R30
B99
YR
Y
B
1
3
FRONT DOOR
SWITCH LH
REAR DOOR
SWITCH RH
REAR GATE LATCH

SWITCH (WAGON)
R3
Y
B
1
3
WG
YR
R38
16 GW
BR
R39
REF. TO GND-07
GE
REF. TO GND-10
1
2
E3
REF. TO GND-08
D46 (BLACK)
1 2
B22
R22
B142
1
2
D46
Y
B
1
3
YB
B
D34
R16
BR
REAR DOOR
SWITCH LH
YR
D35
WG : WAGON
R30
B268
D35
D34
B141
1 2
R16
1 2
3 4
1 2 3
4 5 6
1 2 3
4 5
6 7 8 9 10 11 12
R22
1
2
3
B22 (BROWN)
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B99
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
GR91-21B
WI-185

WIRING SYSTEM
23.Keyless Entry System

A: SCHEMATIC
WI-186

WIRING SYSTEM
K/L(L)-01
K/L(L)-01
1. LHD MODEL
W
23
MB-6
M/B FUSE NO. 6
(B)
WB

FB-35
F/B FUSE NO. 3
(B)
F45
B62
W
WR
2
1
WR
15
16 WB
B74
13 LgB
12
BG
REF. TO TURN(L)-01
KEY WARNING
SWITCH
B176 KEYLESS ENTRY CONTROL MODULE
B74 (BLACK)
1
2
B176
1 2 3 4 5
11 12 13 14
15
F45
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
6 7 8 9 10
16 17 18
GL77-21A
WI-187

WIRING SYSTEM
11
BL
YR
LR
5
LR
A10 LR
LR
3
Y
20
FB-9
M/B FUSE NO. 2
(B)
i1
IGNITION SWITCH
ILLUMINATION
B36
i2
LR
20
B37
COMBINATION
METER
DOOR
B14
A:
i10
B:
i11
LR
YR
B224
LW B13
K/L(L)-02
K/L(L)-02

ROOM LIGHT
i2
7
DIODE
(WAGON)
LOr
B
B90
R50
OFF
B183 CODE
ENTRY
B184 CONNECTOR
R30
B
2
YR
Y
REAR DOOR
SWITCH RH
WG : WAGON
YR
B99
R38
YR
R3
Y
B
REAR GATE LATCH

SWITCH (WAGON)
D34
YR
B
WG
R16
1
2
D46
B
REAR DOOR
SWITCH LH
DOOR
R52
24
B268
1
3
Y
B
Y
1
3
LR
ON
B267
FRONT DOOR
SWITCH RH
1
3
B37
BL
LOr
FRONT DOOR
SWITCH LH
LR
YR
D35
Y
B
R39
B
1
3
B224
D46
1
2
1 2
REF. TO GND-02
REF. TO GND-02
REF. TO GND-01
REF. TO GND-03
R30
B267
R52
B90
D35
D34
1 2
B268
1 2 3
1 2
3 4
1 2
3 4
1 2 3
4 5 6
R16
REF. TO GND-03
R22
REF. TO GND-05
A:
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
R22
1
2
3
B176
1 2 3 4 5
11 12 13 14
15
6 7 8 9 10
16 17 18
B99
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B36
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:
i11
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
GL77-21B
WI-188
WG : WAGON
18
17
14
Or
RG
K/L(L)-03
K/L(L)-03
WIRING SYSTEM
FRONT DOOR
LOCK ACTUATOR
(DRIVER SIDE)
REAR DOOR LOCK

ACTUATOR LH
1
RG
Or
D26
1
D21
RG
Or
B269
14
13
BR
RG
15
RG
Or
10
Or
B30
D1
D72
FRONT DOOR
LOCK ACTUATOR
(PASSENGER SIDE)
REAR DOOR LOCK

ACTUATOR RH
RG
RG
Or
Or
RG
15
RG
Or
10
Or
B265
B101
D11
D18
RG
D27
Or
D32
WG
WG
RG
RG
Or
Or
B99
R3
R38
RG
Or
D34
D47
REF. TO GND-01
REAR GATE LOCK

ACTUATOR (WAGON)
D47
D18
D21
D34
B99
1 2
D26
D27
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
D32
D72
1 2
3 4
B176
1 2 3 4 5
11 12 13 14
15
D1
6 7 8 9 10
16 17 18
D11
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
1 2
3 4
GL77-21C
WI-189

WIRING SYSTEM
K/L(R)-01
K/L(R)-01
2. RHD MODEL
MB-6
M/B FUSE NO. 6
(B)
WB

FB-35
F/B FUSE NO. 3
(B)
KEY WARNING
SWITCH
W
WR
2
1
WR
15
13 LgB
BG
12
16 WB
REF. TO TURN(R)-01
B74
B74 (BLACK)
1
2
B176
1 2 3 4 5
11 12 13 14
15
6 7 8 9 10
16 17 18
GR77-21A
WI-190
K/L(R)-02
K/L(R)-02
WIRING SYSTEM
3
Y
LR
11
BL
MB-10
M/B FUSE NO. 2
(B)
YR
LR
i3
3
21
B38
B36
LR
i2
A:
i10
B:
i11
B224
ROOM LIGHT
DIODE
(WAGON)
LR
LR
YR
DOOR
OFF
FRONT DOOR
SWITCH RH
AT
B14
LOr B13
LR
YR
MT
COMBINATION
METER
DOOR
IGNITION SWITCH
ILLUMINATION
i1
LR
A10 LR
B37
LR
LR
LOr
AT
MT
LOr
B
17
B90
R50
R52
B37
B267
FRONT DOOR
SWITCH LH
ON
i2
YR
1
3
AT : AT MODEL
R30
MT : MT MODEL
R38
D34
REAR GATE LATCH

SWITCH (WAGON)
YR
R3
REAR DOOR
SWITCH RH
B183 CODE
ENTRY
B184 CONNECTOR
B99
WG : WAGON
YR
B268
BL
Y
B
Y
1
3
1
3
REAR DOOR
SWITCH LH
Y
B
WG
YB
B
D46
B
R16
1
2
D35
3
Y
B
R39
B
1
3
B224
1 2
R30
1 2
R22
REF. TO GND-08
REF. TO GND-07
REF. TO GND-07
REF. TO GND-06
REF. TO GND-07
REF. TO GWD-10
D46 (BLACK)
1
2
B267
B268
R52
1 2 3
R16
D35
1 2
3 4
B90
1 2
3 4
A:
D34
1 2 3
4 5 6
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
i1
(BLACK)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
R22
B176
1 2 3 4 5
11 12 13 14
6 7 8 9 10
15 16 17 18
1
2
3
B99
i3
B:
i11
(GREEN)
(BLACK)
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 21 22 23 24 25 26 27 28 29 30
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
GR77-21B
WI-191
WG : WAGON
17
14
RG
LgB 18
K/L(R)-03
K/L(R)-03
WIRING SYSTEM
FRONT DOOR
LOCK ACTUATOR
(DRIVER SIDE)
W
14
13
BR
RG
RG
15
RG
LgB
LgB
10
LgB
REAR DOOR LOCK

ACTUATOR LH
1
RG
LgB
D26
D21
B269
B30
D1
D72
FRONT DOOR
LOCK ACTUATOR
(PASSENGER SIDE)
REAR DOOR LOCK

ACTUATOR RH
RG
RG
LgB
LgB
RG
15
RG
LgB
10
LgB
LgB
RG
B101
D11
D18
RG
RG
5
B97
LgB
B265
LgB
D27
D32
WG
WG
R1
R38
LgB
RG
D34
D47
REF. TO GND-06
REAR GATE LOCK

ACTUATOR (WAGON)
D47
D18
D21
D34
B97
1 2
D26
D27
1 2 3
4 5 6
1 2 3 4
5 6 7 8
D32
D72
1 2
3 4
B176
1 2 3 4 5
11 12 13 14
15
D1
6 7 8 9 10
16 17 18
D11
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
1 2
3 4
GR77-21C
WI-192
BACK-UP LIGHT SYSTEM

WIRING SYSTEM
24.Back-up Light System

BACK/L-01
BACK/L-01
A: SCHEMATIC
FB-17
F/B FUSE NO.18
(IG)
GB

NA
MT
SD : SEDAN
WG
WG : WAGON
AT
TB
BACK-UP LIGHT
SWITCH (MT)
SD
GB
BrY
T1
GB
NA
B24
GB
BrY
WB
WB
BrY 10
BW
BW
B12
B128
T3
T7
B99
R3
BrY
4
T9
AT
LHD RHD
1
6 BrY
BACK-UP LIGHT
SWITCH (MT)
2
MT
TB
BACK-UP
LIGHT LH
(SEDAN)
BACK-UP
LIGHT LH
(WAGON)
3
BrY
SD
WG
BrY
R28
R28
BACK-UP
LIGHT RH
(WAGON)
BACK-UP
LIGHT RH
(SEDAN)
3
BrY
SD
WG
BrY
R26
R26
*1
: LHD MODEL :
REF. TO GND-04
RHD MODEL :
REF.TO GND-09
*1
B24 (GRAY)
B128
R26 : SD
R26 (BLACK) : WG
1 2
1 2
3 4
R28 : SD
R28 (BLACK) : WG
1 2 3
4 5 6
B12
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
2
1
6 5 4 3
B99 : RHD
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
B99 : LHD
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
GG29-21
WI-193
CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM

WIRING SYSTEM
25.Clearance Light and Illumination Light System

A: SCHEMATIC
WI-194

WIRING SYSTEM
1. LHD MODEL
FB-3
F/B FUSE NO.5
FB-10
F/B FUSE NO.12
FB-11
F/B FUSE NO.12
FB-13
BR
Or
BW
ILM(L)-01
FB-12
WR
ILM(L)-01

FB-14
F/B FUSE NO.7
(B)
PARKING SWITCH
OFF ON
C: B136
B
WR
BR
Or
BW C3
ENGINE
CONTROL MODULE
(NON-TURBO )
NA
B69
FRONT ACCESSORY POWER
SUPPLY SOCKET ILLUMI. LIGHT
AT SELECT LEVER
ILLUMI. LIGHT
1
B116
A: B134
TB
BW A17
B119
ENGINE
CONTROL MODULE
(TURBO)
LIGHTING SWITCH
MODE CONTROL PANEL

ILLUMI. LIGHT (MANUAL A/C)

ILLUMI. LIGHT
4
OFF
TC
BW 14
B
EL
16
HC
B160
B168

ILLUMI. LIGHT
BRIGHT SWITCH
AUTO A/C
CONTROL MODULE
B10
B20
11
10
B71
B195
B: B283
HEADLIGHT BEAM LEVELER

SWITCH ILLUMI. LIGHT
POWER & HOLD MODE

ILM(L)-02
ILM(L)-02
ILM(L)-02
B133
B132
RADIO
ILLUMI. LIGHT
REF. TO FOG(L)-01
R/FOG(L)-01
GLOVE BOX ILLUMI. LIGHT
B208
B
B120
REF. TO GND-02
REF. TO GND-0102
B208 (BLACK)
1 2
B69
B119
1 2
3 4
1 2
3 4
B116
B132
B133
B160 (GRAY)
1 2 3 4
B195
1 2 3
4 5 6
B168
B120
1 2
3 4
5 6 7 8 9 10
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1
2
3 4 5 6
B: B283 (GRAY)
B71
1
9
2
10
3 4 5 6
11 12 13 14 15
7
16
8
17
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
A: B134
6 7
1 2 3 4 5
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
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
GL21-22A
WI-195

WIRING SYSTEM
ILM(L)-02
ILM(L)-02
V
WR 14
HAZARD SWITCH
ILLUMI. LIGHT
A8 WR
PL
C3
5
2
i22
COMBINATION
METER
ILLUMINATION LIGHT
A:
i10
B:
i11
C:
i12
B
24
15 OrW
OrW A9
ODO/TRIP LCD
BACK LIGHT
OUT TEMP LCD

BACK LIGHT
1
C5
LB
2
C4
REF. TO AT(L)-01
i2
B37
B
REF. TO AT(L)-02
WR
OrW
DRIVER
YB
3
RB C10
D
W C11
N
Lg C12
R
RL C13
A6
B
GR C14
B15
G
HOLD MODE
INDICATOR LIGHT
B16
POWER MODE
INDICATOR LIGHT
DIMMER CIRCUIT
REF. TO D/R(L)-01
WB B10
AWD-LO
INDICATOR LIGHT
i2
PL
DIMMER CIRCUIT
ILM(L)-01
B37
i1
A7 GOr
CLOCK
i59
B36
GOr
ILM(L)-01
13
PL
ILM(L)-01
23 RW
RW
FB-36
F/B FUSE NO.13
(IG)
i59
i22
1 2 3 4
1 2 3 4
5 6 7 8
i2
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:
i10
C:
(GREEN)
1 2 3 4 5 6 7 8 9 10
B:
i11
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B36
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
GL21-22B
WI-196
ILM(L)-03
ILM(L)-03
WIRING SYSTEM
FB-7
F/B FUSE NO.5
RY
RY
FB-6
F/B FUSE NO.5
RY
RY
WR
17
FRONT CLEARANCE
LIGHT LH
B99
R3
F22
TRAILER
CONNECTOR
1 WR
FRONT CLEARANCE
LIGHT RH
WR
RY
LICENSE PLATE LIGHT

WR
R79
R63
F4
REF. TO GND-01
REAR COMBINATION
LIGHT LH (WAGON)
REAR COMBINATION
LIGHT LH (SEDAN)
1
WR
SD
WG
WR
R28
R28
REAR COMBINATION
LIGHT RH (SEDAN)
1
WR
REAR COMBINATION
LIGHT RH (WAGON)
SD
WR
WG
R26
R26
SD
SD : SEDAN
WG
WG : WAGON
REF. TO GND-04
R63 (BLACK)
2 1
F4
(GRAY)
R26 : SD
R26 : WG
R79
B99
F22
(GRAY)
R28 : SD
R28 : WG
1 2 3 4 5
6 7 8 9 10
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3
1 2 3
4 5 6
2
1
6 5 4 3
GL21-22C
WI-197

WIRING SYSTEM
ILM(ROI)-01
ILM(ROI)-01
2. RHD WITHOUT ILLUMINATION CONTROL MODEL
FB-12
FB-3
F/B FUSE NO.5
FB-10
F/B FUSE NO.12
FB-11
F/B FUSE NO.12
FB-13
WR
BR
Or
BW

FB-14
F/B FUSE NO.7
(B)
PARKING SWITCH
OFF ON
C: B136
B
WR
BR
Or
BW C3
ENGINE
CONTROL MODULE
(NON-TURBO )
NA
B69
AT SELECT LEVER
ILLUMI. LIGHT
1
A: B134
TB
BW A17
B119
B116
LIGHTING SWITCH
MODE CONTROL PANEL


ILLUMI. LIGHT
4
ENGINE
CONTROL MODULE
(TURBO)
OFF
OE FE
BW 15 14
9
TC
EL
16
HC
B168
B160
ILLUMI. LIGHT
BRIGHT SWITCH
AUTO A/C
CONTROL MODULE
B10
B20
FE
11
10
FE
B71
B195
B: B283
HEADLIGHT BEAM LEVELER

POWER & HOLD MODE

OE
OE
RADIO
ILLUMI. LIGHT
ILM(ROI)-02
ILM(ROI)-02

1
FE
FE : FOR EUROPE MODEL
OE
OE : EXCEPT FOR EUROPE MODEL
B208
B
B120
REF. TO FOG(RFE)-01
FOG(ROE)-01
RFOG(FE)-01
RFOG(OE)-01
B69
B119
1 2
3 4
REF. TO GND-07
B116
B132
B160 (
1 2 3 4
1 2
3 4
: GRAY
EUROPE MODEL
*1 ) : FOR
EXCEPT FOR EUROPE MODEL
: BLACK
REF. TO GND-0607
1 2
ILM(ROI)-02
B133
B132
B208 (BLACK)
B195
B168
B120
3 4
1 2
5 6 7 8 9 10
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B133
1)
1 2 3
4 5 6
1
2
3 4 5 6
B71 : FE
1
9
2
10
3 4 5 6
11 12 13 14 15
7
16
B: B283 (GRAY)
B71 : OE
8
17
1
9
2
10
3 4 5 6
11 12 13 14 15
7
16
8
17
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
A: B134
6 7
1 2 3 4 5
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
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
GR21-23A
WI-198

ILM(ROI)-02
ILM(ROI)-02
WIRING SYSTEM
GW
FB-36
F/B FUSE NO.13
(IG)
MT
GW
20
i2
HAZARD SWITCH
ILLUMI. LIGHT
AT
MT
B37
i3
V
GW 22
19
i1
GW
ILM(ROI)-01
B38
B36
14
B
V
ILM(ROI)-01
GW
AT
MT
AT
AT
MT
i22
COMBINATION
METER
ILLUMINATION LIGHT
A:
i10
B:
i11
C:
i12
32
B
21
YL
YL
A9
ODO/TRIP LCD
BACK LIGHT
OUT TEMP LCD

BACK LIGHT
1
C5
LB
2
C4
REF. TO
AT(R)-01
i2
B37
B
REF. TO
AT(R)-02
REF. TO
D/R(R)-01
ILM(ROI)-01
5
2
DRIVER
YL
3
RB C10
D
GrL C11
N
C12
P
RL C13
P
A6
B
Or C14
DIMMER CIRCUIT
HOLD MODE
INDICATOR LIGHT
OrL B15
LY B16
WB B10
AWD-LO
INDICATOR LIGHT
POWER MODE
INDICATOR LIGHT
DIMMER CIRCUIT
V
YL
A8
C3
A7 GW
CLOCK
i59
i59
i22
1 2 3 4
1 2 3 4
5 6 7 8
B:
i11
A:
i10
C:
1 2 3 4 5 6 7 8 9 10
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
i1
(BLACK)
i3
i12
(GREEN)
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
(GREEN)
(BLACK)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
GR21-23B
WI-199

ILM(ROI)-03
ILM(ROI)-03
WIRING SYSTEM
FB-7
F/B FUSE NO.5
WR
WR
FB-6
F/B FUSE NO.5
WR
FRONT CLEARANCE
LIGHT LH
B99
2
WR
WR
R3
F22
TRAILER
CONNECTOR
1 WR
FRONT CLEARANCE
LIGHT RH
WR
WR
LICENSE PLATE LIGHT

WR
R79
R63
F4
REF. TO GND-06
REAR COMBINATION
LIGHT LH (WAGON)
REAR COMBINATION
LIGHT LH (SEDAN)
1
WR
SD
WG
WR
R28
R28
REAR COMBINATION
LIGHT RH (SEDAN)
1
WR
REAR COMBINATION
LIGHT RH (WAGON)
SD
WR
WG
R26
R26
SD
SD : SEDAN
WG
WG : WAGON
REF. TO GND-09
R63 (BLACK)
2 1
F4
(GRAY)
R26 : SD
R26 (BLACK) : WG
R79
B99
F22
(GRAY)
R28 : SD
R28 (BLACK) : WG
1 2 3 4 5
6 7 8 9 10
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
1 2 3
1 2 3
4 5 6
2
1
6 5 4 3
GR21-23C
WI-200

WIRING SYSTEM
ILM(RWI)-01
ILM(RWI)-01
3. RHD WITH ILLUMINATION CONTROL MODEL
FB-12
FB-3
F/B FUSE NO.5
FB-10
F/B FUSE NO.12
FB-11
F/B FUSE NO.12
FB-13
WR
BR
Or
BW

FB-14
F/B FUSE NO.7
(B)
PARKING SWITCH
OFF ON
C: B136
B
WR
BR
Or
NA
BW C3
TB
BW A17
ENGINE
CONTROL MODULE
(NON-TURBO )
B69
AT SELECT LEVER
ILLUMI. LIGHT
A: B134

YL
YL
B116
B119
LIGHTING SWITCH
REF. TO
FOG(RFE)-01
FOG(ROE)-01
RFOG(FE)-01
RFOG(OE)-01
MODE CONTROL PANEL


ILLUMI. LIGHT
ENGINE
CONTROL MODULE
(TURBO)
YL
YL
OFF
TC
BW 15
B
EL
HC
B160
B168

ILLUMI. LIGHT
4
YL
AUTO A/C
CONTROL MODULE
V
B10
LG
12
V1
13
V2
GY
16
V3
B71
YL B20
B195
B: B283
CRUISE CONTROL MAIN

POWER & HOLD MODE

GY
YL
YL
LG
B161
B133
RADIO
ILLUMI. LIGHT
YL
ILM(RWI)-02
B43
ILLUMINATION
CONTROL MODULE
YL
ILM(RWI)-02
B208
ILM(RWI)-02
B120
REF. TO GND-0607
REF. TO GND-07
NA : NON-TURBO
ENGINE MODEL
TB : TURBO
ENGINE MODEL
B208 (BLACK)
1 2
B69
B119
1 2
3 4
1 2
3 4
B43 (BLACK)
B161 (BROWN)
B195
B133
1 2 3
4 5 6
B168
B120
1 2
3 4
5 6 7 8 9 10
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B116
B160 (GRAY)
1
2
3 4 5 6
B71
1
9
2
10
3 4 5 6
11 12 13 14 15
7
16
8
17
B: B283 (GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
A: B134
6 7
1 2 3 4 5
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
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
GR21-24A
WI-201

ILM(RWI)-02
ILM(RWI)-02
WIRING SYSTEM
GW
FB-36
F/B FUSE NO.13
(IG)
AT
B36
GW
i1
20
B37
i3
i2
V
19
GW 22
B38
HAZARD SWITCH
ILLUMI. LIGHT
AT
MT
GW
A
14
ILM(RWI)-01
GW
AT
MT
MT
AT
MT
ILM(RWI)-01
i59
i22
1 2 3 4
1 2 3 4
5 6 7 8
B:
i11
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
ILLUMINATION LIGHT
i10
B:
i11
C:
i12
32
21
YL
YL
A9
ODO/TRIP LCD
BACK LIGHT
OUT TEMP LCD

BACK LIGHT
1
C5
LB
2
C4
A:
i2
B
i10
i1
(BLACK)
i3
i12
(GREEN)
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
(GREEN)
C:
YL
B37
1 2 3 4 5 6 7 8 9 10
(GREEN)
i22
COMBINATION
METER
REF. TO
AT(R)-01
REF. TO
AT(R)-02
REF. TO
D/R(R)-01
ILM(RWI)-01
5
2
DRIVER
YL
3
RB C10
D
GrL C11
N
C12
P
RL C13
P
A6
B
Or C14
DIMMER CIRCUIT
HOLD MODE
INDICATOR LIGHT
OrL B15
LY B16
WB B10
AWD-LO
INDICATOR LIGHT
POWER MODE
INDICATOR LIGHT
DIMMER CIRCUIT
V
YL
A8
C3
A7 GW
CLOCK
i59
(BLACK)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
GR21-24B
WI-202

ILM(RWI)-03
ILM(RWI)-03
WIRING SYSTEM
FB-7
F/B FUSE NO.5
WR
WR
FB-6
F/B FUSE NO.5
WR
FRONT CLEARANCE
LIGHT LH
B99
2
WR
WR
R3
F22
TRAILER
CONNECTOR
1 WR
FRONT CLEARANCE
LIGHT RH
WR
WR
WR
R79
R63
F4
LICENSE PLATE LIGHT
REF. TO GND-06
REAR COMBINATION
LIGHT LH (WAGON)
REAR COMBINATION
LIGHT LH (SEDAN)
1
WR
SD
WG
WR
R28
R28
REAR COMBINATION
LIGHT RH (SEDAN)
1
WR
REAR COMBINATION
LIGHT RH (WAGON)
SD
WR
WG
R26
R26
SD
SD : SEDAN
WG
WG : WAGON
REF. TO GND-09
R63 (BLACK)
2 1
F4
(GRAY)
R26 : SD
R26 (BLACK) : WG
R79
B99
F22
(GRAY)
R28 : SD
R28 (BLACK) : WG
1 2 3 4 5
6 7 8 9 10
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
1 2 3
1 2 3
4 5 6
2
1
6 5 4 3
GR21-24C
WI-203

WIRING SYSTEM
26.Front Fog Light System

A: SCHEMATIC
WI-204

WIRING SYSTEM
FOG(L)-01
FOG(L)-01
1. LHD MODEL
FB-10
F/B FUSE NO.12
FB-11
F/B FUSE NO.12
RL

FB-33
F/B FUSE NO.7
(B)
FRONT FOG
LIGHT RELAY
20
FRONT FOG
LIGHT SWITCH
RL
ON
19 WB
V
OF
*1
OFF
OF
WB
B48
WF
21 BW
WF
23
DIODE
(REAR FOG LIGHT)
1
BW
YW
WB
B62
F45
B196
B160
FRONT FOG
LIGHT LH
WB
REF. TO ILM(L)-01
F21
FRONT FOG
LIGHT RH
WF : WITH REAR FOG LIGHT MODEL

OF : WITHOUT REAR FOG LIGHT MODEL
1
WB
BY
*1
BY
B306
: WITH REAR FOG LIGHT MODEL : YW

WITHOUT REAR FOG LIGHT MODEL : BW
B196
B306 (BLACK)
F21
1 2
(BLACK)
B198
REF. TO GND-03
REF. TO GND-01
REF. TO GND-01
B198
1 2 3 4 5
B160 (GRAY)
1
2
3 4 5 6
F45
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
B48
1
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK (BLACK)
GL22-21
WI-205

WIRING SYSTEM
FOG(RFE)-01
FOG(RFE)-01
2. RHD FOR EUROPE MODEL
FB-10
F/B FUSE NO.12
FB-11
F/B FUSE NO.12
RL

FB-33
F/B FUSE NO.7
(B)
FRONT FOG
LIGHT RELAY
FRONT FOG
LIGHT SWITCH
RL
27
ON
28 WR
24
26
BY
YW
OFF
B48
BY
YW
B61
6
1
2
V
WR
DIODE
(REAR FOG LIGHT)
F44
WR
B196
B160
FRONT FOG
LIGHT LH
WR
REF. TO ILM(RWI)-01
ILM(ROI)-01
F21
FRONT FOG
LIGHT RH
WR
B196
F6
(BLACK)
1 2
F21
(BLACK)
B160 (GRAY)
1
2
3 4 5 6
F6
REF. TO GND-06
REF. TO GND-06
F44
1 2 3 4
5 6 7 8
1 2
B48
1
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK (BLACK)
GR22-22
WI-206

WIRING SYSTEM
FOG(ROE)-01
FOG(ROE)-01
3. RHD EXCEPT FOR EUROPE MODEL
FB-10
F/B FUSE NO.12
FB-11
F/B FUSE NO.12
RL

FB-33
F/B FUSE NO.7
(B)
FRONT FOG
LIGHT RELAY
FRONT FOG
LIGHT SWITCH
RL
27
ON
28 WR
V
26
BY
B48
WR
DIODE
(REAR FOG LIGHT)
BY
OFF
BY
B61
YW
RW
*1
WF
24
REF. TO RFOG(OE)-01
WR
F44
B196
B160
FRONT FOG
LIGHT LH
WR
REF. TO ILM(RWI)-01
ILM(ROI)-01
F21
FRONT FOG
LIGHT RH

1
WR
*1
( 2 ) : WITH ILLUMINATION CONTROL MODEL : (GRAY)

WITHOUT ILLUMINATION CONTROL MODEL : (BLACK)
F6
(BLACK)
(BLACK)
B196
1 2 3
B160 ( 2 )
1
2
3 4 5 6
F6
F21
: WITH ILLUMINATION CONTROL MODEL : YL

WITHOUT ILLUMINATION CONTROL MODEL : B
REF. TO GND-06
REF. TO GND-06
F44
1 2 3 4
5 6 7 8
1 2
B48
1
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK (BLACK)
GR22-23
WI-207
HEADLIGHT SYSTEM
WIRING SYSTEM
27.Headlight System
A: SCHEMATIC
WI-208
HEADLIGHT SYSTEM
WIRING SYSTEM
1. LHD MODEL
MB-3
M/B FUSE NO.8
MB-8
HEADLIGHT
RELAY
RL
H/L(L)-01
MB-2
M/B FUSE NO.9
LW
H/L(L)-01
HEADLIGHT RH
LW
3
HIGH
LOW
YR
F7
HEADLIGHT LH
*1
3
HIGH
LOW
: RW
: WITH REAR FOG LIGHT MODEL
WITHOUT REAR FOG LIGHT MODEL : G
RL
YR
G
22
F45
COMBINATION METER
B62
G
LW
3
R
B61
R
YR
14
F44
LW
YR
F23
HI-BEAM
INDICATOR LIGHT
DIMMER & PASSING

SWITCH
LW
10
11
B37
LW B30
R
i2
B:
B29
i11
UP LOW PASS
8
DIODE (WITH REAR

FOG LIGHT MODEL)
HU
HL
17
YR
16
13
*1
TC
WF
RW
OF
LIGHTING SWITCH
OFF
HC
WF
OF
HF
B71
B85
B
EL
REF. TO GND-02
B85
F7
1 2
F23
B71
F44
1 2 3 4
5 6 7 8
1
2
B:
i11
i2
F45
1
9
2
10
3 4 5 6
11 12 13 14 15
7
16
8
17
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
GL19-21
WI-209
HEADLIGHT SYSTEM
WIRING SYSTEM
2. RHD MODEL
MB-3
M/B FUSE NO.8
MB-8
HEADLIGHT
RELAY
RL
H/L(R)-01
MB-2
M/B FUSE NO.9
LW
H/L(R)-01
HEADLIGHT RH
LW
3
HIGH
LOW
YL
F7
HEADLIGHT LH
*1
HIGH
LOW
RL
YL
: RW
: WITH REAR FOG LIGHT MODEL
WITHOUT REAR FOG LIGHT MODEL : G
FE : FOR EUROPE MODEL

OE : OTHER MODEL
LW
YL
F23
F45
8
F44
LW
YL
B61
COMBINATION METER
B62
HI-BEAM
INDICATOR LIGHT
DIMMER & PASSING

SWITCH
HL
17
10
YL
16
13
14
*1
LW B30
R
i2
B29
i11
B:
DIODE (WITH REAR

FOG LIGHT MODEL)
HU
WF
WF
RW
OF
LIGHTING SWITCH
OFF
HC
B37
FE OE
8
1
HF
OF
UP LOW PASS
LW
TC
B71
B85
B
EL
REF. TO GND-07
B85
F7
1 2
F23
B71 : FE
F44
1 2 3 4
5 6 7 8
1
2
B:
i11
(GREEN)
1 2 3 4 5 6 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
9
2
10
3 4 5 6
11 12 13 14 15
7
16
B71 : OE
8
17
1
9
2
10
3 4 5 6
11 12 13 14 15
7
16
F45
8
17
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
GR19-21
WI-210
IN COMPARTMENT LIGHT SYSTEM

WIRING SYSTEM
28.In Compartment Light System

A: SCHEMATIC
WI-211

WIRING SYSTEM
1. LHD MODEL
LR
WG : WAGON
LR
C/L(L)-01
FB-8
FB-9
M/B FUSE NO.2 M/B FUSE NO.2
(B)
(B)
OK : WITHOUT KEYLESS ENTRY MODEL
*1
C/L(L)-01
WK : WITH KEYLESS ENTRY MODEL
: YR
: WITH KEYLESS ENTRY MODEL
WITHOUT KEYLESS ENTRY MODEL : Y
SPOT LIGHT
LR
LR
LR
LR
20
B36
2
LR
i1
A10 LR
R56
ON
DOOR
LR
DOOR
WARNING LIGHT
ROOM LIGHT
*1
COMBINATION
METER
A:
i10
B:
i11
OFF
B90
11
YR
WK
WK
OK
KEYLESS
ENTRY
CONTROL
MODULE
20
LOr
LW
B37
1
3
Y
B
LR
13
LR
24
B99
Y
B
REF. TO GND-02
REF. TO GND-0203
REF. TO GND-03
R16
B267
R52
B90
R22
B268
1 2 3
1 2
3 4
1 2
A:
i10
(GREEN)
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:
i2
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
3
R16
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
B99
REAR DOOR
SWITCH RH
B176
1
2
3
B36 (BLACK)
C/L(L)-02
1
3
R22
LOr
B
B267
R3
1
3
C/L(L)-02
REAR DOOR
SWITCH LH
Y
B
B268
FRONT DOOR
SWITCH LH
i2
WG
FRONT DOOR
SWITCH RH
R56
LW B13
R50
R52
B176
B14
i11
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
GL21-23A
WI-212
C/L(L)-01
C/L(L)-01
C/L(L)-02
C/L(L)-02
WIRING SYSTEM
DIODE (WAGON)
1
YR
R30
TRUNK ROOM
LIGHT (SEDAN)
LUGGAGE ROOM
LIGHT (WAGON)
1
ON
LR
WG
SD
DOOR
2
1
2
R20
YR
R141
YR
OFF
LR
YR
YR
R38
D34
TRUNK ROOM LIGHT

SWITCH (SEDAN)
REAR GATE LATCH

SWITCH (WAGON)
1
2
YR
B
D35
WG
YR
B
SD
R39
1
2
R27
D46
WG : WAGON
SD : SEDAN
REF. TO GND-0405
D46 (BLACK)
1
2
R20 (BLACK)
R27
R141 (BLACK)
R30
D35
D34
1 2
1 2
3 4
1 2 3
4 5 6
2 1
1
2
GL21-23B
WI-213

WIRING SYSTEM
C/L(R)-01
WK : WITH KEYLESS ENTRY MODEL
AT : AT MODEL
MB-10
M/B FUSE NO.2
(B)
MT : MT MODEL
OK : WITHOUT KEYLESS ENTRY MODEL
C/L(R)-01
2. RHD MODEL
LR
WG : WAGON
*1
: WITH KEYLESS ENTRY MODEL

: YR
WITHOUT KEYLESS ENTRY MODEL : Y
SPOT LIGHT
MT
LR
B36
LR
i1
21
B38
R56
LR
MT
A10 LR
LR
AT
LR
LR
AT
LR
i3
ON
DOOR
LR
DOOR
WARNING LIGHT
ROOM LIGHT
*1
COMBINATION
METER
A:
i10
B:
i11
C/L(R)-02
C/L(R)-02
OFF
B
B90
11
YR
WK
WK
OK
KEYLESS
ENTRY
CONTROL
MODULE
17
LOr
LOr
B37
1
3
Y
B
i2
LR
13
B99
LR
Y
Y
B
1
3
1
3
R3
B268
FRONT DOOR
SWITCH RH
REAR DOOR
SWITCH LH
WG
FRONT DOOR
SWITCH LH
R22
LOr
B
Y
B
B
REF. TO GND-07
REF. TO GND-07
REF. TO GND-08
R52
B267
1 2 3
B268
A:
B90
1 2
3 4
1 2
R16
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
REAR DOOR
SWITCH RH
1
3
R16
B267
R56
LOr B13
R50
R52
B176
B14
i1
(BLACK)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
R22
1
2
3
B176
1 2 3 4 5
11 12 13 14
15
6 7 8 9 10
16 17 18
B:
B99
i3
(BLACK)
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
i11
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
GR21-25A
WI-214
C/L(R)-01
C/L(R)-01
C/L(R)-02
C/L(R)-02
WIRING SYSTEM
DIODE (WAGON)
1
YR
R30
TRUNK ROOM
LIGHT (SEDAN)
LUGGAGE ROOM
LIGHT (WAGON)
1
ON
LR
SD
WG
DOOR
2
YL
R20
YR
R141
YR
OFF
LR
YR
R38
D34
TRUNK ROOM LIGHT

SWITCH (SEDAN)
REAR GATE LATCH

SWITCH (WAGON)
1
2
YR
B
D35
YL
B
SD
WG
R39
1
2
R27
D46
WG : WAGON
SD : SEDAN
REF. TO GND-0910
D46 (BLACK)
1
2
R20 (BLACK)
R27
R141
1
2
R30
D35
D34
1 2
1 2
3 4
1 2 3
4 5 6
2 1
GR21-25B
WI-215
STOP LIGHT SYSTEM

WIRING SYSTEM
29.Stop Light System

STOP/L-01
STOP/L-01
A: SCHEMATIC
LY
FB-31
F/B FUSE NO.16
(B)
STOP LIGHT
SWITCH (RHD)
WC OC
1
LY
2
2 WB
3
RHD
LHD
RHD
LHD
STOP LIGHT
SWITCH (LHD)
LY
WB
B64 : OC
B64
LHD RHD
5
2 WB
B65 : WC
SD : SEDAN
SD
B97
TRAILER
CONNECTOR
WB 3
R1
WB
WG : WAGON
WG
2
1
WC : WITH CRUISE CONTROL MODEL

OC : WITHOUT CRUISE CONTROL MODEL
R79
STOP LIGHT LH (WAGON)
STOP LIGHT LH (SEDAN)

5
WB
SD
WG
R28
WB
R28
STOP LIGHT RH (WAGON)
STOP LIGHT RH (SEDAN)

5
WB
WB
R26
R26
HIGH-MOUNTED STOP
LIGHT (SEDAN)
HIGH-MOUNTED STOP
LIGHT (WAGON)
WB
SD
WG
WB
WB
R39
R19
WB
2
1
R60
R66
D39

(SEDAN-REAR SPOILER)
D35
*1
WB
: LHD MODEL :
REF. TO GND-030405
: RHD MODEL :
REF. TO GND-080910
B
R24
*1
B64 (BLACK)
D39
R19
R24
R66
1 2
1
2
1 2
B97
R79
1 2 3 4
5 6 7 8
1 2 3 4 5
6 7 8 9 10
B65 (BLACK)
D35
1 2
3 4
1 2
3 4
R26 : SD
R26 (BLACK) : WG
R28 : SD
R28 (BLACK) : WG
1 2 3
4 5 6
2
1
6 5 4 3
GG25-21
WI-216
TURN SIGNAL LIGHT AND HAZARD LIGHT SYSTEM

WIRING SYSTEM
30.Turn Signal Light and Hazard Light System

A: SCHEMATIC
WI-217

WIRING SYSTEM
TURN(L)-01
TURN(L)-01
1. LHD MODEL
FB-1
TO FB-4
23
LgB
GW
FB-2
TO FB-5
BG

MB-6
IG
IGNITION RELAY M/B FUSE NO. 6
(B)
(IG)
F45
B62
HAZARD
SWITCH
OFF ON
6
GB
GB
17 GW
24
BrR
BrR
11 BrR
BrR
B32
BY
BY
10
BY
BY
TURN SIGNAL
& HAZARD
MODULE
LgB
LgB
LgB
BG
BG
BG
WR
i1
B36
TURN SIGNAL
SWITCH
L
OrW
BY
13 LgB
LgB
BG
BG
i22
B176
A3 LgB
B71
COMBINATION
TURN
METER
SIGNAL
A: i10
INDICATOR
LIGHT
C: i12
RH
C7 BG
12
TURN(L)-02
TURN(L)-02
A6
LH
KEYLESS ENTRY
CONTROL MODULE
REF. TO ILM(L)-02
B
24
B37
B
i2
REF. TO GND-02
B32 (BLACK)
i22
1 2
3
1 2 3 4
5 6 7 8
15
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
C:
i12
(GREEN)
6 7 8 9 10
16 17 18
B71
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B36 (BLACK)
B176
1 2 3 4 5
11 12 13 14
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
1
9
2
10
3 4 5 6 7
11 12 13 14 15 16
8
17
F45
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
GL26-21A
WI-218

TURN(L)-02
TURN(L)-02
WIRING SYSTEM
FB-5
TO FB-2
FB-4
TO FB-1
BG
LgB
SIDE TURN SIGNAL LIGHT RH
SIDE TURN SIGNAL

LIGHT LH
BG
F54
LgB
BY
B305
BY
B198
FRONT TURN SIGNAL

LIGHT LH
3
BG
FRONT TURN SIGNAL

LIGHT RH
REF. TO GND-03
F22
LgB
2
F4
TRAILER
CONNECTOR
LgB 5
REF. TO GND-01
TURN(L)-01
LgB 22
TURN(L)-01
BG
15
B99
LgB
BG
BG
R3
R79
REAR TURN SIGNAL
LIGHT RH (SEDAN)
REAR TURN SIGNAL

LIGHT LH (SEDAN)
SD
SD
WG
BG
WG
2
4
R28
LgB
R26
REAR TURN SIGNAL

LIGHT LH (WAGON)
BG
B
SD
3
2
SD
REAR TURN SIGNAL

LIGHT RH (WAGON)
WG
WG
R26
R28
LgB
SD
SD : SEDAN
WG
WG : WAGON
REF. TO GND-04
B305
F4
(GRAY)
B198
R26 : SD
R26 : WG
R79
F54
F22
(GRAY)
1 2 3 4 5
R28 : SD
R28 : WG
1 2 3 4 5
6 7 8 9 10
1 2
1 2 3
1 2 3
4 5 6
2
1
6 5 4 3
B99
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
GL26-21B
WI-219

WIRING SYSTEM
TURN(L)-01
TURN(L)-01
2. RHD MODEL
FB-1
TO FB-4
23
LgB
GW
FB-2
TO FB-5
BG

MB-6
IG
IGNITION RELAY M/B FUSE NO. 6
(B)
(IG)
F45
B62
HAZARD
SWITCH
OFF ON
6
GB
GB
17 GW
24
BrR
BrR
11 BrR
BrR
B32
BY
BY
10
BY
BY
TURN SIGNAL
& HAZARD
MODULE
LgB
LgB
LgB
BG
BG
BG
WR
i1
B36
TURN SIGNAL
SWITCH
L
OrW
BY
13 LgB
LgB
BG
BG
i22
B176
A3 LgB
B71
COMBINATION
TURN
METER
SIGNAL
A: i10
INDICATOR
LIGHT
C: i12
RH
C7 BG
12
TURN(L)-02
TURN(L)-02
A6
LH
KEYLESS ENTRY
CONTROL MODULE
REF. TO ILM(L)-02
B
24
B37
B
i2
REF. TO GND-02
B32 (BLACK)
i22
1 2
3
1 2 3 4
5 6 7 8
15
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
C:
i12
(GREEN)
6 7 8 9 10
16 17 18
B71
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B36 (BLACK)
B176
1 2 3 4 5
11 12 13 14
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
1
9
2
10
3 4 5 6 7
11 12 13 14 15 16
8
17
F45
i2
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
GR26-21A
WI-220

TURN(L)-02
TURN(L)-02
WIRING SYSTEM
FB-5
TO FB-2
FB-4
TO FB-1
BG
LgB
SIDE TURN SIGNAL LIGHT RH
SIDE TURN SIGNAL

LIGHT LH
BG
F54
LgB
BY
B305
BY
B198
FRONT TURN SIGNAL

LIGHT LH
3
BG
FRONT TURN SIGNAL

LIGHT RH
REF. TO GND-03
F22
LgB
2
F4
TRAILER
CONNECTOR
LgB 5
REF. TO GND-01
TURN(L)-01
LgB 22
TURN(L)-01
BG
15
B99
LgB
BG
BG
R3
R79
REAR TURN SIGNAL
LIGHT RH (SEDAN)
REAR TURN SIGNAL

LIGHT LH (SEDAN)
SD
SD
WG
BG
WG
2
4
R28
LgB
R26
REAR TURN SIGNAL

LIGHT LH (WAGON)
BG
B
SD
3
2
SD
REAR TURN SIGNAL

LIGHT RH (WAGON)
WG
WG
R26
R28
LgB
SD
SD : SEDAN
WG
WG : WAGON
REF. TO GND-04
B305
F4
(GRAY)
B198
R26 : SD
R26 : WG
R79
F54
F22
(GRAY)
1 2 3 4 5
R28 : SD
R28 : WG
1 2 3 4 5
6 7 8 9 10
1 2
1 2 3
1 2 3
4 5 6
2
1
6 5 4 3
B99
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
GR26-21B
WI-221
OIL PRESSURE WARNING LIGHT SYSTEM

WIRING SYSTEM
31.Oil Pressure Warning Light System

A: SCHEMATIC
WI-222

WIRING SYSTEM
OIL/P(L)-01
OIL/P(L)-01
1. LHD MODEL
23 RW
RW
FB-36
F/B FUSE NO. 13
(IG)
B36
A7 GOr
i1
COMBINATION
METER
A:
i10
B:
i11
GB B2
OIL PRESSURE
WARNING LIGHT
GW
23
GB

i2
*1
B37
GW
NA
TB
I1
GW
14 GW
GW
B209
F76
SMJ
B21
E2
F61
E2
NA
GW
: NON-TURBO ENGINE MODEL : GW

TURBO ENGINE MODEL : G
*1
TB
E11
OIL PRESSURE SWITCH

A:
i10
(GREEN)
B36 (BLACK)
B21 (LIGHT GRAY)

F61 (BLACK)
1 2 3 4 5 6 7 8 9 10
7 8 9 10 11
1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
i2
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:
i11
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
GL66-21
WI-223

WIRING SYSTEM
OIL/P(R)-01
OIL/P(R)-01
2. RHD MODEL
GW
FB-36
F/B FUSE NO. 13
(IG)
GW
AT
GW
MT
B38
GW
GW 22
B36
i1
AT
A7 GW
MT
i3
COMBINATION
METER
OIL PRESSURE
WARNING LIGHT
A:
i10
B:
i11
AT : AT MODEL
*1
*2
i2
B37
: NON-TURBO ENGINE MODEL : 5

TURBO ENGINE MODEL : 14
: NON-TURBO ENGINE MODEL : GW
TURBO ENGINE MODEL : G
B21
E2
*2
*2 *1
WR
WR
14 WR
WR B2
MT : MT MODEL
E11
OIL PRESSURE SWITCH

A:
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
B:
i11
i1
(BLACK)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B21 (LIGHT GRAY)

1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
i3
(BLACK)
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
GR66-21
WI-224
OUTSIDE TEMPERATURE DISPLAY SYSTEM

WIRING SYSTEM
32.Outside Temperature Display System

A: SCHEMATIC
WI-225

WIRING SYSTEM
1. LHD MODEL
O/T(L)-01
LR
FB-9
M/B FUSE NO. 2
(B)
LR
FB-8
M/B FUSE NO. 2
RW
O/T(L)-01

FB-36
F/B FUSE NO. 13
(IG)
LR 20
RW 23
A: B282
B: B283
A11 YB
AUTO A/C
CONTROL
MODULE
B9
BP
AC
B17 BL
AC
LR A10
GOr A7
YB
12
YB
YB B12
BP
22
BP
BP B11
I/F
BL
21
BL
BL
B
AC
A:
i10
B:
i11
B8
A6
24
i2
B37
BL
BL
LCD
BL
4
F45
BP
CUSTOM
CPU
COMBINATION
METER
i1
B62
BP
POWER
CIRCUIT
I/F
I/F
B36
BP
LR
GOr
F78
AMBIENT
SENSOR
F78
(BLACK)
A:
1 2
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
i2
F45
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 GND-02
B: B283 (GRAY)
A: B282 (GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B:
i11
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B36 (BLACK)
7 8 9 10 11
1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
GL96-22
WI-226

WIRING SYSTEM
2. RHD MODEL
FB-36
F/B FUSE NO. 13
(IG)
O/T(R)-01
O/T(R)-01
AT : AT MODEL
LR
GW
MB-10
M/B FUSE NO.2
MT : MT MODEL
MT
AT
LR
GW
LR
GW
AT
MT
i3
B36
AT
LR
GW
21
LR
GW 22
B38
i1
MT
A10 LR
MT
A7 GW
AT
I/F
POWER CIRCUIT
A:
i10
B:
i11
YB
14
Or
13
YB
B
YB
B
B8
A6
Or B11
Or
I/F
A: B282
B: B283
AUTO A/C
CONTROL
MODULE
i2
26
21
YB
B
24
Or
23
AC
W B12
I/F
COMBINATION
METER
LCD
CUSTOM
CPU
B37
A11 W
AMBIENT SENSOR
AC
B17 YB
Or
AC
B
B9
B62
YB
YB
Or
Or
F45
F78
REF. TO GND-07
F78
1 2
(BLACK)
A:
i10
(GREEN)
i1
1 2 3 4 5 6 7 8 9 10
B: B283 (GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
(BLACK)
A: B282 (GRAY)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
i3
(BLACK)
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
B:
i11
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
F45
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
GR96-22
WI-227
PARKING BRAKE AND BRAKE FLUID LEVEL WARNING SYSTEM

WIRING SYSTEM
33.Parking Brake and Brake Fluid Level Warning System

A: SCHEMATIC
WI-228

WIRING SYSTEM
BR/W(L)-01
BR/W(L)-01
1. LHD MODEL
23
RW
FB-36
F/B FUSE NO.13
(IG)
B36
A7 GOr
i1
BRAKE FLUID
LEVEL SWITCH
RY B19
BW B1
RY
BW
PARKING BRAKE/
BRAKE FLUID LEVEL
WARNING LIGHT
COMBINATION
METER
A:
i10
B:
i11
Lg
Lg
5
B37
BW
B62
13 BW
F45
Lg
BW
i2
B16
B99
BW
R3
R4
F26
GENERATOR
REF. TO GND-02
B16 (GRAY)
F26
(GREEN)
1 2 3
1
2
A:
i10
PARKING BRAKE
SWITCH
(GREEN)
i2
B99
F45
1 2 3 4 5 6 7 8 9 10
B36 (BLACK)
7 8 9 10 11
1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
B:
i11
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
GL60-20
WI-229

WIRING SYSTEM
BR/W(R)-01
BR/W(R)-01
2. RHD MODEL
GW
FB-36
F/B FUSE NO.13
(IG)
AT
MT
B36
4
22
B38
i3
i1
MT
A7 GW
AT
BRAKE FLUID
LEVEL SWITCH
BW B1
BW
B19
PARKING BRAKE/
BRAKE FLUID LEVEL
WARNING LIGHT
COMBINATION
METER
A:
i10
B:
i11
P
1
B37
BW
i2
18 BW
BW
B62
F45
B16
17
B99
BW
R3
R4
F26
GENERATOR
REF. TO GND-07
B16 (GRAY)
F26
1
2
(GREEN)
1 2 3
i3
A:
i10
PARKING BRAKE
SWITCH
(GREEN)
i1
(BLACK)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10
F45
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
(BLACK)
B99
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
B:
i11
(GREEN)
i2
1 2 3 4 5 6 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-230
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
GR60-21
POWER WINDOW SYSTEM

WIRING SYSTEM
34.Power Window System

A: SCHEMATIC
WI-231
POWER WINDOW SYSTEM

WIRING SYSTEM
1. LHD MODEL
IG
IGNITION RELAY
(IG)
BW
GW
MB-12
SBF-6
(B)
P/W(L)-01
P/W(L)-01
F44
2
1
B61
BW
POWER WINDOW
CIRCUIT BREAKER
BW
WG
B41
POWER WINDOW
RELAY
A
B
C
17 WG
18 GB
14 GW
16 B
P/W(L)-02
P/W(L)-03
P/W(L)-04
B42
POWER WINDOW MAIN SWITCH

FRONT LH
LOCK
OFF
GB
GB
13
LR
FL U
FL D
GB
UP
DOWN
AUTO-UP AUTO-DOWN
D7
D1
LR
B30
D3
REF. TO GND-01
B41
D3
1
2
(GREEN)
FRONT POWER
WINDOW MOTOR LH
F44
D7
1 2 3 4
5 6 7 8
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16
D1
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
B42
1
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK (BLACK)
WI-232
GL70-20A
POWER WINDOW SYSTEM
P/W(L)-02
P/W(L)-02
WIRING SYSTEM
P/W(L)-01
FRONT POWER WINDOW

SUB-SWITCH RH
OFF
UP

FRONT RH
DOWN
3
GB
GB
BL
BL
BL
BL
RL
RL
RL
RL
LR
OFF
GB
D11
GB
GB
B101
B30
GB
D1
13
BL
FR U
RL
FR D
UP
DOWN
D7
LR
L
D17
2
1
D13
FRONT POWER
WINDOW MOTOR RH
D13 (GREEN)
1
2
D17
3
1 2
4 5 6 7 8
REF. TO GND-01
D7
D1
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
D11
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
GL70-20B
WI-233
POWER WINDOW SYSTEM
P/W(L)-03
P/W(L)-03
WIRING SYSTEM
P/W(L)-01
REAR POWER WINDOW

SUB-SWITCH LH
OFF
UP

REAR LH
DOWN
3
GB
GB
GB
GW
GW
LY
LY
LW
LW
GY
GY
RW
RL
OFF
D22
GB
GB
B270
B30
GB
13
LY
10
RL U
GOr
RL D
D1
UP
DOWN
D7
RL
RW
D25
2
1
D24
REAR POWER
WINDOW MOTOR LH
D24 (GREEN)
1
2
REF. TO GND-01
D22
D25
1 2 3
3
1 2
4 5 6 7 8
D7
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16
D1
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
GL70-20C
WI-234
POWER WINDOW SYSTEM
P/W(L)-04
P/W(L)-04
WIRING SYSTEM
P/W(L)-01
REAR POWER WINDOW

SUB-SWITCH RH
OFF
UP

REAR RH
DOWN
3
GB
GB
GB
GB
GB
GW
GW
GW
LW
LW
LW
RW
RL
OFF
D28
B266
GB
GW
GW 16
RR U
LW
LW
15
RR D
B30
D1
UP
DOWN
D7
RL
RW
D31
13
2
1
D30
REAR POWER
WINDOW MOTOR RH
D30 (GREEN)
1
2
REF. TO GND-01
D28
D31
1 2 3
3
1 2
4 5 6 7 8
D7
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16
D1
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
GL70-20D
WI-235
POWER WINDOW SYSTEM

WIRING SYSTEM
2. RHD MODEL
FB-17
F/B FUSE NO.18
(IG)
GB
P/W(R)-01
MB-12
SBF-6
(B)
BW
P/W(R)-01
POWER WINDOW
CIRCUIT BREAKER
2
1
BW
WG
B41
POWER WINDOW
RELAY
A
B
C
29 WG
30 GB
31 GB
33 B
P/W(R)-02
P/W(R)-03
P/W(R)-04
B42

FRONT RH
LOCK
OFF
GB
GB
GB
12
LR
FR U
FR D
UP
DOWN
AUTO-UP AUTO-DOWN
D7
D1
LR
B30
D3
REF. TO GND-06
B41
D3
1
2
D7
(GREEN)
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
FRONT POWER
WINDOW MOTOR RH
D1
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
B42
1
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK (BLACK)
WI-236
GR70-21A
POWER WINDOW SYSTEM
P/W(R)-02
P/W(R)-02
WIRING SYSTEM
P/W(R)-01
FRONT POWER WINDOW

SUB-SWITCH LH
OFF
UP

FRONT LH
DOWN
3
GB
GB
4
6
7
LR
OFF
GB
BL
BL
RL
RL
D11
GB
GB
GB
BL
BL
RL
RL
B101
B30
D1
BL
FL U
RL
FL D
UP
DOWN
D7
LR
L
D17
12
2
1
D13
FRONT POWER
WINDOW MOTOR LH
D13 (GREEN)
1
2
D17
3
1 2
4 5 6 7 8
REF. TO GND-06
D7
D1
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16
D11
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
GR70-21B
WI-237
POWER WINDOW SYSTEM
P/W(R)-03
P/W(R)-03
WIRING SYSTEM
P/W(R)-01
REAR POWER WINDOW

SUB-SWITCH LH
OFF
UP

REAR LH
DOWN
3
GB
GB
GB
GW
GW
LW
LW
RW
RL
OFF
D22
GB
GB
LY
LY
GY
GY
B
B270
B30
12
LY
10
RL U
GOr
RL D
D1
UP
DOWN
D7
RL
RW
D25
GB
2
1
D24
REAR POWER
WINDOW MOTOR LH
D24 (GREEN)
1
2
REF. TO GND-06
D22
D25
1 2 3
3
1 2
4 5 6 7 8
D7
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16
D1
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
GR70-21C
WI-238
POWER WINDOW SYSTEM
P/W(R)-04
P/W(R)-04
WIRING SYSTEM
P/W(R)-01
REAR POWER WINDOW

SUB-SWITCH RH
OFF
UP

REAR RH
DOWN
3
GB
GB
GB
GB
GB
GW
GW
GW
LW
LW
LW
RW
RL
OFF
D28
B266
GB
GW
GW 14
RR U
LW
LW
13
RR D
B30
D1
UP
DOWN
D7
RL
RW
D31
12
2
1
D30
REAR POWER
WINDOW MOTOR RH
D30 (GREEN)
1
2
REF. TO GND-06
D28
D31
1 2 3
3
1 2
4 5 6 7 8
D7
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16
D1
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
GR70-21D
WI-239
RADIATOR FAN SYSTEM

WIRING SYSTEM
35.Radiator Fan System

A: SCHEMATIC
WI-240
RADIATOR FAN SYSTEM

WIRING SYSTEM
R/F(NA)-01
R/F(NA)-01
MB-1
SBF-1
(B)
FB-19
F/B FUSE NO. 17
(IG)
GB
GOr

FB-18
F/B FUSE NO. 18
(IG)
AIR CONDITIONING
RELAY HOLDER
AIR CONDITIONING
RELAY HOLDER
1
WR
26
28
27
25
1
GB
3
WL
WR
GOr
2
4
18
20
19
17
20A
20A
F27
MAIN
F66 FAN
RELAY
*
*
*
*
RHD LHD
7
2
17 12
WL
B
*3
GR
2
1
: LHD MODEL : GW
RHD MODEL : GR
*3
: LHD MODEL : RL
RHD MODEL : WL
*4
: LHD MODEL : YG
RHD MODEL : YB
*5
: LHD MODEL :
REF. TO GND-01
RHD MODEL :
REF. TO GND-06
A: B134
(BLACK)
F17
(BLACK)
F16
ENGINE
CONTROL
MODULE
*5
F16
2
1
*2
*B4
B62
: LHD MODEL : BW
RHD MODEL : BR
F45
3
A3
A12 GR
F17
*1
SUB FAN
MOTOR
*32
*
MAIN FAN
MOTOR
SUB
F29 FAN
RELAY
F27
F45 : RHD
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
*5
F45 : LHD
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
2 1
F27
1
F29
F66
5 6 9 13 14 17 21 22 25
7
10
15
18
23
26
8 11 12 16 19 20 24 27 28
29
30
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
GG14-23
WI-241
RADIATOR FAN SYSTEM

WIRING SYSTEM
R/F(TB)-01
R/F(TB)-01

GOr
FB-18
FB-19
F/B FUSE NO. 18 F/B FUSE NO. 17
(IG)
(IG)
GB
MB-1
SBF-1
(B)
AIR CONDITIONING
RELAY HOLDER
AIR CONDITIONING
RELAY HOLDER
1
*1
WR
MAIN
FAN
RELAY-1
26
28
27
25
*GB1
*WL3
WR
GOr
3
WG
7
5
6
8
MAIN
FAN
RELAY-2
23
21
22
24
*GB1
*YR2
WG
GOr
2
4
18
20
19
17
30A
F27
F66
F30
F27 30A
*
*
: LHD MODEL : BW
RHD MODEL : BR
*2
: LHD MODEL : GW
RHD MODEL : GR
*4
: LHD MODEL : YG
RHD MODEL : YB
*5
: LHD MODEL :
REF. TO GND-01
RHD MODEL :
REF. TO GND-06
(BLACK)
2
B62
*5
3 : LHD MODEL : RL
RHD MODEL : WL
(BLACK)
SUB
FAN
RELAY-2
*4
WG
1
F16
*1
B
F17
F17
F29
F45
*3
WL
*2
*3
RHD LHD
17 12
YR
GR
F16
SUB
FAN
RELAY-1
SUB FAN
MOTOR
MAIN FAN
MOTOR
F28
*5
3 D17
GR D28
ENGINE CONTROL
MODULE
F45 : LHD
F45 : RHD
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
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
3 2 1
F27
1
F28
F29
F30
F66
5 6 9 13 14 17 21 22 25
15
18
26
7
10
23
8 11 12 16 19 20 24 27 28
29
30
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
GG14-22
WI-242

WIRING SYSTEM
36.Rear Fog Light System

A: SCHEMATIC
WI-243

WIRING SYSTEM
R/FOG(L)-01
R/FOG(L)-01
1. LHD MODEL
FB-11
F/B FUSE NO.12
MB-8
HEADLIGHT
RELAY
22
FB-10
F/B FUSE NO.12
LR

FB-29
F/B FUSE NO.10
(B)
REF. TO FOG(L)-01
F45
DIODE (REAR FOG)
B62
DIODE (LIGHTING)
REAR FOG
LIGHT RELAY
BW
YW
B196
RW
REAR FOG
LIGHT SWITCH
B85
2
LR
LY
ON
V
YW
OFF
B99
LY
21
LY
B131
REAR FOG LIGHT

(WAGON)
WG
SD
R3
TRAILER
CONNECTOR
LY
6
7
RW
LY
R28
B195
R79
WG
REAR FOG LIGHT

(SEDAN)
SD
LY
B85
B196
1 2
B131 (BLUE)
1 2
3 4
R28
REF. TO GND-04
REF. TO GND-01
B195
1
2
3 4 5 6
WG
R28
2
1
6 5 4 3
SD
R28
R79
1 2 3
4 5 6
1 2 3 4 5
6 7 8 9 10
SD
SD : SEDAN
WG
WG : WAGON
F45
B99
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
GL30-20
WI-244

WIRING SYSTEM
RFOG(FE)-01
RFOG(FE)-01
2. RHD FOR EUROPE MODEL
FB-10
F/B FUSE NO.12
FB-11
F/B FUSE NO.12
MB-8
HEADLIGHT
RELAY
LR

FB-29
F/B FUSE NO.10
(B)
REF. TO FOG(RFE)-01
DIODE (REAR FOG)
DIODE (LIGHTING)
REAR FOG
LIGHT RELAY
BY
YW
B196
RW
REAR FOG
LIGHT SWITCH
B85
2
LR
LY
ON
V
YW
OFF
LY
LY
B131
B97
REAR FOG LIGHT

(WAGON)
WG
SD
R1
TRAILER
CONNECTOR
LY
6
7
RW
LY
R26
B195
R79
WG
REAR FOG LIGHT

(SEDAN)
SD
LY
B85 (BLACK)
B196 (BLACK)
1 2
R26
REF. TO GND-09
REF. TO GND-06
B131 (BLUE)
1 2
3 4
B195
1
2
3 4 5 6
WG
R26
2
1
6 5 4 3
SD
R26
B97
R79
1 2 3
4 5 6
1 2 3 4
5 6 7 8
1 2 3 4 5
6 7 8 9 10
SD
SD : SEDAN
WG
WG : WAGON
GR30-22
WI-245

WIRING SYSTEM
RFOG(OE)-01
RFOG(OE)-01
3. RHD EXCEPT FOR EUROPE MODEL
FB-10
F/B FUSE NO.12
FB-11
F/B FUSE NO.12
MB-8
HEADLIGHT
RELAY
LR

FB-29
F/B FUSE NO.10
(B)
REF. TO FOG(ROE)-01
DIODE
BY
DIODE (LIGHTING)
REAR FOG
LIGHT RELAY
RW
RW
YW
B196
REAR FOG
LIGHT SWITCH
B85
2
LR
LY
ON
V
YW
YL
OFF
LY
LY
B131
B97
R1
REAR FOG LIGHT
(WAGON)
TRAILER
CONNECTOR
LY
6
B
LY
SD
WG
B195
R26
REF. TO ILM(RWI)-01
ILM(ROI)-01
R79
LIGHTING SWITCH
OFF
WG
REAR FOG LIGHT

(SEDAN)
SD
LY
HC
RW 14
TC
B
EL
R26
B
B71
REF. TO GND-09
B85 (BLACK)
1 2
B131 (BLUE)
B196
1 2 3
1 2
3 4
SD
SD : SEDAN
WG
WG : WAGON
REF. TO GND-07
B195
1
2
3 4 5 6
WG
R26
2
1
6 5 4 3
SD
R26
B97
R79
1 2 3
4 5 6
1 2 3 4
5 6 7 8
1 2 3 4 5
6 7 8 9 10
B71
1
9
2
10
3 4 5 6
11 12 13 14 15
7
16
8
17
GR30-23
WI-246

WIRING SYSTEM
37.Rear Window Defogger System

A: SCHEMATIC
WI-247

WIRING SYSTEM
R/DEF(L)-01
R/DEF(L)-01
1. LHD MODEL
FB-16
REAR DEFOGGER
RELAY
FB-20
F/B FUSE NO. 17
(IG)
RL
GOr

FB-15
REAR DEFOGGER
RELAY
GOr
L
R
B
4
3
2
1
A3
B21
A13
B296
REAR DEFOGGER
TIMER

SD : SEDAN
A: B134
WG : WAGON
B
WC : WITH CHOKE COIL

MODEL
NA
TB

(TURBO MODEL)
B: B135
OC : WITHOUT CHOKE COIL

MODEL
REF. TO GND-02

(NA MODEL)
A: B282
AUTO A/C CONTROL
MODULE
RL
RL A14
B97
REAR DEFOGGER
(SEDAN)
REAR DEFOGGER
(WAGON-WITHOUT CHOKE COIL)
RL
R1
SD
RL
WG
RL
RL
OC
RL
WC
CHOKE COIL
R130
R39
B
D35
OC
WC
D40
D48
REAR DEFOGGER
(WAGON-WITH CHOKE COIL)
CHOKE COIL
RL
REF. TO GND-03
REF. TO GND-05
D74
A: B282 (GRAY)
D74
R130
D35
B296
B97
1
2
1
2
1 2
3 4
1 2
3 4
1 2 3 4
5 6 7 8
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
A: B134
6 7
1 2 3 4 5
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
B: B135
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
GL52-21
WI-248

WIRING SYSTEM
R/DEF(R)-01
R/DEF(R)-01
2. RHD MODEL
FB-16
REAR DEFOGGER
RELAY
FB-17
F/B FUSE NO. 18
(IG)
RL
GB

FB-15
REAR DEFOGGER
RELAY
GB
L
R
B
4
3
2
1
A3
B21
A13
B296
REAR DEFOGGER
TIMER

SD : SEDAN
A: B134
WG : WAGON
NA
TB

(TURBO MODEL)
B: B135
REF. TO GND-07

(NON-TURBO MODEL)
RL
RL A14
A: B282
AUTO A/C CONTROL
MODULE
B97
REAR DEFOGGER
(SEDAN)
REAR DEFOGGER
(WAGON)
RL
R1
SD
RL
WG
RL
RL
RL
CHOKE COIL
D40
R39
1
2
D35
1 2
3 4
B296
1 2
3 4
R130
R130
REF. TO GND-08
REF. TO GND-10
B97
1 2 3 4
5 6 7 8
A: B282 (GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
D35
D48
A: B134
6 7
1 2 3 4 5
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
B: B135
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
GR52-21
WI-249
REMOTE CONTROLLED REARVIEW MIRROR SYSTEM

WIRING SYSTEM
38.Remote Controlled Rearview Mirror System

A: SCHEMATIC
WI-250

WIRING SYSTEM
R/M(L)-01
MIRROR HEATER
RELAY
RL
YR
FB-28
FB-15
FB-30
F/B FUSE NO. 19 REAR DEFOGGER F/B FUSE NO. 4
(ACC)
RELAY
(B)
RW
R/M(L)-01
1. LHD MODEL
29 RW
30 BY
33 RL
31 B
B171
REMOTE CONTROLLED REARVIEW MIRROR SWITCH
REARVIEW MIRROR LH
WH OH
1
MIRROR HEATER
REMOTE CONTROL SWITCH

L
23
BY
UP DOWN
YR
4
RB
21
RL
LH RH
5
LG
20
LR
22
D5
D1
B30
REARVIEW MIRROR RH
MIRROR HEATER
DOWN
UP
Lg
RL
CHANGE OVER
SWITCH
LR
RB
REF. TO GND-0102
WH OH
1
23
BY
RB
21
RL
LR
20
Lg
22
B284
UP DOWN
6
LH RH
D11
R
B101
WH : WITH MIRROR HEATER MODEL

OH : WITHOUT MIRROR HEATER MODEL
D15
REF. TO GND-03
D5
: OH
D15 : OH
2
1
6 5 4 3
D5
: WH
D15 : WH
3
2 1
8 7 6 5 4
B284
1 2 3 4 5
6 7 8 9 10
D1
D11
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
B171
1
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK (BLACK)
GL79-21
WI-251

WIRING SYSTEM
R/M(R)-01
MIRROR HEATER
RELAY
RL
YR
FB-28
FB-15
FB-30
F/B FUSE NO. 19 REAR DEFOGGER F/B FUSE NO. 4
(ACC)
RELAY
(B)
RW
R/M(R)-01
2. RHD MODEL
18 RW
17 BY
16 RL
14 B
B171
REMOTE CONTROLLED REARVIEW MIRROR SWITCH
REARVIEW MIRROR LH
WH OH
1
MIRROR HEATER
REMOTE CONTROL SWITCH

L
23
BY
UP DOWN
4
RB
21
RB
LH RH
5
LR
20
22
D15
D11
Lg
RL
DOWN
UP
LR
R
B101
REARVIEW MIRROR RH
MIRROR HEATER
YR
CHANGE OVER
SWITCH
LR
RB
REF. TO GND-08
WH OH
1
23
BY
RB
21
RL
Lg
20
Lg
22
B284
UP DOWN
6
LH RH
D1
R
B30
WH : WITH MIRROR HEATER MODEL

OH : WITHOUT MIRROR HEATER MODEL
D5
REF. TO GND-0607
D5
: OH
D15 : OH
1
2
6 5 4 3
D5
: WH
D15 : WH
3
2 1
8 7 6 5 4
B284
1 2 3 4 5
6 7 8 9 10
D1
D11
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
B171
1
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK (BLACK)
GR79-21
WI-252
SEAT BELT WARNING SYSTEM

WIRING SYSTEM
39.Seat Belt Warning System

A: SCHEMATIC
WI-253

WIRING SYSTEM
1. WITHOUT SEAT BELT TIMER MODEL
S/BELT-01
S/BELT-01
GW
FB-36
F/B FUSE NO. 13
(IG)
GW
GW
MT
AT
B38
i1
i3
MT
GW
GW 22
B36
A7 GW
AT
COMBINATION
METER
i10
B:
i11
BL
B9
A:
SEAT BELT
WARNING
LIGHT
19
i2
18
BL
BL
B37
R3
BL
SEAT BELT SWITCH

1
2
B99
BL
B
B
R8
REF. TO GND-03
A:
R8
1
2
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
i1
(BLACK)
B:
B99
1 2 3
4 5 6
7 8 9 10 11 12 13 14
i3
(BLACK)
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
i11
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
i2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
GG87-21
WI-254

WIRING SYSTEM
S/BEL(T)-01
S/BEL(T)-01
2. WITH SEAT BELT TIMER MODEL

23
MB-6
M/B FUSE NO. 6
(B)
W
GB
RW
FB-36
FB-17
F/B FUSE NO. 13 F/B FUSE NO. 18
(IG)
(IG)
B36
23
A7 GOr
i1
F45
B62
COMBINATION
METER
A:
i10
B:
i11
KEY WARNING
SWITCH
SEAT BELT
WARNING
LIGHT
W
WR
2
1
BL
B9
B74
21
i2
GB
9
BL
2
3
B
6
BrW
LOr
SEAT BELT TIMER
B44
18
WR
BL
B37
B99
R3
2
1
FRONT DOOR
SWITCH LH
BL
SEAT BELT SWITCH

BL
B
LOr
B
B267
R8
REF. TO GND-03
B74 (BLACK)
1
2
R8
1
2
B36 (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
1
3
REF. TO GND-02
B267
B44
1
2
3
1 2
3 4
5 6 7 8 9 10
F45
i2
B99
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
WI-255
A:
i10
(GREEN)
1 2 3 4 5 6 7 8 9 10
B:
i11
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
GL87-21
STARTER SYSTEM
WIRING SYSTEM
40.Starter System
A: SCHEMATIC
WI-256
STARTER SYSTEM
WIRING SYSTEM
ST(MT)-01
ST(MT)-01
1. MT MODEL
WB
ST
IGNITION SWITCH
(ST)

BATTERY
B: B135
ENGINE
CONTROL
B28 WB
MODULE
(NON-TURBO
ENGINE MODEL)
NA
STARTER MOTOR
A: B134
ENGINE
CONTROL
A16 WB
MODULE
(TURBO ENGINE
MODEL)
A: B134
6 7
1 2 3 4 5
8 9 10 11 12 13 14 15
16 17
18 19 20 21 22
TB
WB
B14
B: B135
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
GG03-20
WI-257
STARTER SYSTEM
WIRING SYSTEM
ST(AT)-01
ST-(AT)-01
2. AT MODEL
WB
ST
IGNITION SWITCH
(ST)
INHIBITOR SWITCH
P
BATTERY
12
BY
BW
T7
12 WB
11 WR
T3
B12
STARTER MOTOR
B: B135
ENGINE
CONTROL
MODULE
T7
1 2 3 4 5 6
7 8 9 10 11 12
B28 WR
WR
B14
B12
1 2 3 4
5 6 7 8
9 10 11 12
B: B135
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
GG03-21
WI-258
SUNROOF SYSTEM
WIRING SYSTEM
41.Sunroof System
A: SCHEMATIC
IG
IGNITION RELAY
(IG)
GB
GW
*1
*2
LHD
BW
RHD
S/R-01
FB-17
F/B FUSE NO. 18
(IG)
BW
S/R-01

MB-12
SBF-6
(B)
BW
F44
: LHD MODEL : GW
RHD MODEL : GB
: LHD MODEL :
REF. TO GND-01
RHD MODEL :
REF. TO GND-06
POWER WINDOW
CIRCUIT BREAKER
RHD
2
1
B61
LHD
BW
WG
RHD
17
18
14
16
29 WG
30 GB
1
31
33 B
RHD
LHD
B41
LHD
GB
POWER WINDOW
RELAY
B42
GB
B90
R50
GB
R55
SUNROOF SWITCH
OPEN
Br
CLOSE
B
S1
SUNROOF SWITCH
TILT UP
TILT
DOWN
SUNROOF
CONTROL
MODULE &
MOTOR
S2
*2
B41
1
2
B90
S1
1 2
3 4
S2
B42 : LHD
F44
(BLACK)
1 2 3 4 5
1 2 3 4
5 6 7 8
B42 : RHD
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK (BLACK)
GG75-21
WI-259
WIPER AND WASHER SYSTEM (FRONT)

WIRING SYSTEM
42.Wiper and Washer System (Front)

A: SCHEMATIC
WI-260

WIRING SYSTEM
F/W(L)-01
F/W(L)-01
1. LHD MODEL
YB
FB-26
F/B FUSE NO. 15
(ACC)
FRONT WASHER
MOTOR
YB
B61
YB
YB
LgR
2
1
F44
F32
LgR
B62
18 LgR
F45
COMBINATION SWITCH
WASHER
SWITCH
ON OFF
W
LgR 11
EW
FRONT WIPER SWITCH
OFF
INT
LO
HI
OFF MIST OFF MIST OFF MIST OFF MIST
FRONT WIPER MOTOR

5
YB
YB
17
GY
GY
16
BL
BL
ACC
INTERMITTENT
WIPER
MODULE
S1
S2
S3
INT1
RL
RL
B8
INT2
B70
F32
1
2
(GREEN)
INT VOLUME
REF. TO GND-02
REF. TO GND-02
B70
B8
1 2 3
4 5
1
10
2
11
3 4 5 6
12 13 14 15
7
16
8 9
17 18
F44
F45
1 2 3 4
5 6 7 8
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
GL50-20
WI-261

WIRING SYSTEM
F/W(R)-01
F/W(R)-01
2. RHD MODEL
YB
FB-26
F/B FUSE NO. 15
(ACC)
FRONT WASHER
MOTOR
YB
LgR
2
1
B146
COMBINATION SWITCH
WASHER
SWITCH
ON OFF
EC OT
LgR 11 17
W
EW
FRONT WIPER SWITCH
OFF
INT
LO
HI
OFF MIST OFF MIST OFF MIST OFF MIST
FRONT WIPER MOTOR

5
YB
YB
17
11
GY
GY
16
12
BL
BL
ACC
INTERMITTENT
WIPER
MODULE
S1
S2
S3
INT1
RL
RL
B8
INT2
B70
INT VOLUME
EC : EUROPE MODEL
OT : OTHER MODEL
REF. TO GND-07
B146 (GREEN)
1
2
REF. TO GND-07
B70
B8
1 2 3
4 5
1
10
2
11
3 4 5 6
12 13 14 15
7
16
8 9
17 18
GR50-21
WI-262
WIPER AND WASHER SYSTEM (REAR)

WIRING SYSTEM
43.Wiper and Washer System (Rear)

A: SCHEMATIC
WI-263

WIRING SYSTEM
1. LHD MODEL
FB-25
F/B FUSE NO. 14
(ACC)
R/W(L)-01
R/W(L)-01
WR
WG
FB-24
F/B FUSE NO. 14
(ACC)
REAR WASHER
MOTOR
LB
WG
LB
B62
F45
1
2
F33
R116
GR
LB
7
LG
LW
YB
REAR WIPER
INTERMITTENT
MODULE
YB
WR
R1
REAR WIPER MOTOR

1
YB
YB
YB
LG
LG
LG
LW
LW
LW
D34
B97
REAR WIPER &

WASHER SWITCH
WASH OFF ON WASH
LB
14
GR
12
R3
LB
LB
12
GR
GR
10
B99
B70
R38
D43
F33
1
2
R39
D35
REF. TO GND-0405
REF. TO GND-02
D34
D35
B97
1 2 3
4 5 6
D43
R116
1 2
3 4
B70
B99
F45
1 2 3 4
5 6 7 8
1
10
2
11
3 4 5 6
12 13 14 15
7
16
8 9
17 18
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
GL51-21
WI-264

WIRING SYSTEM
2. RHD MODEL
R/W(R)-01
R/W(R)-01
YL
FB-25
F/B FUSE NO. 14
(ACC)
EC : EUROPE MODEL
REAR WASHER
MOTOR
OT : OTHER MODEL
YL
LB
1
2
B147
R116
LG
LW
GR
LB
YL
REAR WIPER
INTERMITTENT
MODULE
YL
R1
REAR WIPER MOTOR

1
YB
YB
YL
LG
LG
LG
LW
LW
LW
D34
B97
LB
GR
R3
YL
REAR WIPER &
WASHER SWITCH
LB
LB
EC OT
12 16
GR
GR
10
18
B99
WASH OFF ON WASH
B70
R38
D43
B147
1
2
R39
D35
REF. TO GND-0910
REF. TO GND-07
B70
D34
D35
B97
1 2 3
4 5 6
D43
R116
1 2
3 4
1 2 3 4
5 6 7 8
1
10
2
11
3 4 5 6
12 13 14 15
B99
7
16
8 9
17 18
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
GR51-21
WI-265
OVERALL SYSTEMS
WIRING SYSTEM
44.Overall Systems
A: LOCATION
1. LHD MODEL
BO0479
(1)
(2)
(3)
(4)
(5)

Front door cord RH
(6)
(7)
(8)
(9)
(10)
Rear door cord RH

Rear wiring harness
Roof cord
Fuel tank cord
Rear gate cord
WI-266
(11)
(12)
(13)
Rear door cord LH

Front door cord LH
Transmission cord
OVERALL SYSTEMS
WIRING SYSTEM
2. RHD MODEL
BO0214
(1)
(2)
(3)
(4)
(5)

Front door cord RH
(6)
(7)
(8)
(9)
(10)
Rear door cord RH

Rear wiring harness
Roof cord
Fuel tank cord
Rear gate cord
WI-267
(11)
(12)
(13)
Rear door cord LH

Front door cord LH
Transmission cord
FRONT WIRING HARNESS

WIRING SYSTEM
45.Front Wiring Harness

A: LOCATION
1. LHD MODEL
No.
F4
F5
F7
F16
F17
F21
F22
F23
F24
F25
F26
F27
F28
F29
F30
F31
F32
F33
F34
F35
F36
F37
F38
F39
F40
F41
F44
F45
F46
F47
F54
F58
F59
F60
F61
F66
F67
F68
F76
F78
F79
Connector
Pole
Color
3
Gray
1
Black
3
2
Black
3
Black
2
Black
3
Black
2
Black
3
Gray
3
3
Gray
1
3
Green
4
Black
4
Black
4
Black
4
Black
4
Black
4
Black
2
Green
2
4
Black
2
Black
3
6
Black
1
8
Black
9
Brown
7
Gray
8
24
2
Black
1
Black
2
3
Black
3
Black
16
Brown
20
Black
4
Black
4
Black
2
Black
4
Black
40
Gray
2
Black
2
Gray
Area
B-1
C-2
B-1
D-1
D-1
C-2
C-2
D-3
B-3
C-2
B-2
B-2
B-2
C-4
C-4
C-4
C-4
C-4
C-4
B-4
B-4
B-4
B-3
A-3
A-3
A-3
B-3
B-3
A-4
A-3
B-3
B-3
C-2
B-4
C-4
B-1
B-4
B-4
C-4
C-4
C-4
B-3
A-3
C-2
B-3
No.
Connecting to
Name
Front clearance light RH and front turn signal light RH
Horn
Headlight RH
Sub fan motor (Non-turbo model)
Sub fan motor (Turbo model)
Radiator main fan motor (Non-turbo model)
Radiator main fan motor (Turbo model)
Front fog light LH
Front clearance light LH and front turn signal light LH
Headlight LH
A/C compressor
Generator
A/C fuse (Relay holder)
A/C sub fan relay-1 (Relay holder-Turbo model)
A/C sub fan relay (Relay holder-Non-turbo model)
Radiator main fan relay-2 (Relay holder-Turbo model)
A/C relay (Relay holder)
Front washer motor
Rear washer motor
SBF holder
M/B
F/B
B61
B62
B108
E3
E2
B209

Horn
Headlight beam leveler LH
Headlight beam leveler RH
Engine wiring harness (Turbo model)
Engine wiring harness (Turbo model)
Radiator main fan relay (Relay holder-Non-turbo model)
FWD switch (AWD AT model)
M/B
Bulkhead wiring harness (SMJ)
Ambient sensor
A/C pressure switch
WI-268

WIRING SYSTEM
Connector
No.
Pole
Color
F94
2
Gray
: Non-colored
Area
A-3
Connecting to
Name
ABS front sensor LH
No.
4
F29
F28
F27
F31
5
F76
F66
F30
F67
F46
F44
F45
F40
F36
F38
GB-1
F37
F94
F25
F59
F79
F41
F54
F35
F4
F61
F39
F60
F7
F26
F24
F22
F23
F78
F68
F58
F34
GB-2
F33
F5
F47
F17
F32
F16
F21
BO0467
WI-269

WIRING SYSTEM
2. RHD MODEL
No.
F4
F5
F6
F7
F16
F17
F21
F22
F23
F24
F25
F26
F27
F28
F29
F30
F31
F34
F35
F39
F41
F44
F45
F47
F49
F51
F58
F59
F62
F66
F67
F73
F74
F78
F79
F94
F95
F96
F97
: Non-colored
Connector
Pole
Color
3
Gray
1
Black
2
Black
3
2
Black
3
Black
2
Black
3
Black
2
Black
3
Gray
3
3
Gray
1
3
Green
4
Black
4
Black
4
Black
4
Black
4
Black
4
Black
4
Black
2
Black
8
Black
7
Gray
8
18
31
Black
2
3
Black
3
Black
8
Gray
4
Black
4
Black
2
Black
1
22
Black
2
Black
2
Gray
2
Gray
2
Gray
1
White
2
Black
Area
B-1
C-2
C-1
B-1
D-1
D-1
D-2
D-2
D-4
C-3
C-3
B-2
B-2
B-2
A-3
A-3
A-4
A-4
A-4
A-3
B-4
B-4
B-4
A-3
A-3
A-2
C-2
A-1
A-2
C-4
B-1
B-2
A-4
A-4
A-4
B-2
A-3
C-2
C-2
A-3
A-2
D-4
A-2
No.
Connecting to
Name
Front clearance light RH and front turn signal light RH
Horn
Front fog light RH
Headlight RH
Sub fan motor (Non-turbo model)
Sub fan motor (Turbo model)
Radiator main fan motor (Non-turbo model)
Radiator main fan motor (Turbo model)
Front fog light LH
Front clearance light LH and front turn signal light LH
Headlight LH
A/C compressor
Generator
A/C fuse (Relay holder)
A/C sub fan relay (Relay holder-Non-turbo model)
A/C relay (Relay holder)
SBF holder
M/B
B61
B62
B200
B255
F/B
Horn
ABS control module
Headlight beam leveler LH
Headlight beam leveler RH
Shield joint connector (ABS)
Radiator main fan relay (Relay holder-Non-turbo model)
Radiator main fan relay-1 (Relay holder)
FWD switch (AWD AT model)
ABS motor ground
Bulkhead wiring harness (ABS)
Ambient sensor
A/C pressure switch
ABS front sensor LH
ABS front sensor RH
ABS condenser
WI-270

WIRING SYSTEM
1
F45
F51
F74
F29
F28
F41
F27
F31
F66
F30
F67
A
F49
GB-1
F95
F44
F97
F59
F94
F25
F35
F62
B
F4
F39
F26
F7
F24
F73
F22
F23
F78
F34
F79
F5
F6
F47
F58
F17
F16
GB-2
F21
F96
BO0468
WI-271
BULKHEAD WIRING HARNESS (IN ENGINE ROOM)

WIRING SYSTEM
46.Bulkhead Wiring Harness (In Engine Room)

A: LOCATION
1. LHD NON-TURBO ENGINE MODEL
No.
B2
B8
B11
B12
B14
B15
B16
B17
B18
B19
B21
B22
B24
B25
B28
B29
B301
B302
B303
B305
B306
: Non-colored
Connector
Pole
Color
3
5
Gray
20
Black
12
2
Gray
2
Gray
3
Area
B-1
A-4
B-3
B-3
B-4
B-2
B-2
B-3
C-2
6
4
20
16
2
2
3
2
31
1
8
2
2
Light gray
Brown
Gray
Brown
Black
Gray
Black
C-2
B-2
C-2
C-2
B-2
C-3
A-2
B-2
B-1
C-1
B-2
A-2
C-1
No.
T4
T3
Connecting to
Name
Front wiper motor
Transmission (AT)
Starter (Magnet)
ABS front sensor RH
Brake fluid level switch
Oxygen sensor (Catalytic converter equipped vehicle without
OBD)
Front oxygen (A/F) sensor (With OBD)
Rear oxygen sensor (With OBD)
E2
E3
T1
T2
T8

Neutral position switch (MT)
CO resistor
Lo (AWD) indicator light switch (MT)
ABS control module
ABS motor ground
Front fog light RH
WI-272

WIRING SYSTEM
1
B305
B28
B25
B8
B15
B301
B16
B29
B12
B14
B2
B24
B303
B11
B19
B302
B17
B18
B24
B21
B22
B29
B25
B306
BO0469
WI-273

WIRING SYSTEM
2. LHD TURBO ENGINE MODEL

Connector
No.
Pole
Color
B3
5
Gray
B8
5
B14
1
B15
2
Gray
B16
2
Gray
B17
4
B18
4
B19
4
B20
10
B127
2
Blue
B128
4
B279
2
B301
31
Black
B302
1
B303
8
Gray
B305
2
B306
2
Black
: Non-colored
Area
B-1
A-4
B-4
B-2
B-4
B-3
A-2
A-2
A-2
B-2
B-3
A-2
B-1
C-1
B-1
A-2
C-1
No.
E1
T9
Connecting to
Name
Mass air flow sensor
Front wiper motor
Starter (Magnet)
ABS front sensor RH
Rear oxygen sensor
Transmission (MT)
ABS control module
ABS motor ground
Front fog light RH
WI-274

WIRING SYSTEM
1
B305
B18
B20
B15
B16
B279
B301
B8
B303
B14
B16
B19
B3
B17
B127
B128
B302
B306
BO0470
WI-275

WIRING SYSTEM
3. RHD NON-TURBO ENGINE MODEL

No.
B2
B7
B8
B11
B12
B14
B16
B17
B18
Connector
Pole
Color
3
6
Black
5
Black
20
Black
12
White
1
2
Gray
3
Black
4
6
B21
20
B22
16
B24
2
B25
2
B28
3
B29
2
B143
3
B144
6
B145
1
B146
2
B147
2
B148
2
B186
4
B255
1
: Non-colored
Area
B-1
C-4
A-2
B-2
B-3
B-3
A-2
C-2
B-2
Light gray
Brown
Gray
Brown
Black
Green
Black
White
C-2
C-2
C-2
B-2
A-2
A-1
B-2
B-3
B-3
C-4
B-3
B-3
A-4
B-3
C-2
No.
T4
T3
Connecting to
Name
Pressure sensor (With OBD)
Front wiper motor
Transmission (AT)
Starter (Magnet)
Oxygen sensor (Catalytic converter equipped vehicle without
OBD)
Front oxygen (A/F) sensor (With OBD)
E2
E3
T1
T2
T8

Neutral position switch (MT)
CO resistor (Without catalytic converter)
Lo (AWD) indicator light switch (MT)
M/B
F96
Front washer motor

Rear washer motor
M/B
Front wiring harness (With ABS)
WI-276

WIRING SYSTEM
1
B8
B28
B25
B148
B144
B16
B143
B29
B186
B12
B14
B24
B2
B147
B11
B146
B22
B17
B21
B18
WO
B18
B7
OO
B145
B255
D
WO : WITH OBD MODEL
BO0471
WI-277

WIRING SYSTEM
4. RHD TURBO ENGINE MODEL

No.
B3
B7
B8
B11
B12
B14
B16
B17
B18
B19
B20
B21
B22
B127
B128
B143
B144
B145
B146
B147
B148
B186
B255
B279
: Non-colored
Connector
Pole
Color
5
Gray
6
Black
5
Gray
20
Black
12
White
1
2
Gray
4
Black
4
10
20
Black
16
Brown
2
4
Gray
3
6
Black
1
2
Green
2
4
Black
1
White
2
Area
B-2
C-4
A-2
B-3
B-3
B-3
B-2
B-2
A-1
B-2
A-1
B-2
C-2
A-1
C-2
A-3
A-3
C-4
B-3
B-3
A-4
B-3
C-2
A-1
No.
T4
T3
E1
E2
E3
T9
Connecting to
Name
Mass air flow sensor
Front wiper motor
Transmission (AT)
Starter (Magnet)
Oxygen sensor
Transmission (MT)
M/B
F96
Front washer motor

Rear washer motor
M/B
Front wiring harness (With ABS)
WI-278

WIRING SYSTEM
1
B8
B18
B20
B279
B127
B148
B143
B144
B16
B12
B186
B14
B19
B11
B147
B17
B3
B146
B21
B128
B22
B7
B145
B255
BO0478
WI-279
BULKHEAD WIRING HARNESS (IN COMPARTMENT)

WIRING SYSTEM
47.Bulkhead Wiring Harness (In Compartment)

A: LOCATION
1. LHD MODEL
No.
B30
B31
B32
B36
B37
B40
B41
B42
Connector
Pole Color
25
6
Yellow
3
Black
24
Black
24
16
Gray
2
Area
D-1
D-1
B-2
B-1
B-3
C-2
C-1
C-1
B43
Black
B44
10
B46
B47
B48
B50
B51
B52
4
6
5
4
8
7
Green
Brown
Blue
C-1
C-4
C-1
C-1
C-1
B-1
B53
12
Black
B-2
B54
B55
B56
B61
B62
B64
24
24
24
8
24
2
Gray
Green
Black
A-2
A-2
A-2
B-1
B-2
B-2
B68
Black
C-3
B69
B70
B71
B72
B74
B75
B76
B77
B79
4
18
17
4
2
2
2
3
14
Blue
Black
Green
Green
Gray
D-2
C-2
C-2
C-2
C-2
C-2
C-2
B-3
C-2
B81
12
C-2
B82
Black
C-2
C-4
C-4
No.
D1
AB1
Connecting to
Name
Front door cord LH
SRS (Airbag) harness
Turn & hazard module
i1
i2
B83
Area
B-3
A-2
B-3
B-4
Brown
B-3
B90
B-4
B91
Black
C-4
B92
B101
B108
8
25
2
C-2
B-4
B-1
B116
D-3
B119
C-3
B120
B121
B125
B126
B129
B131
14
1
1
2
4
Black
Black
B-3
B-3
C-2
C-2
B-1
C-1
B132
C-2
B133
D-4
Stop light switch

Steering roll connector
B134
B135
B136
B137
35
28
30
31
C-4
C-4
C-4
B-3
B141
12
B-2
B152
12
C-1
B157
C-1
B158
B160
10
6
Gray
Gray
D-1
C-1
B168
16
C-3
B169
C-3
B171
C-1
B176
18
C-4
B183
B184
B195
1
1
6
D-1
D-1
C-1
F/B
Shield joint connector
(AT)
Transmission control
module
F44
F45
Connector
Pole Color
17
4
Brown
2
B88
Data link connector

Power window
Power window
Illumination control
module
Seat belt warning
module
Fuel pump relay
Main relay
Front fog light
Blower fan motor relay
C-3
No.
B84
B85
B86
B87
Combination switch
Ignition switch
Key warning switch
Test mode connector
Mode actuator
Check connector
Diagnosis terminal
(Ground)
Diagnosis connector
Shield & sensor
ground joint connector (E/G) (With OBD)
Shield & sensor
ground joint connector (E/G) (Without
OBD)
WI-280
No.
R50
D11
F46
Connecting to
Name
Diode (Rear fog light)
Blower fan resistor
Blower fan motor
Evaporator thermoswitch
Roof cord
FRESH/RECIRC
actuator
Door lock timer
Front door cord RH
Select lever illumination
Cigarette lighter
(Power)
Radio
Audio ground
Kick down switch (AT)
Head light beam leveler switch
AT power mode & hold
mode switch
Immobilizer control
module
F/B
Ignition relay (Relay
block)
F/B
Air conditioning switch
(Manual A/C)
Blower fan switch
(Manual A/C)
Mirror heated relay
Keyless entry control
module
Joint connector (Keyless entry)

WIRING SYSTEM
Connector
No. Pole Color
B196
3
Area
B-4
B198
C-5
B208
A-4
B209
40
B-1
B224
C-3
B225
B256
B264
B271
B275
B282
B283
8
2
4
12
4
16
20
Red
Blue
Gray
Gray
C-1
B-3
C-1
C-1
B-3
C-3
C-3
B284
10
D-4
B292
D-3
B293
B-3
B296
B-4
B300
C-2
B304
2
Black
: Non-colored
A-5
Connecting to
Name
Ground joint connecGB-9
tor
Glove box light
F76
(SMJ)
Ignition switch illumination
Fuse (Relay box)
Evaporator sensor
ABS relay
F/B
Fan control amp.
No.

Remote control rearview mirror switch
ABS sensor
Air mix actuator (Auto
A/C)
Rear defogger timer
Line end check connector
ABS condenser
WI-281

WIRING SYSTEM
1
B157
B225
3
B56
B85
B48
B42
B55
GB-5
B36
B196
B90
B86
B171
B91
B275
GB-4
B54
B77
B137
B47
B46
B304
B135
B141
Relay block
B64
B108
B62
B209
B101
B293
B32
B256
B61
B87
WO
B131
B296
B208
B53
B264
B153
B176
B50
B129
B92
B136
B71
OO
B84
B37
B125
B126
WO
B125
B69
OO
B70
B126
B120
B134
B68
B119
B83
B72
C
B224
C
B122
B74
B81
B184
B282
B82
B283
B168
GB-6
GR
B121
B75
B195
B198
B169
B300
B79
B271
B160
B41
B183
B30
B51
B158
B76
B116
B152
WO : WITH OBD MODEL
B52
B31
B132
B40
B292
B44
B133
B284
BO0472
WI-282

WIRING SYSTEM
2. RHD MODEL
No.
B30
B31
B32
B36
B37
B38
B40
B41
Connector
Pole Color
25
6
Yellow
3
Black
14
Black
32
22
Black
16
Black
2
Area
D-4
D-4
B-3
B-2
B-2
B-2
C-3
C-4
B42
Black
C-4
B43
Black
C-4
B46
B47
4
6
Green
C-1
C-4
B48
C-3
B50
B51
B52
4
8
7
Blue
C-4
C-4
C-4
B-3
12
Black
B-3
B54
B55
B56
B61
B62
B64
24
24
24
8
18
2
Gray
Green
Black
A-3
A-3
A-3
B-4
B-4
B-3
B65
Black
B-3
B68
Black
C-2
B69
B70
B71
B72
B74
B75
B76
B77
B79
4
18
17
4
2
2
2
3
14
Blue
Black
Green
Green
Gray
B-3
C-3
C-3
C-3
C-3
C-3
C-3
B-2
C-3
B81
12
C-3
B82
Black
C-3
No.
D1
AB1
Connecting to
Name
Front door cord RH
SRS (Airbag) harness
Turn & hazard module
i1
i2
i3
F/B
(AT) (Turbo model)
(AT) (Non-turbo
model)
Transmission control
module
F44
F45

Stop light switch
Stop&brake switch
(With cruise control)
Cruise control sub
switch
Combination switch
Ignition switch
Key warning switch
Test mode connector
Mode actuator
Check connector
Diagnosis terminal
(Ground)
Diagnosis connector
Connector
Pole Color
Area
C-2
C-2
12
Black
C-2
B85
B86
B87
2
4
2
Black
Brown
B-3
B-4
B-1
B88
Brown
B-3
B90
B-4
B91
Black
B-2
B92
B101
8
25
C-3
B-1
B107
A-3
B116
D-2
B119
C-2
B120
B121
B125
B126
B129
B131
14
1
1
1
2
4
Black
Black
Blue
B-2
B-2
C-3
C-3
C-4
C-4
B132
C-4
B133
Blue
D-1
B134
B135
B136
B137
22
28
24
31
C-3
C-3
C-3
C-4
B141
14
B-3
B152
12
C-4
B157
C-4
B158
B159
B160
10
9
6
Gray
Brown
Gray
D-1
C-4
C-4
B161
Brown
C-4
B83
Data link connector

Power window circuit
Power window relay
(Relay block)
Illumination control
module
Fuel pump relay
Main relay
(Relay block)
Blower fan motor relay
B53
No.
WI-283
No.
R50
D11
Connecting to
Name
Shield&sensor ground
joint connector (E/G)
(Non-turbo with OBD
model)
Shield & sensor
ground joint connector (E/G) (Turbo
model)
Shield & sensor
ground joint connector (E/G) (Non-turbo
without OBD model)
Blower fan resistor
Blower fan motor
Evaporator thermoswitch
Roof cord
FRESH/RECIRC actuator
Door lock timer
Front door cord LH
Clutch switch (Cruise
control)
Select lever illumination light (AT)
Cigarette lighter
(Power)
Radio
Audio ground
Kick down switch (AT)
Head light beam leveler switch
AT power mode & hold
mode switch
Immobilizer control
module
F/B
Ignition relay (Relay
block)
F/B
F/B
Cruise control sub
switch

WIRING SYSTEM
No.
Connector
Pole Color
Area
B168
10
C-2
B169
C-2
B171
C-3
B176
18
C-4
B183
B184
B195
B196
B198
B199
B200
B208
1
1
6
3
1
1
22
2
Black
Black
D-4
C-4
C-4
B-3
B-2
B-2
B-4
B-1
B224
C-3
B225
B256
B264
B271
B275
B282
B283
8
2
4
12
4
16
20
Black
Pink
Blue
Gray
Gray
C-3
B-2
C-4
C-4
B-2
C-2
C-2
B284
10
D-1
B292
D-1
B293
B-2
B296
B-1
B299
B-3
B300
C-4
No.
Connecting to
Name
Air conditioning switch
(Manual A/C)
Blower fan switch
(Manual A/C)
Mirror heated relay
Keyless entry control
module
Joint connector (Keyless entry)
B199 Joint connection

B198 (Ground)
F74 Front wiring harness
Glove box light
Ignition switch illumination
Fuse (Relay box)
Evaporator sensor
ABS relay
F/B
Fan control amp
ABS sensor
Air mix actuator (Auto
A/C)
Rear defogger timer
(AT) (Turbo model)
Line end check connector
: Non-colored
WI-284

WIRING SYSTEM
1
2
B91
B208
B47
B275
B77
B86
B88
B46
3
B199
4
B56
B36
B54
GB-4
GB-5
B198
B85
B196
B55
B107
5
B42
B32
B225
B141
B171
B48
B157
B87
B135
B136
Relay block
B101
B64
B293
B296
B90
B200
B65
B256
B61
B264
B131
WO
B137
B126
B38
B84
WO
OO
B37
B125
B71
B69
B120
B134
B125
OO
B50
B299
B62
B176
B92
B126
B70
B68
B119
B83
GB-3
B129
B53
B72
B168
B74
B81
B121
B82
B224
GB-6
B169
GR
B43
B184
B75
B283
B195
B300
B282
B76
B116
B79
B132
B40
B161
B160
B271
B159
B152
WO : WITH OBD MODEL
B284
B133
B292
B183
B158
B52
B41
B51
B94
B31
B30
BO0473
WI-285
ENGINE WIRING HARNESS AND TRANSMISSION CORD

WIRING SYSTEM
48.Engine Wiring Harness and Transmission Cord

A: LOCATION
1. SOHC W/O OBD MODEL
No.
E2
E3
E4
E5
E6
E7
E8
E10
E11
E12
E13
E14
E15
E16
E17
E19
E20
: Non-colored
No.
T1
T2
T3
T4
: Non-colored
Connector
Pole
Color
20
Light gray
16
Brown
2
Blue
2
Light gray
2
Light gray
6
Black
3
Light gray
2
Light gray
1
Gray
4
Dark gray
Dark
4
brown
2
2
Black
2
Light gray
2
Light gray
1
4
Black
Connector
Pole
Color
2
Gray
2
Brown
12
20
Black
Area
A-3
A-3
A-2
B-1
A-2
B-1
B-2
B-2
B-2
B-2
B-2
No.
B21
B22
Connecting to
Name
Fuel injector No.1
Fuel injector No.3
Engine coolant temperature sensor and thermometer
Oil pressure switch
Ignition coil and ignitor (1.6L model)
Ignition coil and ignitor (Except 1.6L model)
B-2
B-3
C-3
C-3
B-3
B-1
A-2
Knock sensor
Fuel injector No.2
Fuel injector No.4
Pressure sensor and intake air temperature sensor
Area
D-4
D-4
A-4
A-4
Connecting to
Name
No.
B24
B25
B12
B11
WI-286

WIRING SYSTEM
1
5
T3
E20
T4
GE
E6
E3
E4
E2
E5
E12
E14
E7
AT
E19
E17
C
E16
T2
T1
E11
E13
E10
D
E8
E15
MT
BO0224
WI-287

WIRING SYSTEM
2. SOHC MODEL
No.
E2
E3
E4
E5
E6
E7
E8
E10
E11
E12
E13
E14
E15
E16
E17
E19
E20
E42
: Non-colored
Connector
Pole
Color
20
Light gray
16
Brown
2
Blue
2
Light gray
2
Light gray
6
Black
3
Light gray
2
Light gray
1
Gray
4
Dark gray
Dark
4
brown
2
2
Black
2
Light gray
2
Light gray
1
4
Black
2
Purple
Connector
No.
Pole
Color
T1
2
Gray
T2
2
Brown
T3
12
T4
20
Black
: Non-colored
Area
A-3
A-3
A-2
B-1
B-2
B-1
B-2
B-2
B-2
B-2
B-2
No.
B21
B22
Connecting to
Name
Fuel injector No.1
Fuel injector No.3
Oil pressure switch
Ignition coil and ignitor (1.6L model)
Ignition coil and ignitor (Except 1.6L model)
B-2
B-3
C-3
C-3
B-3
B-1
B-2
B-2
Knock sensor
Fuel injector No.2
Fuel injector No.4
Pressure sensor and intake air temperature sensor
Area
D-4
D-4
A-4
A-4
No.
B24
B25
B12
B11
Connecting to
Name
WI-288

WIRING SYSTEM
1
5
T3
E20
T4
GE
E6
E3
E4
E2
E5
E12
E14
E7
AT
E19
E17
C
E16
T2
T1
E11
E13
E10
E42
E8
E15
MT
BO0223
WI-289

WIRING SYSTEM
3. DOHC TURBO MODEL

No.
E1
Connector
Pole
Color
10
Light gray
Area
A-1
E2
20
Black
C-3
E3
16
Brown
C-3
2
2
2
3
3
2
1
3
2
2
2
2
1
3
3
3
3
3
3
2
3
2
Black
Dark gray
Dark gray
Black
Light gray
Light gray
Black
Gray
Light gray
Dark gray
Dark gray
Black
Black
Black
Black
Black
Black
Black
B-2
B-1
B-2
B-2
B-2
B-1
B-2
B-2
B-3
C-3
C-3
C-3
B-2
B-2
B-1
C-3
B-2
C-3
B-2
B-3
B-2
B-1
E4
E5
E6
E7
E8
E10
E11
E13
E14
E15
E16
E17
E19
E21
E31
E32
E33
E34
E50
E51
E54
E55
: Non-colored
Connector
No.
Pole
Color
T3
12
T4
20
Black
T9
4
: Non-colored
Area
A-4
A-4
D-4
No.
B20
F61
B21
F60
B22
No.
B12
B11
B128
Connecting to
Name
Front wiring harness (LHD model)
Bulkhead wiring harness (RHD model)
Front wiring harness (LHD model)
Fuel injector No.1
Fuel injector No.3
Oil pressure switch
Knock sensor
Fuel injector No.2
Fuel injector No.4
Pressure sensor
Ignition coil No.1
Ignition coil No.2
Ignition coil No.3
Ignition coil No.4
TGV angle sensor LH
TGV LH
TGV angle sensor RH
TGV RH
Connecting to
Name
WI-290

WIRING SYSTEM
1
E33
T3
T4
E54
E1
E6
E21
E7
E5
E13
E51
E14
E55
AT
B
GE
E17
E3
E31
E34
C
E10
C
T9
E11
E19
E4
E2
E50
E8
E15
E16
MT
E32
BO0474
WI-291
INSTRUMENT PANEL WIRING HARNESS

WIRING SYSTEM
49.Instrument Panel Wiring Harness

A: LOCATION
1. LHD MODEL
No.
i1
i2
i10
i11
i12
i22
i51
i59
: Non-colored
Connector
Pole
Color
24
Black
24
10
Green
30
Green
14
Green
8
Area
B-3
B-3
B-3
B-2
B-2
B-4
A-3
A-3
No.
B36
B37
Connecting to
Name
Combination meter
Hazard switch
Sunload sensor
Clock
WI-292

WIRING SYSTEM
1
i59
i51
i11
i10
A
i22
i12
i1
i2
BO0226
WI-293

WIRING SYSTEM
2. RHD MODEL
No.
i1
i2
i3
i10
i11
i12
i22
i51
i59
: Non-colored
Connector
Pole
Color
14
Black
32
22
Black
10
Green
30
Green
14
Green
8
Area
C-3
B-3
B-3
B-4
B-4
B-3
B-2
A-3
A-3
No.
B36
B37
B38
Connecting to
Name
Combination meter
Hazard switch
Sunload sensor
Clock
WI-294

WIRING SYSTEM
1
i59
i51
i11
i12
i22
B
i10
i3
i1
i2
BO0227
WI-295
REAR WIRING HARNESS, BULKHEAD WIRING HARNESS, ROOF CORD AND

FUEL TANK CORD
WIRING SYSTEM
50.Rear Wiring Harness, Bulkhead Wiring Harness, Roof Cord and

Fuel Tank Cord
A: LOCATION
1. LHD MODEL
Connector
No.
Pole
Color
R1
8
R3
24
R4
1
R8
2
R15
6
Black
R22
3
R72
2
R73
2
R97
2
: Non-colored
No.
B97
B99
B265
B266
B267
B268
B269
B270
: Non-colored
Connector
Pole
Color
8
24
Area
B-2
B-2
B-3
C-4
B-3
B-5
A-3
B-5
B-5
Area
B-2
B-2
A-2
A-2
C-4
A-2
B-5
B-4
No.
B97
B99
R57
No.
R1
R3
D27
D28
D21
D22
Connector
No.
Pole
Color
R50
4
R52
3
R55
1
Gray
R56
2
: Non-colored
Area
B-1
A-3
A-2
A-3
No.
B90
Connector
No.
Pole
Color
R57
6
Black
R58
6
R59
2
: Non-colored
Area
B-3
B-3
B-4
No.
R15
Connecting to
Name
Seat belt switch
Fuel tank cord
Rear door switch LH
Rear ABS sensor RH
Rear ABS sensor LH
Antenna amp. (Sedan model)
Connecting to
Name
Rear wiring harness
Rear wiring harness
Rear door cord RH
Rear door cord RH
Front door switch LH
Front door switch RH
Rear door cord LH
Rear door cord LH
Connecting to
Name
Room light
Sunroof
Spot light
Connecting to
Name
Rear wiring harness
Fuel pump assembly
WI-296

FUEL TANK CORD
WIRING SYSTEM
1
2
B265
R55
R52
R56
B266
R58
B268
R59
R22
R72
A
B97
B99
R57
R15
R1
R97
R3
R50
B269
B270
B
R4
GB-7
R73
B267
R8
BO0475
WI-297

FUEL TANK CORD
WIRING SYSTEM
2. RHD MODEL
Connector
No.
Pole
Color
R1
8
R3
22
R4
1
R8
2
R15
6
Black
R22
3
R72
2
R73
2
R97
2
: Non-colored
Area
B-2
B-2
B-3
B-2
B-3
B-5
B-3
B-5
B-5
Connector
No.
Pole
Color
B97
8
B99
22
B265
4
B266
3
B267
3
B268
3
B269
4
B270
3
: Non-colored
Area
B-2
B-2
A-2
A-2
A-2
C-4
B-5
B-4
Connector
No.
Pole
Color
R50
4
R52
3
R55
1
Gray
R56
2
: Non-colored
Area
B-1
A-3
A-2
A-3
No.
B90
Connector
No.
Pole
Color
R57
6
Black
R58
6
R59
2
: Non-colored
Area
B-3
B-3
B-4
No.
R15
No.
B97
B99
R57
No.
R1
R3
D27
D28
D21
D22
Connecting to
Name
Seat belt switch
Fuel tank cord
Rear door switch LH
Rear ABS sensor RH
Rear ABS sensor LH
Antenna amp. (Sedan model)
Connecting to
Name
Rear wiring harness
Rear wiring harness
Rear door cord RH
Rear door cord RH
Front door switch RH
Front door switch LH
Rear door cord LH
Rear door cord LH
Connecting to
Name
Room light
Sunroof
Spot light
Connecting to
Name
Rear wiring harness
Fuel pump assembly
WI-298

FUEL TANK CORD
WIRING SYSTEM
1
2
B265
R56
R55
R52
B266
R58
B267
A
B97
R59
R72
B99
R22
R57
R15
R1
R97
R3
R50
B269
B270
R4
R8
GB-7
R73
B268
BO0476
WI-299
DOOR CORD
WIRING SYSTEM
51.Door Cord
A: LOCATION
1. LHD MODEL
No.
D1
D2
D3
D4
D5
D7
D8
D10
D11
D12
D13
D14
D15
D17
D18
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31
D32
D61
D62
D72
: Non-colored
Connector
Pole
Color
25
2
Black
2
Black
6
8
Black
16
2
Gray
2
25
2
Green
2
8
Black
6
2
Black
6
2
Black
2
Black
6
10
6
Brown
4
Area
C-2
C-3
C-3
C-3
C-3
C-3
C-4
C-4
C-3
C-1
C-1
B-2
B-1
B-1
B-1
B-2
B-2
B-2
C-4
C-4
C-4
B-4
B-4
B-4
B-2
B-2
B-2
A-2
A-2
A-3
C-3
B-2
C-3
No.
B30
B101
B269
B270
B265
B266
Connecting to
Name
Front door speaker (Driver side)
Front power window motor (Driver side)
Front door tweeter (Driver side)
Remote control rearview mirror (Driver side)
Power window main switch
Front door lock actuator LH (Without keyless entry)
Step light LH
Front door speaker RH
Front power window motor RH
Front door tweeter RH
Remote control rearview mirror RH (Without mirror heater)
Remote control rearview mirror RH (With mirror heater)
Front power window sub switch RH
Front door lock actuator RH
Step light RH
Rear wiring harness
Rear door speaker LH
Rear power window motor LH
Rear power window sub switch LH
Rear door lock actuator LH
Rear door speaker RH
Rear power window motor RH
Rear power window sub switch RH
Rear door lock actuator RH
Front door lock switch RH
Front door lock actuator LH (With keyless entry)
WI-300
DOOR CORD
WIRING SYSTEM
1
2
D30
D31
D32
A
D14
D17
D15
D26
D25
D24
D27
D22
D29
D72
D28
D18
D13
D5
D12
C
D1
D23
D11
D7
D3
D21
D8
D
D4
D2
BO0230
WI-301
DOOR CORD
WIRING SYSTEM
2. RHD MODEL
No.
D1
D2
D3
D4
D5
D7
D8
D10
D11
D12
D13
D14
D15
D17
D18
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31
D32
D61
D62
D72
: Non-colored
Connector
Pole
Color
25
2
Black
2
8
Black
16
2
Gray
2
25
2
Green
2
8
Black
8
2
Black
8
2
Black
2
Black
8
10
6
Brown
4
Area
C-1
C-1
B-2
B-1
B-1
B-1
B-2
B-2
C-3
D-3
D-3
C-3
C-3
C-3
C-3
C-4
C-3
B-2
C-4
B-3
C-4
B-4
B-4
B-4
B-2
B-2
B-2
A-2
A-2
A-3
C-3
B-2
B-2
No.
B30
B101
B269
B270
B265
B266
Connecting to
Name
Front door speaker (Driver side)
Front power window motor (Driver side)
Front door tweeter (Driver side)
Power window main switch
Front door lock actuator RH (Without keyless entry)
Step light LH
Front door speaker LH
Front power window motor LH
Front door tweeter LH
Remote control rearview mirror LH (Without mirror heater)
Remote control rearview mirror LH (With mirror heater)
Front power window sub switch LH
Front door lock actuator LH
Step light RH
Rear door speaker LH
Rear power window motor LH
Rear power window sub switch LH
Rear door lock actuator LH
Rear door speaker RH
Rear power window motor RH
Rear power window sub switch RH
Rear door lock actuator RH
Front door lock switch RH
Front door lock actuator RH (With keyless entry)
WI-302
DOOR CORD
WIRING SYSTEM
1
D30
D32
D31
D7
A
D4
D8
D5
D26
D25
D24
D27
D22
B
D29
D18
D28
D3
D72
D15
D2
C
D11
D1
D23
D17
D21
D13
D14
D12
BO0231
WI-303
REAR WIRING HARNESS AND TRUNK LID CORD

WIRING SYSTEM
52.Rear Wiring Harness and Trunk Lid Cord

A: LOCATION
Connector
No.
Pole
Color
R16
3
R17
1
Black
R19
2
R20
2
Black
R24
2
R26
6
R27
2
R28
6
R60
2
R63
2
R65
1
Black
R66
2
R79
10
R122
10
Black
R130
2
: Non-colored
Area
C-3
B-4
B-2
B-2
C-4
C-3
C-1
B-1
B-4
C-1
A-2
C-3
C-3
C-4
B-3
No.
R60
R24
Connecting to
Name
Rear door switch RH
Rear defogger
Trunk room light
Trunk lid cord
Rear combination light RH
Trunk room light switch
Rear combination light LH
Rear wiring harness
License plate light
Rear defogger
High-mounted stop light (Rear spoiler)
Trailer connector
Fuel pump control (Turbo Model)
Rear defogger choke coil
WI-304
REAR WIRING HARNESS AND TRUNK LID CORD

WIRING SYSTEM
R20
R65
A
R19
R17
R16
R130
R28
R60
R24
R66
R26
R27
R122
R79
R63
GR8
BO0486
WI-305
REAR WIRING HARNESS AND REAR GATE CORD

WIRING SYSTEM
53.Rear Wiring Harness and Rear Gate Cord

A: LOCATION
Connector
No.
Pole
Color
R16
3
R26
6
R28
4
R30
2
R38
6
R39
4
Black
R63
2
R79
10
R97
2
R116
8
R122
10
Black
R141
2
: Non-colored
No.
D34
D35
D39
D43
D46
D47
D74
: Non-colored
Connector
Pole
Color
6
4
Black
2
2
Black
4
Area
C-4
C-3
C-1
C-4
C-3
D-4
C-2
D-3
C-1
C-3
C-4
C-3
Area
C-3
D-4
B-3
A-2
A-2
A-2
A-3
No.
D34
D35
Connecting to
Name
Rear door switch RH
Rear combination light RH
Rear combination light LH
Diode
Rear gate cord
License plate light
Trailer connector
Antenna amp.
Fuel pump control (Turbo Model)
Luggage room light
No.
R38
R39
Connecting to
Name
Rear wiring harness
Rear wiper motor
Rear gate latch switch
Rear gate lock actuator cord
Rear defogger choke coil
WI-306

WIRING SYSTEM
1
D47
D46
D74
D43
D39
R122
R16
R28
R116
R141
R26
R97
R38
R30
D
R39
D34
R79
R63
D35
GR8
BO0477
WI-307

WIRING SYSTEM
WI-308

Subaru Impreza 2002

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Subaru Impreza 2002

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2002 Model Year

PDF Service Manual

GENERAL INFORMATION SECTION (Pub.No.G1840GE1)

2002 IMPREZA 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

MT: 12V 48AH (55D23L)

5MT: 5 forward speeds with synchromesh and 1-reverse

Turbo 2.0 L, 2.5 L

Minimum turning circle

Macpherson strut type, Independent, Coil spring

4.5 (4.8, 4.0)

5.0 (5.3, 4.4)

4.5 (4.8, 4.0)

Approx. 4.5 (4.8, 4.0)

0.8 (0.8, 0.6)

Curb weight (C.W.)

Curb weight (C.W.)

1: For option code, refer to ID section. <Ref. to ID-7, Option code.>

1: For option code, refer to ID section. <Ref. to ID-7, Option code.>

Curb weight (C.W.)

Curb weight (C.W.)

D/R: Dual range

Curb weight (C.W.)

D/R: Dual range

Curb weight (C.W.)

Curb weight (C.W.)

1: For option code, refer to ID section. <Ref. to ID-7, Option code.>

Curb weight (C.W.)

1: For option code, refer to ID section. <Ref. to ID-7, Option code.>

Curb weight (C.W.)

Curb weight (C.W.)

D/R: Dual range

Curb weight (C.W.)

Curb weight (C.W.)

D/R: Dual range

Adhere to the following when handing and storing

8. AIRBAG SPECIAL TOOLS

2. STATIC ELECTRICITY DAMAGE

3. IGNITION OFF BATTERY

5. LIFTS AND JACKS

Without side sill cover

Hook for tie-down

Hook for towing

Hook for tie-down

Hook for towing

8. FRONT HOOD STAY INSTALLATION

When wider hood opening is necessary

10.GENERAL SCAN TOOL

For information about training, contact a dealer or

Vacuum hose piping label

Emisson control label

ID plate (Europe model)

Tire inflation pressure label

Model number plate

Saudi Arabia plate (Saudi Arabia model)

GCC countries (Saudi Arabia, etc.)

3. MODEL NUMBER PLATE