2001 USDM Subaru Outback Service Manual BE-BH

GENERAL DESCRIPTION
Automatic Transmission
1 . General Description 55,0.0,

A : SPECIFICATIONS 5510007E49
1 . DRIVE PLATE AND DRIVEN PLATE S570007E4901
1 .6 L 3
2.0 L 4
Plate number of high clutch 2.0 L TURBO 5
2 .5 L 4
3.0 L 5
1 .6 L 1
2.0 L 2
Plate number of reverse clutch 2.0 L TURBO 2
2.5 L 2
3.0 L 2
1 .6 L 2
2.0 L 3
Plate number of 2-4 brake 2.0 L TURBO 4
2.5 L 3
3.0 L 4
1 .6 L 4
2.0 L 4
Plate number of low clutch 2.0 L TURBO 7
2.5 L 6
3.0 L 7
1 .6 L 4
2.0 L 4
Plate number of low and reverse brake 2.0 L TURBO 7
2.5 L 6
3.0 L 7
2 .0 L 4
2.0 L TURBO (Without VTD) 6
2.0 L TURBO (With VTD) 3
Plate number of transfer clutch 2.5 L (Without VTD) 5
2.5 L (With VTD) 3
3.0 L (Without VTD) 6
3.0 L (With VTD) ~ 3
2. AUTOMATIC TRANSMISSION FLUID

CAPACITY S510007E4902
Dexron III type Automatic transmission fluid
1 .6 L 8.0-8 .3 L(8.5-8 .8 US qt, 7.0-7 .3Imp qt)
2.0 L 8.4 - 8 .7 L (8 .9 - 9.2 US qt, 7.4 - 7.7 Imp qt)
2.0 L TURBO, 2 .5 L, 3.0 L 9.3 - 9.6 L (9 .8 - 10 .1 US qt, 8.2 - 8.4 Imp qt)
AT-2
GENERAL DESCRIPTION
B: COMPONENT SSfODOtA05
1 . TORQUE CONVERTER CLUTCH AND

CASE S51000fA0507
l1) (2) (4)
cs) _
T2 0
T2
(16) .I /
(7)
o o
o ~( 9 )*
o ~ o i o T1
J
T2
' T2
*04)~
O
T3 (13) I ~I a \(10)
o\
(11)*
(12)
83M1995A
(1) Pitching stopper bracket (9) Oil drain pipe Tightening torque: N~m (kgf-m, nIb)
(2) O-ring (10) Input shaft
T1 : 18 (1 .8, 13.0)
(3) Differential oil level gauge (11) O-ring
T2: 41 (4.2, 30.4)
(4) Stay (12) Torque converter clutch ASSY
T3: 44 (4.5, 32.5)
(5) Seal pipe (13) Drain plug
(6) Seal ring (14) Gasket
(7) Oil pump shaft (15) Oil seal
(8) Clip (16) Torque converter clutch case
AT-4
GENERAL DESCRIPTION
2. OIL PUMP 5510001A0502
4)
(7)
(6)
T2
(12) *
,(13)
~~_(12) w
T2
~`(13)
T3 / T1
1)* T7
(16)* (~ .~
~,s>*
18) ~
(17)
5)
B3M0876A
(1) Oil pump rotor (12) O-ring

Tightening torque : N~m (kgf-m, ft-Ib)
(2) Oil pump cover (13) Test plug
T1 : 7 (0.7, 5.1)
(3) Seal ring (14) Stud bolt
(4) Thrust needle bearing T2: 13 (1 .3, 9.4)
(15) O-ring
(5) Drive pinion shaft (16) O-ring T3: 18 (1 .8, 13.0)
(6) Roller bearing (17) Oil seal retainer T4: 25 (2.5, 18.1)
(7) Shim (18) Oil seal T5: 39 (4.0, 28.9)
(8) Oil pump housing (19) O-ring T6: 41 (4.2, 30.4)
(9) Nipple (20) Drive pinion collar T7: 121 (12.3, 89.0)
(10) Air breather hose (21) Lock nut
(11) Gasket
AT-5
GENERAL DESCRIPTION
3. TRANSMISSION CASE AND CONTROL

DEVICE 5570001A0503
T4
(5)
(4)
°--~ 3 )*\
(41) (9)
(10)
uU
(36)*
1 (39A
T10`,\
\20) (17)*
i
T2 .
(22)* (21) ~'
T9
(as) i
83M1996A
AT-6
GENERAL DESCRIPTION
(1) Oil level gauge (24) Magnet (47) Gasket

(2) Oil charger pipe (25) Stud bolt (Short) (48) Union screw
(3) O-ring (26) Stud bolt (Long) (49) Inlet pipe (3 .0 L model)
(4) Transfer valve plate (27) Parking rod (50) Plug
(5) Transfer valve ASSY (28) Manual plate (51) Shim (FWD)
(6) Transfer clutch seal (29) Spring pin (52) Gasket (FWD)
(7) Transfer duty solenoid (30) Detention spring (53) Transmission cover (FWD)
(8) Straight pin (31) Ball
(9) Return spring (32) Spring Tightening torque: N~m (kgf-m, ftIb)
(10) Shaft (33) Gasket T1: 3.4 (0.35, 2.5)
(11) Parking pawl (34) Outlet pipe (Except 3.0 L model) T2: 4.9 (0.50, 3.6)
(12) Parking support (35) Union screw T3: 5.9 (0.60, 4.3)
(13) Inlet filter (36) Oil seal
T4: 7.8 (0.80, 5.8)
(14) Gasket (37) Select lever
T5: 12 (1.2, 8.7)
(15) Inlet pipe (Except 3.0 L model) (38) Inhibitor switch ASSY
T6: 12.7 (1 .30, 9.4)
(16) Union screw (39) Nipple
(17) O-ring T7: 13.7 (1 .4, 10.1)
(40) Air breather hose
(18) Test plug (41) Transmission case T8: 17.7 (1 .80, 13.0)
(19) Oil filter (Except 3.0 L model) (42) Plate ASSY T9: 24.5 (2.50, 18.1)
(20) Oil filter stud bolt (43) Washer T10: 24.5 (2.5, 18.1)
(21) Drain plug (44) Outlet pipe (3 .0 L model) T11: 45 (4 .5, 32.5)
(22) Gasket (45) O-ring
(23) Oil pan (46) Cover
AT-7
GENERAL DESCRIPTION
4. CONTROL VALVE AND HARNESS

ROUTING 55~~~A~~
(2)
~6)* \ Ti
~\ (7)
--
l *`
~~ 8 )*
5)
(9)
( 3)
0
Ti
T2 t/^ (10)
(11)
(12)
(14)
T2 °
e (15)
(13)
`i (16)
(17)
(18) (19)
(20)
(25) (21)
T2
(26)
c2>> ' " c~~
T2 T2
`k~ " ~ - (24)
(28)
T2
T2 B3M1833A
(1) Stay (12) Accumulator spring (24) ATF temperature sensor

(2) Transmission harness (13) Side plate (25) Line pressure duty solenoid
(3) O-ring (14) Separate plate (26) Low clutch timing solenoid
(4) O-ring (15) Middle valve body (27) Lock-up duty solenoid
(5) Torque converter turbine speed (16) Separate plate (28) Oil strainer
sensor (17) Fluid filter
(6) O-ring (18) Fluid filter Tightening torque: N"m (kg/-m, ft-Ib)
(7) Front vehicle speed sensor (19) Lower valve body T1: 7 (0.7, 5.1)
(8) O-ring (20) Shin solenoid 2 T2: 8 (0.8, 5.8)
(9) Rear vehicle speed sensor (21) Shift solenoid 1
(10) Upper valve body (22) 2-4 brake timing solenoid
(11) Accumulator piston (23) 2-4 brake duty solenoid
AT-8
GENERAL DESCRIPTION
5. HIGH CLUTCH AND REVERSE CLUTCH

S510007A0505
(1
(9)
(6)* I
(5)* yr yr
D
(3)* i
(2)* ~ ~
(1)
/ (21)
(20)
\ (18 ;
~
/ (16)
(17)
(16)
(15)
(14)
.:
(13)
/ \2)
(11)
(12}
1)
S3M0221A
(1) High clutch drum (8) Spring retainer (15) Dish plate
(2) Lip seal (9) Cover (16) Driven plate
(3) Lathe cut seal ring (10) Snap ring (17) Drive plate
(4) Reverse clutch piston (11) Driven plate (18) Retaining plate
(5) Lathe cut seal ring (12) Drive plate (19) Snap ring
(6) Lathe cut seal ring (13) Retaining plate (20) Thrust needle bearing
(7) High clutch piston (14) Snap ring (21) High clutch hub
AT-9
GENERAL DESCRIPTION
6. PLANETARY GEAR AND 2-4 BRAKE

S57000fA0506
(5)
(3) °
(2) ~o
(13)
(1) ((\ J/ (12)
~J
(11)
X10)
(9)
(7) \\ 1\
(,8)
(19)
(16)
(16)(1
\2
(24)
83M1997A
(1) Thrust needle bearing (10) Washer (19) Snap ring

(2) Front sun gear (11) Thrust needle bearing (20) Spring retainer
(3) Thrust needle bearing (12) Rear internal gear (21) 2-4 brake piston
(4) Snap ring (13) Washer (22) Lathe cut seal ring
(5) Front planetary carrier (14) Snap ring (23) Lathe cut seal ring
(6) Thrust needle bearing (15) Retaining plate (24) 2-4 brake piston retainer
(7) Rear sun gear (16) Drive plate (25) 2-4 brake seal
(8) Thrust needle bearing (17) Driven plate (26) Leaf spring
(9) Rear planetary carrier (18) Pressure rear plate
AT-1 0
GENERAL DESCRIPTION
7. LOW CLUTCH AND LOW & REVERSE
BRAKE S57000fA0507
(1
D X20,
(22)
(21)
i
(19)
(18)
(17)* (29)
(16) (28)
(26)
/ '~~a~ (27)
i 11 \\
B3M1017A
(1) Retaining plate (12) Needle bearing (23) Snap ring

(2) Drive plate (13) Inner snap ring (24) Retaining plate
(3) Driven plate (14) One-way clutch (25) Leaf spring
(4) Dish plate (15) Outer snap ring (26) Drive plate
(5) Snap ring (16) Thrust needle bearing (27) Driven plate
(6) Cover (17) Seal ring (28) Dish plate
(7) Spring retainer (18) Needle bearing (29) Low and reverse brake piston
(8) Lathe cut seal ring (19) One-way clutch inner race
(9) Low clutch piston (20) Socket bolt Tightening torque : Mm (kgf-m, ft-Ib)
(10) Lathe cut seal ring (21) Spring retainer T 25 (2.5, 18.1)
(11) Low clutch drum (22) Return spring
AT-1 1
GENERAL DESCRIPTION
8. REDUCTION GEAR WITHOUT VTD

951000,A0
.508
1
AWD
I
1 / ``
(4) ~\~ Vv
(3)
\, I
(2)
(s)
l9) ~~0 i)*F-T
(a)
(s) (7'
(is)
(s)
(t2)
(2)
* (11 *0
FWD (10)
(8)
(7)
(s)
(5)
83M2114A
(1) Seal ring (7) Ball bearing (13) Ball bearing

(2) Ball bearing (8) Reduction driven gear
(3) Reduction drive gear (9) Snap ring Tightening torque: N~m (kgf-m, nIb)
(4) Reduction drive shaft (10) Washer T 100 (10.2, 73.8)
(5) Drive pinion shaft (11) Lock nut
(6) Snap ring (12) Reduction drive shaft
AT-1 2
GENERAL DESCRIPTION
9. REDUCTION GEAR WITH VTD 5510001A0509
B3M2115A
(1) Ball bearing (13) Thrust washer (25) Drive pinion shaft
(2) Reduction drive gear (14) Rear drive shaft (26) Snap ring
(3) Washer (15) Ball bearing (27) Ball bearing
(4) Needle bearing (16) Multi-plate clutch (LSD) hub (28) Reduction driven gear
(5) Pinion gear (17) Ball bearing (29) Lock washer
(6) Carrier (18) Revolution gear (30) Lock nut
(7) Planetary pinion shaft (19) Driven plate (Thicker) (31) Gasket
(8) Straight pin (20) Drive plate (32) Extension case
(9) Snap ring (21) Driven plate (Thinner)
(10) Seal ring (22) Driven plate (Thicker) Tightening torque: N~m (kgf-m, ft-Ib)
(11) Thrust needle bearing (23) Adjust plate T.100 (10.2, 73.8)
(12) Intermediate shaft (24) Rear drive shaft shim
AT-1 3
GENERAL DESCRIPTION
10. DIFFERENTIAL GEAR 5510007A0510
(14)
O
p (1)
~(2) (15)
(13)'
(3) i
o ~~o ~ o
(4) 0 3)`~=
I (14)
i (15)
O 0
(5)
`r o ~ o 0~V 0
~ T2
o
o (11)
T1 O O T1
(1U
(9) $)* . (6) (7)*
o, ( * (a)* -~-
(7) o
(s) (s)
(io)~
11
I (12)
(10)*
83M1019A
(1) Crown gear (8) O-ring (15) Differential bevel gear

(2) Pinion shaft (9) Differential side retainer
(3) Differential case (RN) (10) Circlip Tightening torque : N~m (kgf-m, ft-Ib)
(4) Straight pin (11) Lock plate T1 : 25 (2 .5, 18.1)
(5) Differential case (LH) (12) Axle shaft T2: 62 (6.3, 45.6)
(6) Taper roller bearing (13) Washer
(7) Oil seal (14) Differential bevel pinion
AT-1 4
GENERAL DESCRIPTION
11 . TRANSFER AND EXTENSION CASE

WITHOUT VTD 5510001A0577
(
(s)
(5) \
(6)
(5)
(4)
(3)
(1)*
,.
./_
T1
83M2116A
(1) Thrust needle bearing (11) Transfer clutch piston (21) Test plug
(2) Needle bearing (12) Rear drive shaft (22) O-ring
(3) Snap ring (13) Ball bearing (23) Clip
(4) Pressure plate (14) Seal ring
(5) Drive plate (15) Gasket Tightening torque : N"m (kgf-m, ft-Ib)
(6) Driven plate (16) Transfer clutch pipe T1 : 13 (1 .3, 9.4)
(7) Pressrue plate (17) Extension case T2: 25 (2.5, 18.1)
(8) Snap ring (18) Transmission hanger
(9) Transfer piston seal (19) Oil seal
(10) Return spring (20) Dust cover
AT-1 5
GENERAL DESCRIPTION
12. TRANSFER AND EXTENSION CASE

WITH VTD 55,~~AO5,2
(5)*
(s)
J
(1)
Ti
(19)*
T3
(12)*
0~ p
rl (18)
(17)*
o
/I 0 o \-'
6) T2
(9) o
0 ~~`~ ° (15)*
v
\ ~ ~ 0 0
o (14)
o°~
OIO
(11)*
°°° (10) (13)
~8)
()
J
B3M2117A
(1) Driven plate (Thicker) (11) Lathe cut seal ring Tightening torque: N~m (kgf-m, ft-Ib)
(2) Drive plate (12) Gasket T1 : 7 (0.7, 5.1)
(3) Driven plate (Thinner) (13) Multi-plate clutch sensor (LSD)
T2: 13 (1 .3, 9.4)
(4) Driven plate (Thicker) pipe
T3: 25 (2.5, 18.1)
(5) Adjust plate (14) Extension case
(6) Snap ring (15) O-ring
(7) Spring retainer (16) Test plug
(8) Plate (17) Oil seal
(9) Lathe cut seal ring (18) Dust cover
(10) Multi-plate clutch (LSD) piston (19) O-ring
ASSY (20) Vehicle speed sensor 1
AT-1 6
GENERAL DESCRIPTION
C : PRECAUTION 5570001F59 of washing rubber parts, perform the job quickly

not to dip them into the washing fluid for long
When disassembling or assembling the automatic time .
transmission, observe the following instructions . (7) Apply the automatic transmission fluid
1) Workshop (ATF) onto the parts immediately prior to
Provide a place that is clean and free from dust . assembly, and the specified tightening torque
Principally the conventional workshop is suitable should be observed carefully.
except for a dusty place. In a workshop where (8) Use vaseline if it is necessary to hold parts
grinding work, etc. which produces fine particles is in the position when assembling .
done, make independent place divided by the vinyl (9) Drain ATF and differential gear oil into a
curtain or the equivalent . saucer so that the conditions of fluid and oil can
2) Worktable be inspected .
The size of 1 x 1 .5 m (40 x 60 in) is large enough (10) Do not support axle drive shaft, stator
to work, and it is more desirable that its surface be shaft, input shaft or various pipes when moving
covered with flat plate like iron plate which is not transmission from one place to another.
rusted too much . (11) Always discard old oil seals and O-ring,
3) Cleaning of exterior and install new ones .
(1) Clean the exterior surface of transmission (12) Be sure to replace parts which are
with steam and/or kerosene prior to damaged, worn, scratched, discolored, etc.
disassembly, however it should be noted that
vinyl tape be placed on the air breather or oil
level gauge to prevent infiltration of the steam
into the transmission and also the cleaning job
be done away from the place of disassembly
and assembly.
(2) Partial cleaning will do, depending on the
extent of disassembly (such as when disassem-
bly is limited to some certain parts) .
4) Disassembly, assembly and cleaning
(1) Disassemble and assemble the transmis-
sion while inspecting the parts in accordance
with the Diagnostics .
(2) During job, do not use gloves . Do not clean
the parts with rags : Use chamois or nylon cloth.
(3) Pay special attention to the air to be used
for cleaning. Get the moisture and the dust rid
of the air as much as possible . Be careful not to
scratch or dent any part while checking for
proper operation with an air gun .
(4) Complete the job from cleaning to comple-
tion of assembly as continuously and speedily
as possible in order to avoid occurrence of sec-
ondary troubles caused by dust . When stopping
the job unavoidably cover the parts with clean
chamois or nylon cloth to keep them away from
any dust .
(5) Use kerosene, white gasoline or the equiva-
lent as washing fluid. Use always new fluid for
cleaning the automatic transmission parts and
never reuse. The used fluid is usable in disas-
semble and assemble work of engine and
manual transmission .
(6) Although the cleaning should be done by
dipping into the washing fluid or blowing of the
pressurized washing fluid, the dipping is more
desirable. (Do not rub with a brush.) Assemble
the parts immediately after the cleaning without
exposure to the air for a while . Besides in case
AT-1 7
GENERAL DESCRIPTION
D : PREPARATION TOOL 55,~,A,~

1 . SPECIAL TOOLS 55IODOIA»o1
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
398527700 PULLER ASSY Used for removing and installing extension case
roller bearing.
46
B3M1977
498057300 INSTALLER Used for installing extension oil seal .
B3M1972
498077000 REMOVER Used for removing differential taper roller bear-
ing.
83M1998
499247400 INSTALLER * Used for installing transfer outer snap ring .
Used with GUIDE (499257300).
B3M1999
AT-1 8
GENERAL DESCRIPTION

499257300 GUIDE * Used for installing transfer outer snap ring .
9 Used with INSTALLER (499247400) .
B3M2000
499787000 WRENCH ASSY Used for removing and installing differential side
retainer.
B3M1953
398437700 DRIFT Used for installing converter case oil seal .
83M2001
398497701 INSTALLER Used for installing converter case oil seal .
B3M1967
AT-1 9
GENERAL DESCRIPTION

398673600 COMPRESSOR Used for removing and installing clutch spring .
6'~9
B3M2002
498255400 PLATE Used for measuring backlash of hypoid gear .
B3M 1973
399893600 PLIERS Used for removing and installing clutch spring .
0
O
B3M2003
498247001 MAGNET BASE 9 Used for measuring gear backlash .
Used with DIAL GAUGE (498247100) .
B3M1945
AT20
GENERAL DESCRIPTION

498247100 DIAL GAUGE * Used for measuring gear backlash .
Used with MAGNET BASE (498247001) .
B3M1946
498517000 REPLACER Used for removing front roller bearing.
83M2004
498627000 SEAT Used for removing spring of transfer clutch pis-
ton.
B3M2005
499095500 REMOVER ASSY Used for removing axle shaft.
B3M2006
AT21
GENERAL DESCRIPTION

499247300 INSTALLER * Used for removing axle shaft.
Used with REMOVER (499095500).
B3M2007
499267300 STOPPER PIN Used for installing inhibitor switch .
B3M2008
499787700 WRENCH ASSY Used for removing and installing drive pinion
lock nut.
9M
B3M2009
499787500 ADAPTER ASSY Used for removing and installing drive pinion
lock nut.
83M2010
AT22
GENERAL DESCRIPTION

398643600 GAUGE Used for measuring total end play, extension
end play and drive pinion height.
B3M1978
498627100 SEAT Used for holding low clutch piston retainer
spring when installing snap ring .
B3M2011
499577000 GAUGE Used for measuring the transmission case mat-
ing surface to the reduction gear end surface.
83M2012
499737000 PULLER Used for removing reduction driven gear
assembly.
B3M2013
AT23
GENERAL DESCRIPTION

499737100 PULLER SET Used for removing reduction drive gear assem-
bly.
83M2014
498077600 REMOVER Used for removing ball bearing.
`~1J
B3M2015
498937110 HOLDER Used for removing and installing drive pinion
lock nut.
B3M2016
498677100 COMPRESSOR Used for installing 2-4 brake snap ring .
83M2017
AT 24
GENERAL DESCRIPTION

498437000 HIGH CLUTCH PIS- Used for installing high clutch piston .
TON GUIDE
69
B3M2018
498437100 LOW CLUTCH PIS- Used for installing low clutch piston .
TON GUIDE
B3M2018
899580100 INSTALLER Used for press-fitting the ball bearing for trans-
fer clutch .
4609M I
B3M2019
2. GENERAL PURPOSE TOOLS 55,~,A,~oz

TOOL NAME REMARKS
Depth gauge Used for measuring transmission end play.
Thickness gauge Used for measuring clearances of clutch, brake and oil pump .
Micro meter Used for measuring thickness of drive pinion .
Spring balance Used for measuring starting torque of drive pinion .
E : PROCEDURE S570001E45 Therefore, in this section, to conduct the particular

procedure within the flow of a section, you need to
* In this section the procedures described under go back and conduct the procedure described pre-
each index are all connected and stated in order. viously in order to do that particular procedure .
It will be the complete procedure for overhauling of
the automatic transmission itself when you go
through all steps in the process.
AT25
AUTOMATIC TRANSMISSION ASSEMBLY
2. Automatic Transmission
Assembly 55,020
A: NOTE 5510207A75
For removal and installation procedures of auto-

matic transmission, refer to "AT" sections for each
model .
AT26
AIR BREATHER HOSE
3 . Air Breather Hose 55,ozo8 2) Insert inhibitor switch and transmission connec-
tor into stay.
A : REMOVAL 55,0208A,8
1) Disconnect transmission harness connector
from stay.
NOTE :
Lift-up lever behind connector and disconnect it
from stay.
2) Disconnect the air breather hoses.
B3M1054A
(A) Transmission harness

(B) Inhibitor switch harness
C: INSPECTION
Make sure the hose is not cracked or clogged.
(A) Air breather hose (Transmission case)

(B) Air breather hose (Oil pump housing)
B : INSTALLATION s5,ozo~
1) Install air breather hoses.
(A) Air breather hose (Transmission case)

(B) Air breather hose (Oil pump housing)
AT27
OIL CHARGER PIPE
4. Oil Charger Pipe 5510203
A : REMOVAL S5,ozo3A,8
1) Remove the oil charger pipe, and remove the
O-ring from the flange face . Attach the O-ring to the
pipe .
3M1052B
(A) Oil level gauge

(B) Oil charger pipe
B : INSTALLATION s5,ozo~
1) Install the oil charger pipe with O-ring .
CAUTION:
Be careful not to damage the O-ring .
Tightening torque:
41 N~m (4.2 kgf-m, 30.4 ft-Ib)
(a)
----~Y
r
v
B3M10528
(A) Oil level gauge

(B) Oil charger pipe
C: INSPECTION s5,ozo~,o
Make sure the oil charger pipe is not deformed or
otherwise damaged.
AT28
OIL COOLER PIPES
5 . Oil Cooler Pipes 55,020.9 Except 3.0 L model
A: REMOVAL 55,ozo9A,8
(B)
1) Remove oil charger pipe . <Ref . to AT-28
REMOVAL, Oil Charger Pipe .>
2) Remove the oil cooler inlet and outlet pipes. I
CAUTION :
When removing outlet pipes, be careful not to 0
lose balls and springs used with retaining _ ~ I . I1
screws.
3.0 L model
Except 3.0 L model
~0 (gym
II r ~ .
-'\ o
~(fNI B3M2112A
3.0 L model (A) Outlet pipe

(B) Inlet pipe
4) Install oil charger pipe with O-ring . <Ref . to
m t
1 AT-28 INSTALLATION, Oil Charger Pipe.>
C : INSPECTION SS,ozo9A,o
o ~l Make sure the oil cooler pipe is not deformed or
otherwise damaged.
~a)I m
B3M2112A
(A) Outlet pipe

(B) Inlet pipe
B: INSTALLATION S510209A11
1) Insert oil cooler outlet ball and spring .

2) Install the oil cooler outlet pipe with gaskets .
CAUTION :
Be sure to use a new gasket.
Tightening torque:
44 N~m (4.5 kgf-m, 32.5 ft-Ib)
3) Install the oil cooler inlet pipe with gaskets .
CAUTION :
Tightening torque:
25 N~m (2.5 kgf-m, i8.1 ft-Ib)
AT 29
VEHICLE SPEED SENSORS AND TORQUE CONVERTER TURBINE SPEED
SENSOR
6 . Vehicle Speed Sensors and 10) Remove rear vehicle speed sensor.
Torque Converter Turbine

Speed Sensor 5510586
A : REMOVAL 5510586A78
1) Extract the torque converter clutch assembly .

<Ref. to AT-34 REMOVAL, Torque Converter
Clutch Assembly .>
a o
0
O
o
O
0
O
B3M2020

from stay.
NOTE : (A) Rear vehicle speed sensor
Lift-up lever behind connector and disconnect it
from stay. 11) Remove front vehicle speed sensor and
torque converter turbine speed sensor.
o'
I) B3M1066C
(B) Stay (A) Front vehicle speed sensor
(B) Torque converter turbine speed sensor
3) Disconnect inhibitor switch connector from stay.
12) Remove the inhibitor switch.
4) Disconnect the air breather hoses. <Ref . to
AT-27 REMOVAL, Air Breather Hose.>
5) Wrap vinyl tape around the nipple attached to
the air breather hose .
6) Remove pitching stopper bracket.
7) Remove the oil charger pipe . <Ref . to AT-28
8) Remove the oil cooler pipes. <Ref . to AT-29
REMOVAL, Oil Cooler Pipes .>
9) Insert a shop cloth into the installation holes of
oil charger pipe and oil cooler pipe .
83M1087
AT30
vcni~Lt brttu btN,urc, HIVU IVfiGtUt (:UNVthi I tFi IUHt31Nt SNEEU
SENSOR
13) Prepare a block of wood. Turn over the trans- 16) Remove transmission harness.
mission case and make it secure with the block of
wood. G
NOTE : 1
Turn over in the direction the inhibitor switch was
installed .
14) Remove the oil pan. J)
NOTE:
Use a scraper to remove oil pan .
OLJ ~\\
B3M1067B
U B : INSTALLATION S510586A11
1) Install and route the transmission harness.

CAUTION :
~OC~ Be careful not to damage the harness .
B3M2022
G
15) Disconnect the harness connectors for the
solenoids, duty solenoids, ATF temperature sensor
and the ground cord .
(a) (J) (a) (c) J)
"oo ~
'-
< o
L
` \\
oyo,o
0, o~° °°~°
(c ~^00 ~1 - 83M1067B
0
o 2) Connect all connectors.
(G) (F )
(A) (J) (B) (c)
gpM2263H
--/
(A) Lock-up duty solenoid (Blue) 1 r Oc
(B) Low clutch timing solenoid (Gray) 00 0
(C) Line pressure duty solenoid (Red) toJ 0
(D) Shift solenoid 2 (Yellow) C~ o
o 0 0 0 -0
(E) Shift solenoid 1 (Green) o ° ~^
(F) 2-4 brake timing solenoid (Black)
('~ ~",,U f ~ \Q~ (H)
(G) 2-4 brake duty solenoid (Red)
(H) ATF temperature sensor (G) (F ) gpM2263H
(I) Transfer duty solenoid (Brown)
(J) Transmission ground (A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(H) ATF temperature sensor
(J) Transmission ground
AT31
VEHICLE SPEED SENSORS AND TORQUE GONVEFiTER TURBINE SPEEU
SENSOR
3) Apply proper amount of liquid gasket to the A

entire oil pan mating surface.
Liquid gasket
THREE BOND 12178 (B
83M7066C
(A) Front vehicle speed sensor

(B) Torque converter turbine speed sensor
7) Install the rear vehicle speed sensor.

Tightening torque:
(A) THREE BOND (Part No . 12178) 7 Mm (0.7 kgf-m, 5.'1 ft-Ib)
(B) Oil pan
4) Install the oil pan to the transmission case

assembly, and secure with 20 bolts .
NOTE :
Tighten the bolts evenly.
Tightening torque:
4.9 N~m (0.50 kgf-m, 3.6 ft-Ib)
4a
°o
B3M2022
5) Turn over the transmission case to its original

position.
6) Install torque converter turbine speed sensor
(A) Rear vehicle speed sensor
and front vehicle speed sensor .
Tightening torque: 8) Remove the vinyl tape, and then install air
7 Mm (0.7 kgf-m, 5.1 ft-Ib) breather hose . <Ref . to AT-27 INSTALLATION, Air
Breather Hose .>
9) Install the oil cooler pipes. <Ref . to AT-29
INSTALLATION, Oil Cooler Pipes.>
10) Install the oil charger pipe . <Ref. to AT-28
INSTALLATION, Oil Charger Pipes .>
11) Install the torque converter clutch assembly .
<Ref . to AT-34 INSTALLATION, Torque Converter
Clutch Assembly .>
12) Install inhibitor switch and adjust the inhibitor
switch by referring to Supplement AT section .
13) Install inhibitor switch connector and transmis-
sion connector to the stay.
14) Install pitching stopper bracket.
AT32
VCFiI(:Lt SF'CtU 5tN5UFi5 ANU IVFi(,1Ut t:VIVVtI-{ I tFi IUFit31NE SF'EEU
SENSOR
Tightening torque:
41 N"m (4.2 kgf-m, 30.4 ft-Ib)
AT 33
TORQUE CONVERTER CLUTCH ASSEMBLY
7. Torque Converter Clutch 3) Insert the input shaft while turning lightly by
hand .
Assembly 55,02,0 CAUTION:
A : REMOVAL 5510210A18 Be careful not to damage the bushing.
1) Extract the torque converter clutch assembly . Normal protrusion A:
50 - 55 (1.97 - 2.17 in)
NOTE:
Extract the torque converter clutch horizontally.
Be careful not to scratch the bushing inside the oil
pump shaft.
Note that oil pump shaft also comes out .
0
O
o
O
4) Holding the torque converter clutch assembly
0
by hand, carefully install it to the torque converter
o clutch case . Be careful not to damage the bushing .
B3M2020 Also avoid undue contact between the oil pump
shaft bushing and stator shaft portion of the oil
2) Remove the input shaft. pump cover.
5) Rotate the shaft lightly by hand to engage the
NOTE : splines securely .
When the torque converter clutch assembly is
removed, the input shaft will come out. Dimension A:
1.6 L and 2.0 L models; -1.3 to -1.1 mm
(-0.051 to -0.043 in)
on 2.0 L TURBO, 2.5 L and 3.0 L models; 2.7

- 2.9 mm (0.106 - 0.114 in)
n
n
o
n
B3M2021
3) Extract the oil pump shaft from torque converter

clutch .
4) Remove the clip from torque converter clutch .
(A) Dimension A
B : INSTALLATION 5510210A11
1) Install the clip to torque converter clutch . C : INSPECTION 55,

.,o
.,
2) Install the oil pump shaft to the torque converter Make sure the ring gear is not damaged and that
clutch . the protrusion on the edge of the torque converter
NOTE: clutch is not deformed or otherwise damaged.
Make sure the clip fits securely in its groove.
AT34
TRANSMISSION COVER
8. Transmission Cover 55,~~ NOTE :

Add 0 .05 mm (0.0020 in) and 0.20 mm (0.0079 in)
A: REMOVAL S5fO640A18 thick shims to area "T". Calculate formula 2 to
determine "H" . The calculated "H" refers to the
1) Remove transmission cover.
shim thickness range . Select shims of suitable
thicknesses within the calculated "H" range.
(0 to 6 teeth)
T=(L+G)-f -H
T: Shim clearance
L: Distance from end of extension case to end of
rear drive shaft
G : Gasket thickness [0.45 mm (0.0177 in)]
Height from end of transmission case to end of
reduction drive gear
H : Shim thickness
H3M1841
0 .05 - 0.25 mm (0 .0020 - 0.0098 in)
2) Take out shim from transmission cover.
Adjusting shim
Pan No . Thickness mm (in)
31288AA020 0.15 (0.0059)
1) Measure distance L from end of transmission
cover point at bearing location with ST 4) Attach the selected adjusting shim to transmis-
ST 398643600 GAUGE sion cover.
L = Measured value - 15 mm 5) Install the transmission cover to the transmis-
sion case.
CAUTION:
6) Tighten bolts to secure the case .
Tightening torque:
25 N~m (2.5 kgf-m, 18.1 ft-Ib)
2) Measure the distance "E" from the transmission

case mating surface to end of bearing with ST.
f = Measured value - 15 mm
ST 398643600 GAUGE
H3M1841
C : INSPECTION 55,~,oA,o
Make sure that the transmission cover has no
cracks .
3) Calculation equation :
AT35
EXTENSION CASE
Extension Case 55,0587 3) Tighten bolts to secure the case.

Tightening torque:
A: REMOVAL S5f0587A78
25 N~m (2.5 kgf-m, 18.1 ft-Ib)
1) Remove rear vehicle speed sensor. L\ A,.,4_--I \
83M1057
4) Install the rear vehicle speed sensor .

Tightening torque:
7 N~m (0.7 kgf-m, 5.1 ft-Ib)
2) Separate transmission case and extension

case sections .
B3M1057 (A) Rear vehicle speed sensor
B : INSTALLATION S5f0587A77
1) Attach the selected thrust needle bearing to the

end surface of reduction drive gear with vaseline .
NOTE:
Install thrust needle bearing in the correct direc-
tion.
2) Install the extension case to the transmission
case .
AT36
EXTENSION CASE
C : DISASSEMBLY S570587A06 2. WITH VTD 5510587A0602
y . WITHOUT VTD 55,o587AOSO, 1) Using ST1, ST2, ST3 and a press, remove
snap ring.
1) Take out the transfer clutch by lightly tapping
ST1 398673600 COMPRESSOR
the end of the rear drive shaft .
ST2 498627100 SEAT
CAUTION: ST3 398663600 PLIERS
Be careful not to damage the oil seal in the
extension.
(A)
(B)
B3M1089BI
21 Remove test nlua .
(A) Extension case

(B) Transfer clutch
2) Remove the transfer pipe .

CAUTION:
Be careful not to bend the nine_
\!-,/ -Lciioiui . ~.aav
(B) Test plug
3) Remove clutch piston by comnresseci air
~(,/ ~nici iaivi i ~aac

L
(B) Transfer clutch O
3) Remove the dust cover from the extension
case .
4) Remove the oil seal from the extension case.
H3M1848
AT37
EXTENSION CASE
4) Remove transfer clutch pipe . NOTE :

Insert the clutch assembly fully into position until
CAUTION:
the bearing shoulder bottoms .
Be careful not to bend the pipe .
(o/
1
a or
B3M11068
(A) Transfer clutch

5) Remove the dust cover trom the extension (B) Extension case
case .
6) Remove the oil seal from the extension case . 2. WITH VTD 5510587A0202
1) Using the ST and a press, press in a new oil

D : ASSEMBLY S5f0587A02
seal.
1 . WITHOUT VTD S5f0587A0201 ST 498057300 INSTALLER
1) Using the ST and a press, press in a new oil 2) Press in the dust cover.
seal . 3) Install transfer clutch pipe .
ST 498057300 INSTALLER CAUTION :
2) Press in the dust cover. Be careful not to bend the pipe .
3) Install the transfer pipe to extension case .
CAUTION :
Be careful not to bend the pipe .
p O (A)
O `
°
0 4) Install test plug .
B3M1090B
Tightening torque:
-dn we .Y /" 13 I--t ... A A is 11.1
(A) Extension case

(B) Transfer pipe
4) Install the transfer clutch assembly to the case .

CAUTION :
Be careful not to damage the seal rings.
1- Njuy
(B) Extension case
AT38
EXTENSION CASE
Automat ic Transmission
5) Insert the multi-plate clutch, the drive plate, the

driven plate, and the spring retainer.
(A) Spring retainer

(B) Multi-plate clutch (LSD) piston ASSY
6) Using the ST1, ST2, and ST3, install the snap

ring .
ST2 498627100 SEAT
ST3 398663600 PLIERS
ST1
ST2
,/ rN 1r
ST3
O
---, (D
H3M1846A
E : INSPECTION 55,o58~A,o
* Use forced air to make sure the transfer pipe
and extension case routes are not clogged and do
not leak .
* Measure the extension end play and adjust it to
within specifications .
WITHOUT VTD <Ref . to AT-44 WITHOUT VTD,
ADJUSTMENT, Transfer Clutch .>
WITH VTD <Ref . to AT-44 WITH VTD,
AT 39
TRANSFER CLUTCH
10. Transfer Clutch s5,o588 B : INSTALLATION 55,058

1) Install the transfer clutch assembly to the case.
A: REMOVAL 5510588A78
CAUTION :
1) Remove rear vehicle speed sensor .
J
B)
> - -
O O
\\
(A)
)--
O ~v
p I
B3M1056C O p
~
B3M1106B~'

(A) Transfer clutch
(B) Front vehicle speed sensor
(B) Extension case
2) Tighten bolts to secure the case .
case sections .
Tightening torque:
O ` 25 N~m (2.5 kgf-m, 18.1 ft-Ib)
B3M1057
3) Take out the transfer clutch by lightly tapping I B3M,o5,l

the end of the rear drive shaft.
CAUTION : C : DISASSEMBLY
Be careful not to damage the oil seal in the
S570588A06
extension . 1) Remove the seal ring .

CAUTION:
Be careful not to damage the seal ring .
(A)
B3M10898
(A) Transfer clutch

(B) Extension case
(B) Transfer clutch
AT40
TRANSFER CLUTCH
Au tomatic Transmission
2) Using a press and ST, remove the ball bearing . 5) Apply compressed air to the rear drive shaft to
CAUTION : remove the piston .
Do not reuse the bearing.
ST 498077600 REMOVER
G3M0497
D : ASSEMBLY 55,.°z
3) Remove the snap ring, and take out the pres- 1) Install the transfer clutch piston .
sure plate, drive plates, and driven plates .
(A) Transfer clutch piston

(A) Snap ring (B) Transfer clutch
(B) Transfer clutch
2) Install return spring to transfer piston .
4) Remove the snap ring with ST1, ST2 and ST3,
and take out the return spring and transfer clutch
piston seal .
ST1 399893600 PLIERS
ST3 398623600 SEAT
(A) Return spring

(B) Transfer clutch
(A) Snap ring

(B) Return spring
AT41
TRANSFER CLUTCH
Auto mat ic Transmission
3) Install transfer clutch piston seal. 6) Using ST1 and ST2, install snap ring to rear
drive shaft.
NOTE :
After installing snap ring, remove ST1 and ST2.
ST1 499257300 SNAP RING OUTER GUIDE
ST2 499247400 INSTALLER
I ST2 I
ST1
(A) Transfer clutch piston seal (A)
(B) Transfer clutch
4) Install ST to rear drive shaft.

ST 499257300 SNAP RING OUTER GUIDE (B)
83M1181CI
ST (A) Snap ring

(B) Transfer clutch
7) Install the driven plates, drive plates, pressure

plate and snap ring .
-(A)
B3M1402C
(A) Transfer clutch
5) Install snap ring to ST.

ST 499257300 SNAP RING OUTER GUIDE
ST
(A) Snap ring
8) Apply compressed air to see if the assembled

parts move smoothly.
83M 11 BOC
(A) Snap ring

(B) Transfer clutch
AT42
TRANSFER CLUTCH
9) Check the clearance. 11) Coat the seal ring with vaseline, and install it
in the seal ring groove of the shaft.
NOTE :
Before measuring clearance, place the same CAUTION:
thickness of shim on both sides to prevent pres- Do not expand the seal ring excessively when
sure plate from tilting . installing .
* If the clearance is not within specification, adjust
it by selecting a suitable pressure plate on the
transfer clutch piston side .
Standard value:
0.7 - 1.1 mm (0.028 - 0.043 in)
Allowable limit:
1.6 mm (0.063 in)
(A) Seal rings

(B) Transfer clutch
12) Install the transfer clutch assembly to the

case.
CAUTION :
Available pressure plates

Part No . Thickness mm (in)
31593AA151 3.3 (0 .130)
31593AA161 3.7 (0 .146)
31593AA171 4.1 (0 .161)
31593AA181 I 4.5 (0.177)
10) Press-fit the ball bearing with ST.

ST 899580100 INSTALLER
(A) Transfer clutch
(B) Extension case
E : INSPECTION S570588A70
* Check the drive plate facing for wear and dam-

age.
Check the snap ring for wear, return spring for
permanent set and breakage, and return spring for
deformation .
Check the lathe cut ring for damage .
" Measure the extension end play and adjust it to
(A) Ball bearing within specifications .
WITHOUT VTD <Ref. to AT-44 WITHOUT VTD,
AT43
TRANSFER CLUTCH
F : ADJUSTMENT 5510588A01 Thrust needle bearing

1 . WITHOUT VTD 5510588A0707
Part No. Thickness mm (in)
806536020 3.8 (0 .150)
1) Measure distance L from end of extension case 806535030 4.0 (0 .157)
and rear drive shaft with ST. 806535040 4.2 (0 .165)
ST 398643600 GAUGE
806535050 4.4 (0 .173)
L = Measured value - 15 mm
806535060 4.6 (0 .181)
(L = Measured value - 0.59 in)
806535070 4.8 (0 .189)
806535090 5.0 (0 .197)
2. WITH VTD S510588A0102
ST 1) Install the rear drive shaft into the reduction

drive gear and center differential assembly.
0
B3M0985A
2) Measure the distance "E" from the transmission

case mating surface to the reduction drive gear
end surface with ST1 and ST2 .
f = Measured value - 50 mm
(2 = Measured value - 1 .97 in)
ST1 398643600 GAUGE
(A) Rear drive plate
ST2 499577000 GAUGE
(B) Center differential carrier
ST2
2) Measure the distance "C" from the transmission
ST1
case mating surface to the reduction drive gear
end surface with ST
~ = Measured value - 50 mm
(~ = Measured value - 1 .97 in)
e ST 398643600 GAUGE
l
I B3M1114A
NOTE:
Add 0 .05 mm (0.0020 in) and 0 .25 mm (0.0098 in)
thick shims to area "T". Calculate formula 2 to
thicknesses within the calculated "H" range.
T=(L+G)-f -H
T: Shim clearance
rear drive shaft
G: Gasket thickness [0.45 mm (0.0177 in)]
2: Height from end of transmission case to end of
H: Thrust needle bearing thickness
0 .05 - 0 .25 mm (0.0020 - 0.0098 in)
AT44
TRANSFER CLUTCH
NOTE:
Add 0 .05 mm (0.0020 in) and 0 .20 mm (0 .0079 in)
thick shims to area "T". Calculate formula 2 to
thicknesses within the calculated "H" range .
(0 to 4 teeth)
T=(L+G)-f -H
T: Shim clearance
rear drive shaft
G: Gasket thickness [0.45 mm (0 .0177 in)]
f : Height from end of transmission case to end of
H : Shim thickness
0.05 - 0 .25 mm (0 .0020 - 0 .0098 in)
Adjusting shim
Part No . Thickness
3281 AA001 0.2
3281 AA011 ~ 0 .5
AT45
MULTI-PLATE CLUTCH
11 . Multi-plate Clutch 5510589

3) Measure the height "2" from mating surface of
the transmission case to end surface of the center
A: REMOVAL S5,o589A,e differential clutch drum .
ST 499577000 GAUGE
The multi-plate clutch is removed in the same way f = Measured value - 35 mm
that the extension case is removed. <Ref. to AT-36 (f = Measured value - 1 .38 in)
REMOVAL, Extension Case .>
The multi-plate clutch is installed in the same way

that the extension case is installed . <Ref . to AT-36
INSTALLATION, Extension Case .>
C : INSPECTION 5570589A70
* Check the drive plate facing for wear and dam-

age.
Check the snap ring for wear, return spring for
permanent set and breakage, and return spring for 4) Calculation equation:
deformation . T = (L + 0.45) - f
Check the lathe cut ring for damage. T: Measurements between end surface of clutch
" Measure the clearance of the multi-plate clutch drum and multi-plate clutch (LSD) piston .
and adjust it to within specifications . <Ref . to AT-46 L: Distance from mating surface of extension
ADJUSTMENT, Multi-plate Clutch .> case to multi-plate clutch (LSD) piston .
0 .45 : Gasket thickness
D : ADJUSTMENT 5510589A01
Height from mating surface of transmission
case to end surface of the center differential clutch
1) Remove the drive plate and driven plate from drum.
the center differential carrier. NOTE :
2) Measure the distance "L" from mating surface Measure thickness of driven and drive plates of
of extension case to multi-plate clutch (LSD) pis- multi-plate clutch (LSD) and determine clearance
ton . between measured value and "T".
ST 399643600 GAUGE
L = Measured value - 15 mm Standard value:
(L = Measured value - 0.59 in) 0.2 - 0.6 mm (0.008 - 0.024 in)
Allowable limit:
1.6 mm (0.063 in)
If out of specification, replace plate set (drive and
driven plate) and select a multi-plate clutch (LSD)
piston side adjusting plate to make it within speci-
15 mm (0 .59 in)
fication .
~L
Available driven plates
31589AA041 1 .6 (0 .063)
/ H3M1855A 31589AA050 2.0 (0 .079)
31589AA060 2.4 (0 .094)
31589AA070 2.8 (0 .110)
AT46
REAR DRIVE SHAFT
12. Rear Drive Shaft s5,°,56 2) Using a press, remove the front and rear side
ball bearings and clutch hub.
A : REMOVAL 55W15.18
1) Remove rear vehicle speed sensor and sepa-

rate the extension case from the transmission
case. <Ref . to AT-36 REMOVAL, Extension Case.>
2) Extract the rear drive shaft from the center dif-
ferential assembly .
(A) Rear ball bearing

(B) Rear drive shaft
(C) Clutch hub
D : ASSEMBLY 5510156A02
Assembly is in the reverse order of disassembly.

(A) Rear drive shaft CAUTION :
(B) Center differential carrier * Be sure to use a new ball bearings and revo-
lution gear.
3) Remove the drive plate and driven plate * Pay attention to the direction of the clutch
hub.
1) Install the drive plate and driven plate.

cB~
(A) (c)
2) Insert the rear drive shaft into the center differ-
ential assembly.
3) Combine the transmission case with the exten-
sion case, and install the rear vehicle speed sen-
sor. <Ref . to AT-36 INSTALLATION, Extension
Case .>
C : DISASSEMBLY 5570156A06 ( D)
H3M1869B
1) Using a press, remove the revolution gear.
(A) Front
(B) Clutch hub
(C) Rear
(D) Revolution gear
E : INSPECTION S510156A70
* Make sure that each component is free of harm-

ful gouges, cuts, or dust .
9 Measure the extension end play and adjust to
within specifications . <Ref . to AT-44 WITH VTD,
(A) Revolution gear
AT47
REDUCTION DRIVEN GEAR
13 . Reduction Driven Gear S5f0590

3) Straighten the staked portion, and remove the
lock nut.
A : REMOVAL S5,o59oA,8 NOTE :
1 . WITHOUT VTD S510590A1807
Set the range select lever to "P".
1) Remove rear vehicle speed sensor, and sepa-
rate the transmission case and extension case .
<Ref . to AT-36 REMOVAL, Extension Case .>
2) Straighten the staked portion, and remove the
lock nut.
NOTE:
Set the range select lever to "P".
(B)
a
0 4) Using the ST1 and ST2, extract the reduction
o\ .(A) driven gear.
0 ST1 499737000 PULLER
ST2 899524100 PULLER SET
0 5) Extract center differential assembly. <Ref . to
AT-53 REMOVAL, Center Differential Carrier.>
83M1058C B : INSTALLATION 5510590A77
(A) Reduction driven gear 1 . WITHOUT VTD 5510590A1101
(B) Reduction drive gear

1) Using a plastic hammer, install reduction driven
3) Using the ST1 and ST2, extract the reduction gear assembly, and tighten drive pinion lock nut.
driven gear. CAUTION :
ST1 499737000 PULLER Be sure to use a new lock nut and a washer.
ST2 899524100 PULLER SET NOTE :
" Set the select lever in the "P" range.
After tightening, stake the lock nut securely.
Tightening torque:
100 N~m (10.2 kgf-m, 73.8 ft-Ib)
- ~ ( B)
0
--- , a
o ~
o (A)
O
(A) Reduction driven gear

o
0
o ~ ro
2. WITH VTD 5510590A1802

B3M1058C
1) Remove the rear vehicle speed sensor, and (A) Reduction driven gear
separate the transmission case and extension (B) Reduction drive gear
case . <Ref . to AT-36 REMOVAL, Extension Case .>
2) Remove the rear drive shaft. <Ref . to AT-47 2) Combine the transmission case with the exten-
REMOVAL, Rear Drive Shaft.> sion case, and install rear vehicle speed sensor.
<Ref . to AT-36 INSTALLATION, Extension Case .>
AT48
REDUCTION DRIVEN GEAR
2. WITH VTD S5,oSWA o2 2) Using ST, remove ball bearing from reduction
driven gear.
1) Using a plastic hammer, install reduction driven
gear assembly.
2) Using a plastic hammer, install center differen-
tial .
3) Tighten drive pinion lock nut.
CAUTION:
Be sure to use a new lock nut and a washer.
NOTE :
" Set the range select lever in the "P" range .
After tightening, stake the lock nut securely.
Tightening torque:
100 N~m (10.2 kgf-m, 73.8 ft-Ib)
(A) Ball bearing
3) Remove snap rings from reduction driven gear .

(2 .5 L US model and 3.0 L model)
1) Install snap rings to reduction driven gear. (2.5

L US model and 3.0 L model)
2) Using a press, install ball bearing to reduction
driven gear.
4) Insert the rear drive shaft assembly. <Ref. to

AT-47 INSTALLATION, Rear Drive Shaft.>
A)
sion case, and install rear vehicle speed sensor.
C : DISASSEMBLY
1) Remove snap ring from reduction driven gear.
B3M1128B
(A) Ball bearing
3) Install snap ring to reduction driven gear.
(A)
B3M 11258
(A) Snap ring
83M1125B~
(A) Snap ring
E : INSPECTION 5510590A10
Check ball bearing and gear for dents or damage.
AT49
REDUCTION DRIVE GEAR
14. Reduction Drive Gear 55,059, C: DISASSEMBLY 5570597A06
A . REMOVAL S5f0591A18
," FWD 5510597A0601
1) Remove rear vehicle speed sensor, and sepa- 1) Take out the seal rings.
rate the transmission case and extension case . CAUTION:
<Ref . to AT-36 REMOVAL, Extension Case .> Be careful not to damage the seal rings.
2) Remove the reduction driven gear. <Ref . to
AT-48 WITHOUT VTD, REMOVAL, Reduction
Driven Gear.>
3) Using ST, extract the reduction drive gear .
ST1 499737100 PULLER
ST2 899524100 PULLER SET f~ &
(A) Seal rings

(B) Reduction drive shaft
2) Using ST, remove the ball bearing of rear side.

(A) Reduction drive gear
1) Install the reduction drive gear assembly .

NOTE :
Insert it fully into position until the bearing shoulder
bottoms .
\- ~\
(A)
(A) Ball bearing
. `` o (B) Reduction drive gear
3) Using a press, remove the reduction drive gear.

o
~~ \o 0
T~ B3M1113B
2) Install the reduction driven gear . <Ref . to AT-48

WITHOUT VTD, INSTALLATION, Reduction Drive
Gear.>
AT50
4) Using a press, remove the ball bearing . 3) Using a press, remove the reduction drive gear.
ST1 499577000 ADAPTER
ST2 498077600 REMOVER
D : ASSEMBLY S51Q59fA02
2. AWD S570591A0602
1 . FWD 5570591A0207
1) Take out the seal rings.
1) Press-fit the ball bearing to the reduction drive
CAUTION: gear .
Be careful not to damage the seal rings. ST 398437700 ADAPTER
(A) Seal rings (A) Ball bearing

(B) Reduction drive shaft (B) Reduction drive gear
2) Using ST, remove the ball bearing . 2) Press-fit the reduction drive gear.
ST 498077600 REMOVER 3) Press-fit the ball bearing to reduction drive
shaft.
ST 398437700 ADAPTER
ST
- -- i -
B3M0962C
(A) Ball bearing

(A) Ball bearing
AT51
4) Attach two seal rings .

NOTE :
To make subsequent assembly easier, apply vase-
line to the grooves of the shaft and to the exterior
of the seal ring .
(A) Seal rings

2. AW D 5570591A0202
1) Press-fit the reduction drive gear to the shaft.

2) Press-fit the ball bearing to the reduction drive
gear.
3) Attach two seal rings .
NOTE :
To make subsequent assembly easier, apply vase-
line to the grooves of the shaft and to the exterior
of the seal ring .
(A) Seal rings

E : INSPECTION 55,o59,A,o
* Make sure that each component is free of harm-
e Measure the extension end play and adjust it to
within specifications . <Ref . to AT-44 WITHOUT
VTD, ADJUSTMENT, Transfer Clutch .>
AT52
CENTER DIFFERENTIAL CARRIER
15. Center Differential Carrier C : DISASSEMBLY 5510592A06
5510592
1) Remove seal ring.
A: REMOVAL S510592Ai8 CAUTION :
1) Remove rear vehicle speed sensor, and sepa- Be careful not to damage the seal rings.
rate the extension case form the transmission
case . <Ref . to AT-36 REMOVAL, Extension Case .>
2) Pull out the rear drive shaft. <Ref . to AT-47
REMOVAL, Rear Drive Shaft.>
3) Using ST, extract the center differential carrier
assembly.
ST1 499737100 PULLER
(A) Seal rings
2) Using a press and ST, remove the ball bearing .

4) Extract shim from transmission case .
B : INSTALLATION S510592A11
1) Install the center differential assembly with

shim .
NOTE:
Insert it fully into position until the bearing shoulder 3) Remove snap ring, and pull out shafts from
bottoms . center differential assembly.
2) Insert the rear drive shaft . <Ref. to AT-47 (A) Snap ring
INSTALLATION, Rear Drive Shaft.> (B) Shaft
AT53
CENTER DIFFERENTIAL CARRIER
4) Remove thrust washer, pinion gears and wash-

ers from center differential assembly .
(A)
H3M18668
(A) Pinion gear
5) Pull out intermediate shaft and thrust bearing.
D : ASSEMBLY S5,o59zAOz
1) Install thrust washer to intermediate shaft.
2) Install thrust bearing and intermediate shaft.
3) Install pinion gears and washers .
4) Put shaft in center differential assembly .
5) Install snap ring.
6) Using a press, press-fit the ball bearing to cen-
ter differential assembly .
CAUTION:
Be sure to use a new ball bearing.
(A) Plate
(B) Center differential carrier
E : INSPECTION S5,o592A,o
Make sure that each component is free of harm-
o Measure the extension end play and adjust it to
within specifications . <Ref . to AT-44 WITH VTD,
AT54
TRANSFER DUTY SOLENOID AND VALVE BODY
16. Transfer Duty Solenoid and 5) Pull out inlet filter

Valve Body s5,o,6,
A: REMOVAL S510167A18
1) Remove rear vehicle speed sensor . il t_~
(A) Inlet filter
6) Remove the oil seal from the transfer valve

body.
B : INSTALLATION S5f016fA77
1) Insert the oil seal into the transfer valve body.

2) Install inlet filter to transmission case .

case sections . <Ref . to AT-36 REMOVAL, Exten-
sion Case .> (A) Inlet filter
3) Disconnect connector from transfer duty sole-
noid . 3) Install transfer valve plate, valve body and
4) Remove transfer valve body and transfer duty transfer duty solenoid to transmission case .
solenoid . CAUTION :
9 Be sure to install transfer seal lip to transfer
control valve body.
* If transfer seal lip is damaged, replace seal
with new one.
Tightening torque:
8 N~m (0.8 kgf-m, 5.8 ft-Ib)
(A) Transfer valve body

(B) Transfer duty solenoid
AT55
(A) Transfer valve body

(B) Transfer duty solenoid
4) Install the extension case from the transmission

case . <Ref . to AT-36 INSTALLATION, Extension
Case .>
CAUTION :
5) Install the rear vehicle speed sensor.
Tightening torque:
7 N~m (0.7 kgf-m, 5.1 ft-Ib)
C : INSPECTION 5510161A70
Check each component for harmful cuts, damage

and other faults .
AT56
PARKING PAWL
17. Parking Pawl S5f0201 B : INSTALLATION S570207A17
A: REMOVAL ~,o2o,A,e 1) Install the parking pawl, shaft and return spring .
1) Remove rear vehicle speed sensor.
(A) Parking pawl

(B) Return spring
2) For the model without VTD, install the reduction

drive gear. For the model with VTD, install the cen-
ter differential gear assembly.
Without VTD: <Ref . to AT-50 INSTALLATION,
Reduction Drive Gear.>
With VTD : <Ref . to AT-53 INSTALLATION, Center
Differential Carrier.>
case .
CAUTION :
(A) Rear vehicle speed sensor Be sure to use a new gasket.
2) Separate transmission case and extension 4) Install the rear vehicle speed sensor.
case sections . <Ref . to AT-36 REMOVAL, Exten- Tightening torque:
sion Case .> 7 N~m (0.7 kgf-m, 5.1 ft-Ib)
3) For the model without VTD, remove the reduc-
tion drive gear. For the model with VTD, remove
the center differential gear assembly .
Without VTD: <Ref . to AT-50 REMOVAL, Reduc-
tion Drive Gear.>
With VTD: <Ref . to AT-53 REMOVAL, Center Dif-
ferential Carrier.>
4) Remove the parking pawl, return spring and
shaft.
(A) Parking pawl

(B) Return spring
AT57
PARKING PAWL
C: INSPECTION S51020fAf0
Make sure that the tab of the packing pole on the

reduction gear is not worn or otherwise damaged.
AT58
TORQUE CONVERTER CLUTCH CASE
18. Torque Converter Clutch 4) Disconnect transmission harness connector

from stay.
Case
NOTE :
A : REMOVAL S5,o2o6A,e Lift-up lever behind the connector and disconnect
1) Extract the torque converter clutch assembly . it from stay.
<Ref. to AT-34 REMOVAL, Torque Converter 5) Disconnect inhibitor switch connector from stay.
Clutch Assembly.> 6) Disconnect the air breather hose . <Ref . to
NOTE : AT-27 REMOVAL, Air Breather Hose .>
Be careful not to scratch the bushing inside the oil REMOVAL, Oil Charger Pipe .>
8) Remove the oil cooler inlet and outlet pipes.
pump shaft.
<Ref. to AT-29 REMOVAL, Oil Cooler Pipes.>
Note that oil pump shaft also comes out.
9) Separation of torque converter clutch case and
transmission case sections
CAUTION :
* Be careful not to damage the oil seal and
bushing inside the torque converter clutch
case by the oil pump cover.
9 Be careful not to lose the rubber seal.
NOTE :
Separate these cases while tapping lightly on the
housing.
B3M2020
2) Remove the input shaft.
10) Wrap the axle shaft serration with vinyl tape.
(A) Vinyl tape
(A) Pitching stopper bracket
AT59
11) Remove the differential side retainer with ST. B : INSTALLATION SS,oz~
CAUTION: 1) Check the appearance of each component and
Hold the differential case assembly by hand to clean.
avoid damaging retainer mounting hole of the
torque converter clutch case and speedometer CAUTION :
gears. Make sure each part is free of harmful cuts,
damage and other faults .
ST 499787000 WRENCH ASSY
12) Extract the axle shaft with ST1 and ST2. 2) Force-fit the oil seal to the torque converter
CAUTION: clutch case with ST.
ST 398437700 DRIFT
Do not reuse the circlip .
ST1 499095500 REMOVER
:qvv
Y--~~ `~~~~~\
\
\,l\~/I\ ~ ST1
~--'i-
i
;~ ST2 3) Install the differential assembly to the case,
G3M0956 paying special attention not to damage the inside
of the case (particularly, the differential side
13) Remove the differential assembly .
retainer contact surface) .
CAUTION :
* Remove the seal pipe if it is attached. (Reus-
ing is not allowed.)
* Be careful not to damage the retainer mount-
ing hole of the torque converter clutch case.
(A) Differential assembly
4) Install the circlip to the axle shaft, insert the

shaft into the differential assembly, and tap it into
position with a plastic hammer.
(A) Seal pipe
CAUTION:
14) Remove the oil seal from torque converter e If no play is felt, check whether the shaft is
clutch case . fully inserted. If shaft insertion is correct,
replace the axle shaft.
e Be sure to use a new circlip.
Thrust play:
0.3-0.5mm (0.012-0.020 in)
AT60
5) Wrap vinyl tape around the splined portion of 9) Install the rubber seal to the torque converter
the axle shaft. clutch case .
CAUTION :
Be careful not to lose the rubber seal.
(A) Vinyl tape
6) Install the oil seal and outer race (taper roller

bearing) to the differential side retainer. Then (A) Rubber seal
screw in the retainer and the O-ring after coating 10) Apply proper amount of liquid gasket to the
the threads with oil. entire torque converter clutch case mating surface.
CAUTION: Liquid gasket:
" Pay attention not to damage the oil seal lips . THREE BOND 1215
" Do not confuse the RH and LH oil seals.
" Keep the O-ring removed from the retainer. NOTE :
Make sure that the rubber seal and seal pipe are
7) Using ST, install the left and right side retainers. fitted in position.
<Ref . to AT-81 ADJUSTMENT, Front Differential .>
8) Install the seal pipe to the torque converter
clutch case.
CAUTION :
Be sure to use a new seal pipe.
(A) THREE BOND (Part No . 1215)

(B) Rubber seal
(A) Seal pipe
AT61
11) Install the torque converter clutch case assem- 16) Install the pitching stopper bracket.
bly to the transmission case assembly, and secure Tightening torque:
with six bolts and four nuts . 41 N~m (4.2 kgf-m, 30.4 ft-Ib)
CAUTION:
When installing, be careful not to damage the
torque converter clutch case bushing and oil
seal.
Tightening torque:
41 N-m (4.2 kgf-m, 30.4 ft-Ib)
(A) Pitching stopper
17) Insert the input shaft while turning lightly by

hand .
CAUTION:
Be careful not to damage the bushing .
12) Install air breather hose . <Ref . to AT-27 Normal protrusion A :
INSTALLATION, Air Breather Hose.> 50-55 mm (1.97-2.17 in)
13) Insert inhibitor switch and transmission con-
nector into stay.
14) Install the oil cooler pipes. <Ref . to AT-29
INSTALLATION, Oil Cooler Pipes .>
15) Install the oil charger pipe with O-ring . <Ref . to
AT-28 INSTALLATION, Oil Charger Pipe .>
18) Install the torque converter clutch assembly.

Clutch Assembly.>
C : INSPECTION s5.o
Measure the backlash and adjust to within specifi-
cations. <Ref . to AT-74 ADJUSTMENT, Drive Pin-
ion Shaft .>
AT62
OIL PUMP
19. Oil Pump 55,000 9) Remove rear vehicle speed sensor.
A : REMOVAL 5510070AiH

NOTE :
pump shaft.
0
O
O
0
O
~
O
B3M2020

case sections .
11) Remove the reduction driven gear.
Without VTD <Ref . to AT-48 WITHOUT VTD,
REMOVE, Reduction Driven Gear.>
With VTD <Ref . to AT-48 WITH VTD, REMOVE,
Reduction Driven Gear.>
12) Loosen the taper roller bearing mounting
bolts.
from stay.
NOTE:
Lift-up lever behind the connector and disconnect O
it from stay.
5) Disconnect the air breather hose . <Ref . to
AT-27 REMOVAL, Air Breather Hose .>
B3M1063
7) Remove the oil cooler inlet and outlet pipes .
<Ref . to AT-29 REMOVAL, Oil Cooler Pipes .>
transmission case sections <Ref . to AT-59
REMOVAL, Torque Converter Clutch Case .>
AT63
OIL PUMP
13) Place two wooden blocks on the workbench, CAUTION:

and stand the transmission case with its rear end Be careful not to damage O-ring .
facing down. 17) Remove the drive pinion assembly .
CAUTION :
* Be careful not to scratch the rear mating sur- B : INSTALLATION 55,~~oA
face of the transmission case. 1) Assemble the drive pinion assembly to the oil
Note that the parking rod and drive pinion pump housing .
protrude from the mating surface.
CAUTION :
" Be careful not to bend the shims.
" Be careful not to force the pinion against the
housing bore .
2) Tighten four bolts to secure the roller bearing.
JJ
Tightening torque:
41 N~m (4.2 kgf-m, 30.4 ft-Ib)
55 mm
(2 .17 in)
B3M1064A
14) Remove the oil pump housing .

CAUTION :
Be careful not to lose the total end play adjust-
ing thrust washer.
3) Install two oil seals to the oil seal retainer with

ST.
CAUTION :
Always discard old oil seals, and install new
ones .
* Pay attention to the orientation of the oil
seals .
(A) Oil pump housing
15) Remove the oil seal retainer. (a)

Also remove the O-ring and oil seal (air breather) .
O( e)
B3M2089A
(A) Oil seal

(B) Oil seal retainer
(A) Oil seal retainer

(B) Drive pinion shaft
16) Remove 0-rings from oil pump housing.
AT64
OIL PUMP
4) Attach the O-ring to the oil seal retainer with

vaseline . Install the seal to the oil pump housing
bore.
CAUTION :
Always discard old O-rings and install new
ones.
~e
0o ~ D0 0
° o 0
7) Apply proper amount of liquid gasket to the

entire torque converter clutch case mating surface.
Liquid gasket:
\1B3M1093C THREE BOND 1215
(A) O-ring NOTE :
5) Install the oil seal retainer taking care not to fitted in position.
damage the oil seal lips . Then secure with three
bolts .
NOTE:
Make sure the O-ring is fitted correctly in position.
Tightening torque;
7 N~m (0.7 kgf-m, 5.1 ft-Ib)
(A) THREE BOND (Pan No . 1215)

(B) Rubber seal
8) Install the torque converter clutch case assem-

bly to the transmission case assembly, and secure
with six bolts and four nuts .
CAUTION:
(A) Oil seal retainer When installing, be careful not to damage the
(B) Drive pinion shaft torque converter clutch case bushing and oil
seal.
6) Secure the housing with two nuts and the bolt.
Tightening torque:
Tightening torque: 41 N~m (4.2 kgf-m, 30.4 ft-Ib)
41 N~m (4.2 kgf-m, 30.4 ft-Ib)
AT65
OIL PUMP
9) Install reduction driven gear. <Ref . to AT-48 C : DISASSEMBLY SS,...

WITHOUT VTD, INSTALLATION, Reduction
Driven Gear.> <Ref . to AT-49 WITH VTD, 1) Remove four seal rings.
INSTALLATION, Reduction Driven Gear .> CAUTION :
10) Combine the extension case with the trans- Be careful not to damage O-ring .
mission case, and install vehicle speed sensor 1
(rear) . <Ref . to AT-36 INSTALLATION, Extension
Case .> Y
11) Install air breather hose . c A)
12) Insert inhibitor switch and transmission con- J
nector into stay.
o
A)
B3M 095E
(A) Seal rings
2) Remove the oil pump cover.

NOTE:
B3M 1054A Lightly tap the end of the stator shaft to remove the
cover.
13) Install the oil cooler pipe . <Ref . to AT-29

INSTALLATION, Oil Cooler Pipe .>
AT-28 INSTALLATION, Oil Charger Pipes.>
hand .
CAUTION:
Be careful not to damage the bushing.
Normal protrusion A :
50 - 55 mm (1.97 - 2.17 in) (A) Oil pump cover
(B) Oil pump housing
3) Remove the inner and outer rotor.

Clutch Assembly.> (A) Inner rotor
(B) Outer rotor
AT 66
OIL PUMP
D : ASSEMBLY SS,oo7oAOz
1) Install oil pump rotor assembly to oil pump Y
housing.
J
B3M1095E
(A) Seal rings
E : INSPECTION 55,~~oA,o
1) Check seal ring and O-ring oil seal for breaks or
(A) Inner rotor
damage.
(B) Outer rotor
2) Check other parts for dents or abnormalities .
2) Install the oil pump cover. 3) Selection of oil pump rotor assembly
(1) Tip clearance
Tightening torque : Install inner rotor and outer rotor to oil pump .
25 N~m (2.5 kqf-m, 18. i ft-Ib) With rotor gears facing each other, measure
NOTE : crest-to-crest clearance.
* Align both pivots with the pivot holes of the Tip clearance:
cover, and install the cover being careful not to 0.02 - 0.15 mm (0.0008 - 0.0059 in)
apply undue force to the pivots .
9 After assembling, turn the oil pump shaft to
check for smooth rotation of the rotor.
(A)
l. (B)
1I'
no O V O
opo o 0 o
0 OoOd~0 ~
o 00
83M 18378
(A) Thickness gauge

(B) Inner rotor
(C) Outer rotor
(A) Oil pump cover
(B) Oil pump housing
Install the oil seal retainer and seal rings . After

adjusting the drive pinion backlash and tooth con-
tact.
AT67
OIL PUMP
(2) Side clearance 2) Using ST, measure the distance from the oil
Set a depth gauge to oil pump housing, then pump housing mating surface to the top surface of
measure oil pump housing-to-rotor clearances . the oil pump cover with thrust needle bearing.
Side clearance: ST 398643600 GAUGE
0.02 - 0.04 mm (0.0008 - 0.0016 in)
~(,a)
0
l ~Q;=w' .,~
o (c)
(B)~
0 000 °~ 0 a 0
o v~op
Ooh o
oao 00
o
B3M1838B
3) Calculation of total end play
(A) Depth gauge
Select suitable bearing race from among those
(B) Inner rotor listed in this table so that clearance C is in the 0.25
(C) Outer rotor to 0.55 mm (0.0098 to 0.0217 in) range .
C=(L+G)-C
(3) If depth and/or side clearances are outside
specifications, replace rotor assembly. C Clearance between concave portion of high clutch
and end of clutch drum support
Oil pump rotor assembly Length from case mating surface to concave por-
Part No . Thickness mm (in) tion of high clutch
15008AA060 11 .37 - 11 .38 (0 .4476 - 0.4480) G Gasket thickness (0 .28 mm, 0.0110 in)
15008AA070 11 .38 - 11 .39 (0 .4480 - 0.4484) Height from housing mating surface to upper sur-
15008AA080 11 .39 - 11 .40 (0 .4484 - 0.4488) face of clutch drum support
* Measure the total end play and adjust to within

specifications . <Ref . to AT-68 ADJUSTMENT, Oil
Pump .>
F : ADJUSTMENT 5570070A01
1) Using ST, measure the distance from the trans-

mission case mating surface to the recessed por-
tion of the high clutch drum "L".
ST 398643600 GAUGE
ST
Thrust needle bearing
806528050 4.1 (0 .161)
806528060 4.3 (0 .169)
806528070 4.5 (0 .177)
806528080 4.7 (0 .185)
806528090 4.9 (0 .193)
806528100 5.1 (0 .201)
B3M0982A
4) After completing end play adjustment, insert the

bearing race in the recess of the high clutch . Attach
the thrust needle bearing to the oil pump cover with
vaseline .
AT68
OIL PUMP
Autom atic Transmission
5) After correctly installing the gasket to the case

mating surface, carefully install the oil pump hous-
ing assembly . Be careful to avoid hitting the drive
pinion against the inside of the case .
CAUTION:
e Be careful not to damage the seal ring .
9 Be sure to use a new gasket.
6) Install both parts with dowel pins aligned . Make
sure no clearance exists at the mating surface.
NOTE :
Any clearance suggests a damaged seal ring .
AT69
DRIVE PINION SHAFT
20 . Drive Pinion Shaft x,02,6 9) Remove rear vehicle speed sensor.
A : REMOVAL 55,oz,sA,e
NOTE:
pump shaft.

from stay. (A) Rear vehicle speed sensor
NOTE : 10) Separate transmission case and extension

Lift-up lever behind the connector and disconnect case sections .
it from stay. 11) Remove the reduction driven gear.
4) Disconnect inhibitor switch connector from stay. Without VTD <Ref . to AT-48 WITHOUT VTD,
5) Disconnect the air breather hose . <Ref . to REMOVAL, Reduction Driven Gear.>
AT-27 REMOVAL, Air Breather Hose.> With VTD <Ref . to AT-48 WITH VTD, REMOVAL,
6) Remove the oil charger pipe . <Ref . to AT-28 Reduction Driven Gear.>
REMOVAL, Oil Charger Pipe .> 12) Loosen the taper roller bearing mounting
7) Remove the oil cooler inlet and outlet pipes. bolts.
<Ref . to AT-29 REMOVAL, Oil Cooler Pipes.>
O
CAUTION:
9 Be careful not to lose the rubber seal .
NOTE :
Separate these cases while tapping lightly on the B3M1063
housing .
AT70
DRIVE PINION SHAFT
13) Place two wooden blocks on the workbench, CAUTION :

and stand the transmission case with its rear end Be careful not to damage O-ring .
facing down . 17) Remove the drive pinion assembly.
CAUTION:
. Be careful not to scratch the rear mating sur- B : INSTALLATION S510276A11
face of the transmission case . 1) Assemble the drive pinion assembly to the oil
Note that the parking rod and drive pinion pump housing .
protrude from the mating surface.
CAU TIO N.
" Be careful not to bend the shims.
" Be careful not to force the pinion against the
housing bore .
2) Tighten four bolts to secure the roller bearing .
Tightening torque:
41 N~m (4.2 kgf-m, 30.4 ft-Ib)
55 mm
(2 .17 in)
B3M1064A

CAUTION:
ing thrust washer.
3) Attach the O-ring to the oil seal retainer with

vaseline . Install the seal to the oil pump housing
bore .
CAUTION:
Always discard old O-rings and install new
ones .
(A) Oil pump housing -~oL' O

15) Remove the oil seal retainer .
Also remove the O-ring and oil seal (air breather) . o (A>
\~J
° °
B3M1093C
(A) O-ring
4) Install the oil seal retainer taking care not to

damage the oil seal lips . Then secure with three
bolts .
NOTE :
Make sure the O-ring is fitted correctly in position.
(B) Drive pinion shaft
Tightening torque:
16) Remove 0-rings from oil pump housing. 7 N~m (0.7 kgf-m, 5.1 ft-Ib)
AT71
DRIVE PINION SHAFT
8) Install the reduction driven gear.

Without VTD <Ref . to AT-48 WITHOUT VTD,
INSTALLATION, Reduction Driven Gear.>
With VTD <Ref . to AT-49 WITH VTD,
9) Combine the extension case with the transmis-
sion case, and install vehicle speed sensor 1
(rear) . <Ref . to AT-36 INSTALLATION, Extension
Case.>
10) Install air breather hose . <Ref . to AT-27
INSTALLATION, Air Breather Hose .>
(B) Drive pinion shaft nector into stay.
12) Install the oil charger pipe with O-ring .
5) Secure the housing with two nuts and the bolt 13) Insert the input shaft while turning lightly by
hand .
Tightening Torque:
T.' 41 N~m (4.2 kgf-m, 30.4 ft-Ib) CAUTION :
Normal protrusion A:
50-55 mm (1.97-2.17 in)

Liquid gasket: <Ref . to AT-34 INSTALLATION, Torque Converter
THREE BOND 1215 Clutch Assembly.>
NOTE:
Make sure that the rubber seal and seal pipe are C : DISASSEMBLY S5f0216A06
fitted in position. 1) Straighten the staked portion of the lock nut,

and remove the lock nut while locking the rear
spline portion of the shaft with ST1 and ST2 . Then
pull off the drive pinion collar .
ST1 498937110 HOLDER
ST2 499787700 WRENCH

(B) Rubber seal
7) Combine the torque converter case with the

transmission case. <Ref. to AT-60 INSTALLATION,
Torque Converter Clutch Case .>
AT72
DRIVE PINION SHAFT
2) Remove the O-ring . NOTE:
3) Using a press, separate the rear roller bearing If too much pressure is applied, the roller bearing
and outer race from the shaft. will not turn easily.
A)
B3M2086A
(A) Outer race (A) Drive pinion shaft

(B) Roller bearing
4) Using a press and ST, separate the front roller
bearing from the shaft. 3) After fitting the O-ring to the shaft, attach the
ST 498517000 REPLACER drive pinion collar to the shaft.
CAUTION:
Be careful not to damage the O-ring .
4) Tighten the lock washer and lock nut with ST1,
ST2 and ST3.
Calculate lock washer and lock nut specifications
using the following formula.
T2 = L1/(L1 + L2) x T1
T1 : 116 N~m (11 .8 kgf-m, 85.3 ft-Ib)
[Required torque setting]
T2: Tightening torque
L1 : ST2 length 0.072 m (2 .83 in)
(A) Front roller bearing L2 : Torque wrench length
Example :
D: ASSEMBLY S5,o2,6402
1) Measure dimension "A" of the drive pinion Torque wrench length Tightening torque
m (in) N~m (kgf-m, ft-Ib)
shaft.
0.1 (3 .94) 49 (5 .0, 36)
ST 398643600 GAUGE
0.15 (5.91) 37 (3 .8, 27)
0.2 (7 .87) 30 (3 .1, 22)
0.25 (9 .84) 25(2 .6, 19)

ISTI
A
83M1176A
2) Using a press, force-fit the roller bearing in

position.
CAUTION :
Do not change the relative positions of the
outer race and bearing cone .
AT 73
DRIVE PINION SHAFT
NOTE : Available drive pinion shims

" Pay attention to the orientation of lock washer. Pan No . Thickness mm (in)
" Install ST2 to torque wrench as straight as pos- 31451AA050 0.150 (0.0059)
sible.
31451AA060 0.175 (0 .0069)
31451 AA070 0.200 (0 .0079)
31451 AA080 0225 (0.0089)
31451 AA090 0.250 (0.0098)
31451 AA100 ~ 0.275 (0 .0108)
E : INSPECTION SS,oz,6A,o
* Make sure that all component parts are free of
harmful cuts, gouges, and other faults .
Adjust the teeth alignment. <Ref . to AT-74
ADJUSTMENT, Drive Pinion Shaft.>
5) Measure the starting torque of the bearing. F: ADJUSTMENT .,02,.0,

Make sure the starting torque is within the speci-
fied range. If out of the allowable range, replace 1) Install the oil pump housing assembly to the
the roller bearing . torque converter clutch case, and secure evenly by
tightening four bolts.
Starting torque:
0.3 - 2.0 N" m (0.03 - 0.2 kgf-m, 0.2 - CAUTION:
1.4 ft-Ib) Thoroughly remove the liquid gasket from
the case mating surface beforehand .
e Use an old gasket or an aluminum washer so
as not to damage the mating surface of the
housing.
Tightening torque :
41 N~m (4.2 kgf-m, 30.4 ft-Ib)
6) Stake the lock nut securely at two places .

7) Measure dimension "B" of the drive pinion
shaft.
ST 398643600 GAUGE
2) Rotate the drive pinion several times with ST1

ISTI and ST2.
ST2
0
ST1
B3M0590DI
8) Determine the thickness "t" (mm) of the drive

pinion shim .
NOTE: I ~'`= 1
The number of shims must be three or less.

G3M0384
t = 6.5±0.0625 - (B - A)
AT74
DRIVE PINION SHAFT
3) Apply red lead evenly to the surfaces of three If tooth contact is improper, readjust the backlash
or four teeth of the crown gear. Rotate the drive or shim thickness. <Ref . to AT-81 ADJUSTMENT,
pinion in the forward and reverse directions several Front Differential .>
times . Then remove the oil pump housing, and
check the tooth contact pattern .
Checking item Contact pattern Corrective action

Tooth contact
Toe side/
Tooth contact pattern is slightly shifted
toward to under no-load rotation .
[When loaded, contact pattern moves -
toward heel .] Heel side
83M0317A
Face contact This may cause noise and chipping at Increase thickness of drive pinion height
Backlash is too large. tooth ends . adjusting shim in order to bring drive pin-
ion close to crown gear.
B3M0319 -
B3M0323
Flank contact Backlash is too small. This may cause noise and stepped wear Reduce thickness of drive pinion height
on surfaces . adjusting shim in order to move drive
pinion away from crown gear.
I
B3M0320
83M0324
Toe contact This may cause chipping at toe. Adjust as for flank contact.
(Inside end contact)
Contact areas is small.
r- ,
.-
B3M0321 B3M0324
Heel contact (Outside end contact) This may cause chipping at heel ends . Adjust as for face contact.
Contact area is small.
B3M0322 B3M0323
Adjusting direction of drive pinion

Adjusting direction of crown gear
AT75
DRIVE PINION SHAFT
Automatic Transmissio n
4) If tooth contact is correct, mark the retainer

position and loosen it. After fitting the O-ring, screw
in the retainer to the marked position . Then tighten
the lock plate to the specified torque .
Tightening torque:
25 N~m (2.5 kgf-m, 18.1 ft-Ib)
(A) Lock plate
AT76
FRONT DIFFERENTIAL
21 . Front Differential S5,o,5z NOTE :

A : REMOVAL S5,o,5ZA,B housing .
1) Extract the torque converter clutch assembly.
<Ref . to AT-34 REMOVAL, Torque Converter
Clutch Assembly.>
NOTE :
pump shaft.
0
0 9) Wrap the axle shaft serration with vinyl tape.
0o -
o a~ °
`~=J
0 0
o
B3M2020
a \ I
I1I (A) Vinyl tape
10) Remove the differential side retainer with ST.

CAUTION:
Hold the differential case assembly by hand to
avoid damaging retainer mounting hole of the
n torque converter clutch case and speedometer
B3M2021
gears.
from stay. 11) Extract the axle shaft with ST1 and ST2.
NOTE : CAUTION :
Lift-up lever behind the connector and disconnect Do not reuse the circlip.
it from stay. ST1 499095500 REMOVER
4) Disconnect inhibitor switch from stay. ST2 499247300 INSTALLER
6) Remove the oil charger pipe . <Ref . to AT-28 i 1,\
- ,\\\
C_ ~`lj`~ ~ (: J .

---
transmission case sections `~ sTi '
CAUTION:
e Be careful not to damage the oil seal and ~ ST2
bushing inside the torque converter clutch G3M0956
12) Remove the differential assembly.
* Be careful not to lose the rubber seal .
AT77
FRONT DIFFERENTIAL
CAUTION: " Do not confuse the RH and LH oil seals.

9 Remove the seal pipe if it is attached. (Reus- " Keep the O-ring removed from the retainer.
ing is not allowed.) 5) Using ST, install the side retainers. <Ref . to
Be careful not to damage the retainer mount-
AT-77 ADJUSTMENT, Front Differential .>
ing hole of the torque converter clutch case.
B : INSTALLATION 55,o,5zA 6) Install the lock plate .
1) Install the differential assembly to the case, Tightening torque:
paying special attention not to damage the inside 25 N~m (2.5 kgf-m, 18.1 ft-Ib)
of the case (particularly, the differential side
retainer contact surface) . ca>
L _0
-o
B3M2062A
7) Install the seal pipe to the torque converter

clutch case.
(A) Differential assembly
CAUTION :
2) Install the circlip to the axle shaft, insert the Be sure to use a new seal pipe.
shaft into the differential assembly, and tap it into
position with a plastic hammer.
CAUTION :
* If no play is felt, check whether the shaft is
fully inserted . If shaft insertion is correct,
replace the axle shaft.
* Be sure to use a new circlip.
Thrust play:
0.3-0.5mm (0.012-0.020 in)
3) Wrap vinyl tape around the splined portion of
the axle shaft.
(A) Seal pipe
8) Install the rubber seal to the torque converter

clutch case .
CAUTION:
Be careful not to lose the rubber seal .
(A) Vinyl tape
4) Install the oil seal and outer race (taper roller

bearing) to the differential side retainer. Then
screw in the retainer and the O-ring after coating
the threads with oil .
CAUTION:
* Pay attention not to damage the oil seal lips .
AT78
FRONT DIFFERENTIAL

entire torque converter clutch case mating surface. (B
A)
Liquid gasket:
THREE BOND 1215
NOTE :
fitted in position. --
B3M1054A

13) Install oil cooler pipes. <Ref . to AT-29

14) Install the oil charger pipe with O-ring <Ref . to
AT-28 INSTALLATION, Oil Charger Pipe.>
hand .
(B) Rubber seal CAUTION :
10) Install the torque converter clutch case
assembly to the transmission case assembly, and Normal protrusion A:
secure with six bolts and four nuts . 50-55 mm (1.97-2.17 in)
CAUTION:
seal .
Tightening torque:
41 N-m (4.2 kg-m, 30.4 ft-Ib)

<Ref. to AT-34 INSTALLATION, Torque Converter
Clutch Assembly.>
C : DISASSEMBLY S5,o,5zA~
1) Using a press and ST, remove the taper roller
bearing.
11) Install air breather hose . ST 498077000 REMOVER
nector into stay.
AT79
FRONT DIFFERENTIAL
2) Secure the case in a vise and remove the the differential case (RH), and connect both cases.
crown gear tightening bolts, then separate the 3) Install the crown gear and secure by tightening
crown gear, case (RN) and case (LH) . the bolt.
Standard tightening torque:
62 N~m (6.3 kgf-m, 45.6 ft-Ib)
(A) Crown gear

(B) Differential case (RH)
(C) Differential case (LH)
(A) Crown gear
3) Pull out the straight pin and shaft, and remove (B) Differential case (RN)
the differential bevel gear, washer, and differential (C) Differential case (LH)
bevel pinion .
4) Measurement of backlash (Selection of washer)
Measure the gear backlash with ST1 and ST2, and
insert ST2 through the access window of the case.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
NOTE :
Measure the backlash by applying a pinion tooth
between two bevel gear teeth .
Standard value:
0.13 - 0.18 mm (0.0051 - 0.0071 in)
(A) Differential case (RN)
D : ASSEMBLY 55,o,5zAO2
1) Install the washer, differential bevel gear and
differential bevel pinion in the differential case
(RN) . Insert the pinion shaft, and fit the straight pin.
NOTE :
Install straight pin from reverse direction .
(A) Differential case (RN)
2) Install the washer and differential bevel gear to

the differential case (LH) . Then put the case over
AT80
FRONT DIFFERENTIAL
5) Using ST, install taper roller bearing. CAUTION :

ST 398487700 DRIFT Thoroughly remove the liquid gasket from
the case mating surface beforehand .
9 Use an old gasket or an aluminum washer so
as not to damage the mating surface of the
housing.
IST I Tightening torque:
41 N~m (4.2 kqf-m, 30.4 ft-Ib)
(A)
B3M2067A
(A) Taper roller bearing
E: INSPECTION 5570152A70
9 Check each component for harmful cuts, dam-

age and other faults .
Measure the backlash and adjust to within
specifications . 4) Rotate the drive pinion several times with ST1
<Ref . to AT-81 ADJUSTMENT, Front Differential .> and ST2.
F : ADJUSTMENT S570152A07
1) Using ST, screw in the retainer until light con-
tact is felt . --' '~ ST2
NOTE :
Screw in the RH side slightly deeper than the LH ST1
side .
-,
tf
~
r .a
G3M0384
5) Tighten the LH retainer until contact is felt while

rotating the shaft. Then loosen the RH retainer.
Keep tightening the LH retainer and loosening the
RH retainer until the pinion shaft can no longer be
turned . This is the "zero" state.
@
2) Remove the oil pump housing.
3) Install the oil pump housing assembly to the
°~ r
torque converter clutch case, and secure evenly by - o
tightening four bolts . 0
- ~ I
(A)
B3M2068A
(A) Retainer
AT81
FRONT DIFFERENTIAL
6) After the "zero" state is established, back off the 7) Turn the drive pinion several rotations with ST1
LH retainer 3 notches and secure it with the lock and check to see if the backlash is within the stan-
plate . Then back off the RH retainer and retighten dard value with ST2, ST3, ST4 and ST5.
until it stops. Repeat this procedure several times. NOTE :
Tighten the RH retainer 1-3/4 notches further. This After confirming that the backlash is correct, check
sets the preload. Finally, secure the retainer with the tooth contact.
its lock plate.
(a ) ST2 498247001 MAGNET BAS E
ST3 498247100 DIAL GAUGE
r ST4 499787500 ADAPTER WRENCH
ST5 498255400 PLATE
o
_ O° ~ o Backlash :
0.13 - 0.18 mm (0.0051 - 0.0071 in)
83M2062A
(A) Lock plate

NOTE:
Turning the retainer by one tooth changes the
backlash about 0.05 mm (0.0020 in).
0.05 mm
~ --(0 .0020 in) ~,
p--- -I
J CO)
- -- O --
Cr
H3M1256B
AT82
CONTROL VALVE BODY ASSEMBLY
22. Control Valve Body 9) Remove the inhibitor switch .
Assembly S5,o593 NOTE :

For removal procedures of inhibitor switch, refer to
A : REMOVAL S5f0593A18 "AT" sections for each model .
Clutch Assembly .>
NOTE :
pump shaft.
B3M1087Bj
(A) Inhibitor switch
10) Prepare a block of wood. Turn the transmis-

sion case over, and support it with the block of
wood .
NOTE:
Turn the transmission case in the direction the
inhibitor switch was installed.
11) Remove the oil pan .
NOTE :
from stay. Use a scraper to remove oil pan.
NOTE:
Lift-up lever behind the connector and disconnect
it from stay.
4) Disconnect inhibitor switch from stay.
6) Remove the oil charger pipe . <Ref . to AT-28 D
REMOVAL, Oil Charger Pipe .> SOD
7) To plug the hole, wrap vinyl tape around the
nipple attached to the air breather hose . B3M2022 1
AT83
12) Disconnect the harness connectors for the B : INSTALLATION 55,059

solenoids, duty solenoids, ATF temperature sensor
and the ground cord . 1) Set the select lever in range "N".
2) Align the groove of the manual valve to the
protrusion of the manual lever, and then install the
control valve body assembly.
Tightening torque:
8 N~m (0 .8 kgf-m, 5.8 ft-Ib)
(A) Lock-up duty solenoid (Blue)

(A) Short bolts
(B) Long bolts
(I) Transfer duty solenoid (Brown) 3) Tighten the valve body to the specified torque .
CAUTION :
13) Remove the control valve body assembly . Tighten the control valve mounting bolts
evenly.
Tightening Torque:
8 N~m (0.8 kgf-m, 5.8 ft-Ib)
4) Connect all connectors .

AT84
5) Attach the magnet at the specified position 10) Install inhibitor switch and adjust the inhibitor
switch by referring to Supplement AT section.
o nector into stay.
(B) o
o
(B
A)
\O ~
\ \ \ B3M 11058 l-\ /
(A) Magnet
(B) Oil pan
83M1054A
6) Apply proper amount of liquid gasket to the (A) Transmission harness

entire oil pan mating surface. (B) Inhibitor switch harness
Liquid gasket:
THREE BOND 1217B 12) Insert the input shaft while turning lightly by
hand.
CAUTION :
50 - 55 mm (1.97 - 2.17 in)
7) Install the oil pan to the transmission case

assembly, and secure with 20 bolts.
NOTE :
Tighten the bolts evenly .
Tightening torque: <Ref . to AT-34 INSTALLATION, Torque Converter
4.9 N~m (0.50 kgf-m, 3.6 ft-Ib) Clutch Assembly.>
C : DISASSEMBLY 5510593A06
1) Remove oil strainer from lower control valve

body.
U
0
B3M2022

position.
INSTALLATION, Air Breather Hose.>
AT 85
2) Remove the duty solenoids, solenoids and sen- o 00 0

sor from the lower valve body. Sp p o ao . c
r
o o
o 0 o do
o ~° °o(C~QD 0 0
0 0
o 0 0 oa
o
(A) Ij
o ~o ° op p o ~B)
L
O
O a
O 0 4 p
B3M1132C
(A) Upper separator plate

(B) Side plate
(A) Lock-up duty solenoid (Blue) 6) Remove valve springs from upper valve body .
(B) Low clutch timing solenoid (Gray) 7) Using air compressor, remove accumulator pis-
(C) Line pressure duty solenoid (Red) ton from upper valve body .
3) Remove the upper-lower valve body tightening

bolts .
D: ASSEMBLY 5510593A02
1) Install accumulator pistons, valve springs and

steel balls to upper valve body.
NOTE :
Insert steel balls in their proper positions.
4) Separate the control valve body.
CAUTION:
* Do not lose the ten (10) steel balls contained
in the upper valve body and middle valve body.
* Do not lose strainers contained in the lower
valve body.
NOTE:
During ordinary servicing, clean the control valve
bodies in this condition, without further disassem-
bly. In the event of a seized clutch or other
problem, disassemble the control valve bodies
(A) Steel balls
further, and clean the component parts.
(B) Valve spring
5) Remove upper separator plate from middle
valve body.
AT86
2) Install support plate and upper separator plate 4) Install three filters to lower valve body.
to middle valve body. CAUTION:
NOTE: Pay attention to the location of filters .
Align the hole in side plate with the hole in sepa-
rator plate .
Tightening torque:
8 N~m (0.8 kgf-m, 5.8 ft-Ib)
o__300
,. , 0 c
Soo o a oo~ o
/
= D p ~O
U
Q O
O ~00 °~
o ° O
- 0 0
00 a 00 0
o
0
0 B)
o ° °0 0 (A) Strainer
a IQ
o °
(B) Lower valve body
0 0 0 0
B3M1132C 5) Install lower separate plate to lower valve body .
(A) Upper separator plate

(B) Side plate
J
3) Install steel balls to middle valve body.

~o o
0 `'~ . u °0p
o ~ o o~ . o
NOTE : 0O0 ~ ~ ~ r y
Insert steel balls in their proper positions. o o

0 o
V ~ V
~ ` y~ I
-o
o
i(~»1~~i--~-° ~~ ~' 0 _- (B)
e3, n B)
~>»» »>i~~ ~~ yl0

o J0 ~ B3M1137BI
0 nt=o
U 7~11JJ tr (A) Lower separator plate
01 ~ o~~
(B) Lower valve body
o aJ13~ (A)
6) Temporarily assemble valve body.
°1(~ °00 J~N~IS
0 0
coo
0~ 0 ~np00 CAUTION :
B3M1135C Be careful not to drop the middle valve body
and upper body interior steel ball, or the lower
(A) Steel ball body filter.
(B) Middle valve body
AT87
7) Tighten bolts .
Tightening torque:
8 N~m (0.8 kgf-m, 5.8 ft-Ib)
(A) Short bolts

(B) Middle bolts
(C) Long bolt
(D) Reamer bolts
8) Install the sensor, solenoids and duty sole-

noids .
Tightening torque:
T 8 N~m (0.8 kgf-m, 5.8 ft-Ib)
(C) (D)
0 T
0 El
0 (A), (B) I
(E)
0
0 T L9
0
00
000
0 T (H)
0
0 u
T
(F)
B3M1039B

9) Install oil strainer to lower valve body .

Tightening torque:
8 N~m (D.8 kgf-m, 5.8 ft-Ib)
Make sure that each component is free of harmful

gouges, cuts, or dust .
AT88
HIGH CLUTCH AND REVERSE CLUTCH
23. High Clutch and Reverse 10) Take out the high clutch and reverse clutch
assembly .
Clutch S5f0213
CAUTION:
A : REMOVAL .,o2,.,8 Be careful not to lose thrust needle bearing.
<Ref . to AT-34 REMOVAL, Torque Converter A
Clutch Assembly .> e
2) Remove the input shaft. o-" ( (( ~~) ~ I
B3M1070C
(A) High clutch and reverse clutch assembly

(B) Thrust needle bearing
11) Take out the high clutch hub and the thrust
bearing .
3) Disconnect transmission harness connector o
from stay. (A)
O
NOTE:
it from stay.
5) Disconnect the air breather hose . ry
REMOVAL, Oil Charger Pipe .> 1111
7) Remove the oil cooler inlet and outlet pipes. B3M1071C
8) Separation of torque converter clutch case and (A) High clutch hub
transmission case sections (B) Thrust needle bearing
CAUTION:
9 Be careful not to lose the rubber seal .
NOTE:
housing.
9) Remove the oil pump housing.

<Ref . to AT-63 REMOVAL, Oil Pump .>
AT89
NOTE :
1) Install the high clutch hub and thrust needle fitted in position .
bearing.
Attach the thrust needle bearing to the hub with
vaseline and install the hub by correctly engaging
the splines of the front planetary carrier.
(c)
(D)
V
(B) I ~ I~ 0
(a) (A) THREE BOND (Part No . 1215)

(B) Rubber seal
- ' ' B3M2035A
6) Install the torque converter clutch case assem-
(A) High clutch hub bly to the transmission case assembly, and secure
(B) Thrust needle bearing with six bolts and four nuts .
(C) Up side CAUTION :
(D) Down side
2) Install the high clutch assembly. torque converter clutch case bushing and oil
seal .
NOTE :
Correctly engage the high clutch hub and clutch Tightening torque:
splines. 41 N~m (4.2 kgf-m, 30.4 ft-Ib)
(A) ° ~ (B)
O (D)
D
O
o ~o
O
83M2036A
(A) High clutch and reverse clutch assembly 7) Install air breather hose.
(B) Thrust needle bearing 8) Insert inhibitor switch and transmission connec-
(C) Up side tor into stay.
(D) Down side
3) Adjust total end play. <Ref . to AT-68 (A)

ADJUSTMENT, Oil Pump.>
4) Install the oil pump housing assembly.
5) Apply proper amount of liquid gasket to the - - , -
Liquid gasket:
THREE BOND 1215
B3M 1054A

AT90
9) Install oil cooler pipes . <Ref. to AT-29 2) Remove snap ring, and take out the retaining
INSTALLATION, Oil Cooler Pipes .> plate, drive plates and driven plates .
hand. ~~ ~ , ,
CAUTION :
Be careful not to damage the bushing. O
50 - 55 mm (1.97 - 2.17 in)
B3M1143B
(A) Snap ring
3) Using ST1 and ST2, remove snap ring .

ST2 498627100 SEAT
ST1
( A ) f-r`

Clutch Assembly.> -ill
ST2
C : DISASSEMBLY 5510213A06
1) Remove the snap ring, and take out the retain- B3M 1144C
ing plate, drive plates, driven plates .
(A) Snap ring
4) Take out clutch cover, spring retainer, high

clutch piston and reverse clutch piston .
(A) Snap ring
(A) Reverse clutch piston

(B) Cover
(C) Return spring
AT91
5) Remove seal rings and lip seal from high clutch 4) Install spring retainer to high clutch piston .
piston and reverse clutch piston .
(A)
(A
B)
B3M1149C
83M 1146C
(A) Return spring
(A) High clutch piston (B) High clutch drum
(B) Reverse clutch piston
5) Install ST to high clutch piston .
ST 498437000 HIGH CLUTCH PISTON
GAUGE
1) Install seal rings and lip seal to high clutch pis-
ton and reverse clutch piston .
2) Install high clutch piston to reverse clutch pis-
ton .
(A
B)
6) Install cover to high clutch piston .
CAUTION:
B3M1146C
Be careful not to fold over the high clutch pis-
(A) High clutch piston ton seal during installation .
(B) Reverse clutch piston 7) Using ST1 and ST2, install snap ring .
3) Install reverse clutch to high clutch drum . NOTE :
NOTE : After installing snap ring, remove STs.
Align the groove on the reverse clutch piston with ST1 398673600 COMPRESSOR
the groove on the high clutch drum during installa- ST2 498627100 SEAT
tion. ST3 498437000 HIGH CLUTCH PISTON
GAUGE
(A)
ST1
O
ST3
r
r f
`D (B)
ST2
B3M1148C
B3M0973C
(A) Reverse clutch piston
(B) High clutch drum
AT 92
8) Install driven plate, drive plate and retaining High clutch retaining plate
plate to high clutch drum . Pan No . Thickness mm (in)
NOTE: 31567AA710 4 .7 (0 .185)
Install thicker driven plate on the piston side . 31567AA720 4.8 (0 .189)
31567AA730 4.9 (0 .193)
31567AA740 5.0 (0 .197)
31567AA670 5.1 (0.201)
31567AA680 5.2 (0.205)
31567AA690 5.3 (0.209)
31567AA700 5.4 (0.213)
13) Install driven plate, drive plate, retaining plate

and snap ring.
B3M1151
9) Install snap ring to high clutch drum .

10) Apply compressed air intermittently to check
for operation.
B3M 1153
14) Apply compressed air intermittently to check

for operation.
11) Measure the clearance between the retaining

NOTE:
Do not press down retaining plate during clearance
measurements.
Standard value:
0.8 - 1.1 mm (0.031 - 0.043 in)
Allowable limit :
1 .5 mm (0.059 in)
(A)
B3M1152B
(A) Thickness gauge
12) If specified tolerance limits are exceeded,

select a suitable high clutch retaining plate .
AT93
15) Measure the clearance between the retaining

NOTE :
Do not press down retaining plate during clearance
measurements.
Standard value:
0.5 - 0.8 mm (0.020 - 0.031 in)
Allowable limit:
1.2 mm (0.047 in)
(A)
B3M115481
(A) Thickness gauge
16) If specified tolerance limits are exceeded,

select a suitable high clutch retaining plate.
Reverse clutch retaining plates
31567AA910 4.0 (0 .157)
31567AA920 4.2 (0 .165)
31567AA930 4.4 (0 .173)
31567AA940 4.6 (0 .181)
31567AA950 4.8 (0.189)
31567AA960 5.0 (0 .197)
31567AA970 5.2 (0 .205)
Drive plate facing for wear and damage

Snap ring for wear, return spring for setting and
breakage, and snap ring retainer for deformation
Lip seal and lathe cut ring for damage
Piston and drum check ball for operation
Adjust total end play. <Ref . to AT-68
ADJUSTMENT, Oil Pump .>
AT94
PLANETARY GEAR AND LOW CLUTCH
24. Planetary Gear and Low NOTE :

Clutch S5,02,2 housing .
A : REMOVAL SS,oz,ZA,e
Clutch Assembly .>
o /1I
0
0 11) Place two wooden blocks on the workbench,

n and stand the transmission case with its rear end
facing down .
CAUTION :
B3M2021 * Be careful not to scratch the rear mating sur-
face of the transmission case.
3) Disconnect transmission harness connector Note that the parking rod and drive pinion
from stay. protrude from the mating surface.
NOTE :
from stay.
O~
5) Disconnect the air breather hose . <Ref . to IJ
6) Remove the oil charger pipe, and remove the
J,
O-ring from the flange face . Attach the O-ring to the 55 mm
pipe . <Ref. to AT-28 REMOVAL, Oil Charger (2 .17 in)
Pipe.> 133M 1064A
<Ref . to AT-29 REMOVAL, Oil Cooler Pipes.> 12) Remove the oil pump housing .
8) Remove rear vehicle speed sensor, and sepa- CAUTION:
rate the transmission case and extension case . Be careful not to lose the total end play adjust-
<Ref . to AT-36 REMOVAL, Extension Case .> ing thrust washer.
9) Remove reduction driven gear.
REMOVAL, Reduction Driven Gear.>
WITH VTD <Ref . to AT-48 WITH VTD, REMOVAL,
10) Separation of torque converter clutch case
and transmission case sections
CAUTION :
* Be careful not to lose the rubber seal . (A) Oil pump housing
AT95
13) Take out the high clutch and reverse clutch 17) Take out retaining plate, drive plate and driven
assembly. <Ref . to AT-89 REMOVAL, High Clutch plate of 2-4 brake .
and Reverse Clutch .>
14) Take out the front sun gear and the thrust O
%-- ,
bearing.
. 0 B3M1075
(B) II II 18) Take out the thrust needle bearing, planetary

B3M1072C
gear assembly and the low clutch assembly .
(A) Front sun gear

15) Pull out leaf spring .

CAUTION :
Be careful not to bend leaf spring during
removal.
NOTE :
Remove it while pressing down on lower leaf
spring .
B : INSTALLATION 55,o2,2A
(A)
1) Install planetary gear and low clutch assembly
to transmission case .
O Install carefully while rotating the low clutch and
planetary gear assembly slowly paying special
S attention not to damage the seal ring .
O(B) Imo/ °
83M1104C
(A) Leaf spring

(B) Retaining plate
16) Remove snap ring and thrust needle bearing.
2) Install the 2-4 brake. <Ref. to AT-106

INSTALLATION, 2-4 Brake .>
(A) Snap ring

AT96
3) Install leaf spring of 2-4 brake. 6) Install the high clutch assembly.
NOTE: NOTE :
Be careful not to mistake the location of the leaf Correctly engage the high clutch hub and clutch
spring to be inserted . splines.
O~ I (a) ° ~ (B)
o~~ ~ (v)
0
o
o
oBl o ~ o, C
' B3M1104C 83M2036A
(A) Leaf spring (A) High clutch and reverse clutch assembly
(B) Retaining plate (B) Thrust needle bearing
(C) Up side
4) Install thrust needle bearing and snap ring. (D) Down side
NOTE :
Install thrust needle bearing in the correct direc- 7) Install the high clutch hub and thrust needle
bearing .
tion .
NOTE :
tion.
(A) Snap ring

(C) Up side
(D) Down side
5) Install front sun gear and thrust needle bearing.

(A) High clutch hub
(C) Up side
(D) Down side
8) Install oil pump housing assembly with gasket .

9) Install torque converter clutch case . <Ref . to
AT-60 INSTALLATION, Torque Converter Clutch
Case .>
nector into stay .
12) Install oil cooler pipes . <Ref . to AT-29
AT 97
13) Install the oil charger pipe with O-ring . <Ref. to

hand .
CAUTION :
50-55mm11_97-2.17 in)
(A) Front planetary carrier

(B) Needle bearing
(C) Low clutch drum
3) Take out rear sun gear.

Clutch Assembly.>
C : DISASSEMBLY SS,oz,zAOs
1) Remove snap ring from the low clutch drum .
(A) Rear sun gear
(B) Rear planetary carrier
4) Take out rear planetary carrier, washer and

u thrust needle bearing.
u. ,
(A)
B3M1156C
(A) Snap ring

e)
(B) Low clutch drum
2) Take out front planetary carrier and thrust

needle bearing from low clutch drum. B3M1159B
(A) Rear planetary carrier

(B) Low clutch drum
AT98
5) Take out rear internal gear.

(A)
c )
(A
o~~p
o a a O
0 0
B3M0960C
B3M1160BI (A) Apply compressed air

(A) (B) One-way clutch inner race
Rear internal gear
(B) Low clutch drum
9) Remove the one-way clutch inner race .
6) Remove the snap ring from the low clutch drum 10) Remove the one-way clutch after taking out
the snap ring.
(A)
)~-"
r
r
i
B3M1163C
(B) Low clutch drum (A) Snap ring

(B) Plate
7) Compress the spring retainer, and remove the (C) one-way crutch
snap ring from the low clutch drum, by using ST1
and ST2 . 11) Remove the needle bearing after taking out
ST1 498627100 SEAT the snap ring .
(B)
(A)
B3M1164C
(A) Needle bearing

(B) Snap ring
(A) Snap ring '
(B) Low clutch drum
D: ASSEMBLY 55,o2,zAOz
8) Install the one-way clutch inner race to the low 1) Install lathe cut seal ring to low clutch piston .
clutch drum, and apply compressed air to remove 2) Fit the low clutch piston to the low clutch drum .
the low clutch piston .
AT99
ST3 498437100 LOW CLUTCH PISTON

> GUIDE
ST2
ST3
ST1
B3M11658
(A) Low clutch piston

B3M 1168D
(B) Low clutch drum
3) Install spring retainer to low clutch piston 6) Install the dish plate, driven plates, drive plates,
and retaining plate, and secure with the snap ring .
NOTE:
Pay attention to the orientation of the dish plate .
(A)
O(c) O
c
B3M1166B1
I I I ~ t I r
V. ~ r J%
(A) Spring retainer
(B) Low clutch drum (B)
83M1169C
4) Install ST to low clutch drum .

(A) Snap ring
ST 498437100 LOW CLUTCH PISTON
(B) Low clutch drum
GUIDE
(C) Dish plate
(D) Low clutch piston side
7) Check the low clutch for operation.

ST Set the one-way clutch inner race, and apply com-
pressed air for checking .
(A)
B3M11678
5) Set the cover on the piston with a press using

ST1 and ST2, and attach the snap ring . r~ll
.-~--( B )
a U
0 0 0 ~ io
CAUTION : o u o
Be careful not to fold cover seal during instal- B3M0960D
lation .
(A) Apply compressed air
NOTE: (B) Low clutch drum
After installing snap ring, remove ST1, ST2 and
ST3 . 8) Checking low clutch clearance
Measure the gap between the retaining plate and
ST1 498627100 SEAT the operation of the low clutch .
AT-1 00
NOTE :
Before measuring clearance, place the same thick-
ness of shim on both sides to prevent retaining
plate from tilting . (A)
If the clearance is out of the specified range, select
a proper retaining plate so that the standard clear-
ance can be obtained.
Standard value:
0.7 - 1.1 mm (0.028 - 0.043 in) B>
Allowable limit: B3M1160C

1.6 mm (0.063 in)
(A) Rear internal gear
(B) Low clutch drum
11) Install thrust needle bearing .

NOTE:
tion .
(A)
(A) Thickness gauge

(B) Low clutch drum
Available retaining plates B)

31567AA830 3.8 (0 .150) B3M1171 B
31567AA840 4.0 (0 .157)
31567AA850 4 .2 (0 .165) (A) Thrust needle bearing
(B) Low clutch drum
31567AA860 4.4 (0 .173)
31567AA870 4.6 (0.181) 12) Install washer to rear planetary carrier.
9) Install washer to rear internal gear. NOTE :
Make sure washer tooth is inserted into hole on
planetary carrier.
(B)
(A) (A)
I oUo
B3M1170C
(A) Rear internal gear

B3M1172C
(B) Washer
(A) Washer
10) Install rear internal gear. (B) Rear planetary carrier
13) Install rear planetary carrier to low clutch

drum.
AT-1 01
(A)
(A)
(C)
i~uu, o~
o
(D)
B)
B3M1159B B3M1174C
(A) Rear planetary carrier (A) Thrust needle bearing

(B) Low clutch drum (B) Front planetary carrier
(C) Rear sun gear side
14) Install thrust needle bearing to rear planetary (D) Front planetary carrier side
carrier .
17) Install front planetary carrier to low clutch
NOTE :
drum .
tion . (c)
(a) itffbj
((~ (o)
O (s)
--
B3M2039A
B3M1173 Front planetary carrier

Needle bearing
15) Install rear sun gear. (C) Up side
NOTE: (D) Down side
Pay attention to the orientation of the rear sun
18) In stall snap ring to low clutch drum .
gear.
(A) Rear sun gear " '

(B) Front planetary carrier
Rear planetary carrier '(B)
19) Install the needle bearing, and secure with the
16) Install thrust needle bearing to front planetary
snap ring .
carrier.
NOTE :
Pay attention to the orientation of the thrust needle
bearing.
AT-1 02
(B)
B3M1164C
(A) Needle bearing

(B) Snap ring
20) Install the one-way clutch, one-way clutch

inner race and plate, and secure with the snap ring.
NOTE :
Set the inner race . Make sure that the forward
clutch is free in the clockwise direction and locked
in the counterclockwise direction, as viewed from
the front of the vehicle .
(A) Locked
(B) Free
E: INSPECTION SS,oz,zA,o
" Snap ring for wear, return spring for breakage or
setting, and spring retainer for deformation
Lip seal and lathe cut seal ring for damage
Piston check ball for operation
" Measure the total end play and adjust to within
specifications .
<Ref . to AT-68 ADJUSTMENT, Oil Pump .>
AT-1 03
2-4 BRAKE
25. 2-4 Brake S5f0205

NOTE :
A : REMOVAL S5f0205A18 housing .
Clutch Assembly.>
11) Place two wooden blocks on the workbench,

and stand the transmission case with its rear end
facing down .
CAUTION :
3) Disconnect transmission harness connector * Be careful not to scratch the rear mating sur-
from stay. face of the transmission case.
Note that the parking rod and drive pinion
NOTE : protrude from the mating surface.
it from stay.
6) Remove the oil charger pipe . <Ref. to AT-28
7) Remove the oil cooler inlet and outlet pipes with
washers . <Ref . to AT-29 REMOVAL, Oil Cooler 55 mm
Pipes.> (2 .17 in)
8) Remove rear vehicle speed sensor, and sepa- B3M 1064A I

rate the transmission case and extension case .
<Ref . to AT-36 REMOVAL, Extension Case.> 12) Remove the oil pan and control valve body .
9) Remove reduction driven gear. <Ref . to AT-83 REMOVAL, Control Valve Body.>
WITHOUT VTD <Ref . to AT-48 WITHOUT VTD, 13) Remove the oil pump housing.
REMOVAL, Reduction Driven Gear.> CAUTION:
WITH VTD <Ref . to AT-48 WITH VTD, REMOVAL, Be careful not to lose the total end play adjust-
Reduction Driven Gear.> ing thrust washer.
10) Separation of torque converter clutch case
and transmission case sections
CAUTION :
e Be careful not to damage the oil seal and
9 Be careful not to lose the rubber seal . 0
0
B3M 1068
AT-1 04
2-4 BRAKE
14) Remove 2-4 brake seal . 18) Remove snap ring and thrust needle bearing .
o
C
o iu . .
O' a
0 v \
0 l
d
U B3M2087
15) Take out the high clutch and reverse clutch (A) Snap ring
assembly. <Ref. to AT-89 REMOVAL, High Clutch (B) Thrust needle bearing
16) Take out the front sun gear and the thrust 19) Take out retaining plate, drive plate and driven
bearina. plate of 2-4 brake.
J
// / f~~ ~~1 . \C O
o
I'
B I (1
B3M1075
B3M1072C
(A) Front sun gear 20) Take out the thrust needle bearing, planetary
(B) Thrust bearing gear assembly and the low clutch assembly.

CAUTION :
removal.
NOTE :
spring .
I B3M1076
(A)
B3M1104C
(A) Leaf spring

(B) Retaing plate
AT-1 05
2-4 BRAKE
21) Remove snap ring . 24) Separate 2-4 brake piston and piston retainer.
(A) (B)
1
83M1080C
(A) Snap ring (A) 2-4 brake piston

(B) 2-4 brake piston (B) 2-4 brake piston retainer
22) Take out 2-4 brake return spring . B : INSTALLATION 5510205A11
1) Install 2-4 brake piston to 2-4 brake piston

retainer.
(A) (B)
o 0 0 ° o
~~°ooooo
o~o
m
o ~ I UI ~ - ~n I o B3M1078
23) Take out 2-4 brake piston and piston retainer. 1

B3M1080C
CAUTION :
When removing the brake piston 2-4 and piston (A) 2-4 brake piston
retainer, be careful not to rub or bump them (B) 2-4 brake retainer
against the transmission case.
2) Install 2-4 brake piston and retainer to transmis-
(A)
sion case.
CAUTION:
Align the hole in the 2-4 brake seal of transmis-
sion case with the hole in 2-4 brake piston
retainer during installation .
J o
(A)
I ( B) °
'' o 0 0 0
0 7
~ I OCS~000
B3M1079C
(A) 2-4 brake piston

(B) 2-4 brake piston retainer
B
{ o o- 0 0
~n000 rJ
0 4 83M1079C
(A) 2-4 brake piston

(B) 2-4 brake piston retainer
AT-1 06
2-4 BRAKE
3) Install 2-4 brake piston return spring to trans- 7) Install 2-4 brake oil seal to transmission case .
mission case . NOTE :
Be sure to use a new one .
o OI a
v \ /
o O
4) Position snap ring in transmission . Using ST, B3M2087
press the snap ring into place. 8) After all 2-4 brake component parts have been
ST 498677100 COMPRESSOR installed, blow in air intermittently and confirm the
operation of the brake.
5) Install planetary gear and low clutch assembly

Install carefully while rotating the low clutch and
attention not to damage the seal ring . <Ref . to
AT-96 INSTALLATION, Planetary Gear and Low
Clutch .>
6) Install pressure plate, drive plate, driven plate,
retaining plate and snap ring .
0
X
i 0
/B3OM1075
AT-1 07
2-4 BRAKE
9) Measure the clearance between the retaining 11) Install thrust needle bearing .
plate and the snap ring. NOTE :
NOTE : Install thrust needle bearing in the correct direc-
Select a retaining plate with a suitable value from tion .
the following table, so that the clearance becomes
the standard value .
Standard value:
0.8 - 1.2 mm (0.031 - 0.047 in)
Allowable limit:
1.5 mm (0.059 in)
o ~~.
-=
o (A) Snap ring

(C) Up side
o (D) Down side
o \o 12) Install front sun gear and thrust needle bear-

B3M0980
ing .
NOTE :
Available retaining plates Install thrust needle bearing in the correct direc-
Part No . Thickness mm (in) tion.
31567AA610 5.6 (0 .220)
31567AA620 5.8 (0 .228)
31567AA630 6.0 (0 .236)
31567AA640 62 (0 .244)
31567AA650 6.4 (0 .252)
31567AA660 6.6 (0 .260)
10) Install leaf spring of 2-4 brake .

NOTE :
Be careful not to mistake the location of the leaf
spring to be inserted .
(A) Front sun gear
(A)
(C) Up side
(D) Down side
O 13) Install the high clutch assembly. <Ref. to

AT-90 INSTALLATION, High Clutch and Reverse
Clutch .>
OMB)
B3M1104C
(A) Leaf spring

(B) Retaining plate
AT-1 08
2-4 BRAKE
14) Secure the housing with two nuts . CAUTION :

Tightening torque: When installing, be careful not to damage the
T 41 N~m (4.2 kgf-m, 30.4 ft-Ib)
seal .
Tightening torque:
41 N-m (4.2 kgf-m, 30.4 ft-Ib)
B3M1068
15) Install the control valve body and oil pan.

<Ref . to AT-84 INSTALLATION, Control Valve
Body.>
16) Apply proper amount of liquid gasket to the 18) Install air breather hose . <Ref . to AT-27
entire torque converter clutch case mating surface. INSTALLATION, Air Breather Hose .>
Liquid gasket: nector into stay.
THREE BOND 1215 20) Install the oil cooler pipes. <Ref . to AT-29
NOTE: INSTALLATION, Oil Cooler Pipes .>
Make sure that the rubber seal and seal pipe are 21) Install the oil charger pipe with O-ring . <Ref . to
AT-28 INSTALLATION, Oil Charger Pipe.>
fitted in position .
hand .
CAUTION:
50 - 55 mm (1.97 - 2.17 in)
o
- A
A
' U
(A) Rubber seal
(B) Seal pipe
\~ 0o
assembly to the transmission case assembly, and
secure with six bolts and four nuts . B3M1050E

Clutch Assembly.>
C: INSPECTION .,o
" Snap ring for wear and spring retainer for defor-
mation
Lip seal and lathe cut seal ring for damage
" Measure the total end play and adjust to within
Pump.>
AT-1 09
ONE-WAY CLUTCH
26. One-way Clutch 55,°2,5 9) Remove rear vehicle speed sensor.
A: REMOVAL SS,oz,5A,8
<Ref. to AT-34 REMOVAL, Torque Converter
Clutch Assembiy.>
0 1
.,
I/ ) n
n
' ~ 83M2021

from stay.
NOTE :
it from stay. (A) Rear vehicle speed sensor
4) Disconnect inhibitor switch connector from stay. 10) Separate transmission case and extension
5) Disconnect the air breather hose . <Ref . to case sections . <Ref . to AT-36 REMOVAL, Exten-
AT-27 REMOVAL, Air Breather Hose .> sion Case.>
6) Remove the oil charger pipe . <Ref. to AT-28 11) Remove the reduction driven gear.
REMOVAL, Oil Charger Pipe .> WITHOUT VTD <Ref . to AT-48 WITHOUT VTD,
7) Remove the oil cooler inlet and outlet pipes. REMOVAL, Reduction Driven Gear.>
<Ref . to AT-29 REMOVAL, Oil Cooler Pipes.> WITH VTD <Ref . to AT-48 WITH VTD, REMOVAL,
8) Separation of torque converter clutch case and Reduction Driven Gear.>
transmission case sections 12) Remove the reduction drive gear. <Ref . to
AT-47 REMOVAL, Reduction Drive Gear.>
CAUTION :
9 Be careful not to damage the oil seal and and stand the transmission case with its rear end
bushing inside the torque converter clutch facing down .
* Be careful not to lose the rubber seal . CAUTION:
9 Be careful not to scratch the rear mating sur-
NOTE : face of the transmission case .
Separate these cases while tapping lightly on the Note that the parking rod and drive pinion
housing . protrude from the mating surface.
~1 J, -~
1 ~-,
55 mm
(2.17 in)
B3M1064A
AT-1 10
ONE-WAY CLUTCH
A utomatic Transmission
14) Remove oil pan . 19) Remove snap ring and thrust needle bearing .
15) Remove control valve assembly . -Ref
. to
AT-83 REMOVAL, Control Valve Body.>
CAUTION:
ing thrust washer.
III~~ ~,
B3M1074CI
(A) Snap ring

20) Take out retaining plate, drive plate and driven

plate of 2-4 brake.
B3 M1068
17) Take out the high clutch and reverse clutch J - - O / O

assembly. <Ref . to AT-89 REMOVAL, High Clutch
CAUTION:
removal.
/O
NOTE:
3M1075
spring . 21) Take out the thrust needle bearing, planetary
gear assembly . <Ref . to AT-95 REMOVAL, Plan-
O~ I etary Gear and Low Clutch .>
(A) 22) Remove snap ring.
O cB)~~ o
i B3M1104C
(A) Leaf spring

(B) Retaining plate
(A) Snap ring

(B) 2-4 brake piston
23) Take out 2-4 brake return spring, piston and

piston retainer. <Ref . to AT-104 REMOVAL, 2-4
Brake.>
AT-1 11
ONE-WAY CLUTCH
24) Pull out leaf spring . 27) Turn the transmission case upside down, and
then take out the socket bolts while holding the
CAUTION:
one-way clutch inner race with hand .
removal.
(A) Leaf spring

B : INSTALLATION 55,°2,5A
1) Install the one-way clutch inner race, spring
25) Remove snap ring . retainer and return spring .
2) Tighten eight socket head bolts from the rear
uu r
side of the transmission case .
Tightening torque:
25 Mm (2.5 kgf-m, 18.1 ft-Ib)
7 CAUTION:
O Be sure to tighten evenly.
O
I I \ ~~ ~ B3M1081C
(A) Snap ring
26) Take out retaining plate, drive plate, driven

plate and dish plate .
uu
3) Install thrust needle bearing .
NOTE:
O Place transmission case with the front facing up .
J
/7/
n B3M,o8z
AT-1 12
ONE-WAY CLUTCH
4) Installation of the low & reverse brake: Available retaining plates

Install dish plate, driven plates, drive plates, and a Pan No . Thickness mm (in)
retaining plate, and secure with a snap ring . 31667AA320 4.2 (0 .165)
NOTE: 31667AA330 4.5 (0 .177)
Pay attention to the orientation of the dish plate. 31667AA340 4 .8 (0 .189)
31667AA350 5.1 (0 .201)
` /`, 31667AA360 5.4 (0 .213)
31667AA370 5.7 (0 .224)
31667AA380 6.0 (0 .236)
Y
7) Install leaf spring of low and reverse brake.

J CAUTION :
Pay attention to the direction and position of
0 leaf spring during installation .
B3M1081C
(A) Snap ring
5) Apply compressed air intermittently to check for

operation.
(A) Leaf spring
8) Install 2-4 brake piston, retainer and return

spring to transmission case . <Ref . to AT-106
INSTALLATION, 2-4 Brake .>
9) Position snap ring in transmission . Using ST,
6) Check the clearance . (Selection of retaining press the snap ring into place.
ST 498677100 COMPRESSOR
plate)
NOTE :
Before measuring clearance, place the same thick-
plate from tilting .
Standard value:
0.7 - 1.2 mm (0.028 - 0.047 in)
Allowable limit:
2.2 mm (0.087 in)
0
- ~-.
L o 10) Install planetary gear and low clutch assembly
Ii
Install carefully while rotating the low clutch and
\~O .n io attention not to damage the seal ring. <Ref . to
-- - AT-96 INSTALLATION, Planetary Gear & Low
^ O
Clutch .>
83M0977
AT-1 13
ONE-WAY CLUTCH
Automatic Transmiss io n
11) Install pressure plate, drive plate, driven plate, 14) Install snap ring and thrust needle bearing.
retaining plate and snap ring . NOTE :
J tion.
' 0 i 0
/ B3M1075
O
12) After all 2-4 brake component parts have been

installed, blow in air intermittently and confirm the
operation of the brake . (A) Snap ring
(C) Up side
(D) Down side
15) Install front sun gear and thrust needle bear-

ing.
NOTE :
tion .
13) Install leaf spring of 2-4 brake .

NOTE :
Be careful not to mistake the location of the leaf
O~ I
(A)
(A) Front sun gear

O
S (C) Up side
IV (D) Downside
O(B)
r
%B3M1104C
(A) Leaf spring

(B) Retaining plate
AT-1 14
ONE-WAY CLUTCH
16) Install the high clutch hub and thrust needle NOTE:
bearing. Make sure that the rubber seal and seal pipe are
Attach the thrust needle bearing to the hub with fitted in position .
NOTE :
tion .
° (c)
(D)
V
(B) (A) THREE BOND (Pan No . 1215)
I (B) Rubber seal
I 23) Install the torque converter clutch case

B3M2035A
secure with six bolts and four nuts .
(A) High clutch hub CAUTION:
(B) Thrust needle bearing When installing, be careful not to damage the
(C) Up side torque converter clutch case bushing and oil
(D) Down side seal .
17) Install the high clutch assembly. <Ref . to Tightening torque:
AT-90 INSTALLATION, High Clutch and Reverse 41 N~m (4.2 kgf-m, 30.4 ft-Ib)
Clutch .> 24) Install reduction drive gear.
18) Install the oil pump housing assembly. 25) Install reduction driven gear.
19) Secure the housing with two nuts and the bolt. WITHOUT VTD <Ref . to AT-48 WITHOUT VTD,
Tightening torque: INSTALLATION, Reduction Driven Gear.>
T 41 N~m (4.2 kgf-m, 30.4 ft-Ib) WITH VTD <Ref . to AT-49 WITH VTD,
0
0
B3M1068
20) Install control valve assembly. <Ref . to AT-84

INSTALLATION, Control Valve Body Assembly.>
21) Install oil pan .
Liquid gasket:
THREE BOND 1215
AT-1 15
ONE-WAY CLUTCH
26) Install the extension case to the transmission C : DISASSEMBLY 5510215A06
case . <Ref. to AT-36 INSTALLATION, Extension

Case .> 1 . ONE-WAY CLUTCH INNER RACE 5570275A0601
27) Install the rear vehicle speed sensor. 1) Remove seal rings.
Tightening torque:
7 N~m (0.7 kgf-m, 5.1 ft-Ib) (A)
28) Install air breather hose . <Ref . to AT-27 0

nector into stay.
(B
A) V
B3M 1100C
(A) One way clutch inner race
P
(B) Seal rings
2) Using ST, remove needle bearing.
31W/
ST 398527700 PULLER ASSY
B3M1054A 2. ONE-WAY CLUTCH OUTER RACE

S510215A0602
(B) Inhibitor switch harness 1) Remove the one-way clutch after taking out the
snap ring .
30) Install the oil cooler pipes. <Ref. to AT-29
hand .
CAUTION :
50-55 mm (1.97-2.17 in)
(A) Snap ring
(B) Plate
(C) One-way clutch
O
2) Remove the needle bearing after taking out the

snap ring.
v
° -~v
(A),
B3M1050E

Clutch Assembly .> U~y
~ II II ~_ I ~ ~I I ~ B3M1164C
(A) Needle bearing

(B) Snap ring
AT-1 16
ONE-WAY CLUTCH
D : ASSEMBLY S5f0215A02 2. ONE-WAY CLUTCH OUTER RACE

5510215A0202
y . ONE-WAY CLUTCH INNER RACE 5510215A0201
1) Install the needle bearing, and secure with the
1) Using a press and ST, install the needle bear- snap ring .
ing to the inner race .
(A) Needle bearing

(B) Snap ring
2) Install two seal rings to one-way clutch inner
race . 2) Install the one-way clutch, one-way clutch inner
race and plate, and secure with the snap ring .
NOTE :
NOTE :
Apply vaseline to the groove of the inner race and
Set the inner race . Make sure that the forward
to the seal ring after installation, so that the seal clutch is free in the clockwise direction and locked
ring will not expand. in the counterclockwise direction, as viewed from
the front of the vehicle .
(A)
0
o 01
0 1~
(A)
(B)
(B) 0
0
B3M1100C o a o
u o
83M1175C
(A) One-way clutch inner race
(B) Seal rings (A) Locked
(B) Free
E : INSPECTION S5f0215Af0
o Make sure the snap ring is not worn and the seal
rings are not damaged .
o Measure the total end play and adjust to within
Pump.>
AT-1 17
LOW AND REVERSE BRAKE
27. Low and Reverse Brake 5570594

9) Remove rear vehicle speed sensor.
A : REMOVAL 5510594A78

Clutch Assembly .>
from stay.
NOTE :
it from stay.
5) Disconnect the air breather hose. <Ref . to
<Ref . to AT-29 REMOVAL, Oil Cooler Pipes .>
CAUTION:
9 Be careful not to damage the oil seal and (A) Rear vehicle speed sensor
case by the oil pump cover. 10) Separate transmission case and extension
* Be careful not to lose the rubber seal . case sections . <Ref. to AT-36 REMOVAL, Exten-
sion Case .>
NOTE: 11) Remove the reduction driven gear.
housing. REMOVAL, Reduction Driven Gear.>
WITH VTD <Ref . to AT-48 WITH VTD, REMOVAL,
12) Remove the reduction drive gear. <Ref . to
AT-50 REMOVAL, Reduction Drive Gear.>
and stand the transmission case with its rear end
facing down .
CAUTION:
* Be careful not to scratch the rear mating sur-
face of the transmission case .
Note that the parking rod and drive pinion
protrude from the mating surface .
0~
JJ
55 mm
(2 .17 in)
B3M1064A
AT-1 18
14) Remove the oil pump housing . 20) Take out retaining plate, drive plate and driven
plate of 2-4 brake.
CAUTION :
ing thrust washer. J 0 / O
0 /B3M1075
O
21) Take out the thrust needle bearing, planetary

B3M1068
gear assembly. <Ref . to AT-95 REMOVAL, Plan-
etary Gear and Low Clutch .>
15) Remove oil pan .
16) Remove control valve assembly . <Ref . to 22) Remove snap ring .
AT-83 REMOVAL, Control Valve Body Assembly.>
17) Take out the high clutch and reverse clutch
assembly. <Ref . to AT-89 REMOVAL, High Clutch
CAUTION :
removal.
NOTE :
spring . (A) Snap ring
19) Remove snap ring and thrust needle bearing.
23) Take out 2-4 brake return spring, piston and
piston retainer. <Ref . to AT-104 REMOVAL, 2-4
(A) (B) Brake.>
CAUTION :
l ~ \\
rl u removal .
83M 1074C
(A) Snap ring

(A) Leaf spring
AT-1 19
25) Remove snap ring . 29) Take out the spring retainer, return spring and
low & reverse piston .
B : INSTALLATION S5f0594A71
1) Install the low and reverse piston .

Y
O CAUTION :
* Be careful not to tilt the piston when install-
ing.
* Be careful not to damage the lip seal .
O
/-B3M1081C
(A) Snap ring
26) Take out retaining plate, drive plate, driven

plate and dish plate.
u
o 2) Install return spring
/7/
n B3M,o82
27) Turn the transmission case upside down, and
then take out the socket bolts while holding the
one-way clutch inner race with hand .
3) Install spring retainer .
28) Take out the low & reverse piston by applying

compressed air.
4) Install the one-way clutch inner race.
AT-1 20
5) Tighten eight socket head bolts from the rear 9) Check the clearance . (Selection of retaining
side of the transmission case. plate)
Tightening torque: NOTE :
25 Mm (2.5 kgf-m, 18.1 ft-Ib) Before measuring clearance, place the same thick-
CAUTION : plate from tilting .
Be sure to tighten evenly.
Standard value:
0.7 - 1.2 mm (0.028 - 0.047 in)
Allowable limit:
2.2 mm (0.087 in)
o 0
'J=
-- ~~\
\o
6) Install thrust needle bearing.

NOTE :
Place transmission case with the front facing up. B3M0977
7) Installation of the low & reverse brake :

Install dish plate, driven plates, drive plates, and a Available retaining plates
retaining plate, and secure with a snap ring. Part No . Thickness mm (in)
31667AA320 4.2 (0 .165)
NOTE :
31667AA330 4.5 (0 .177)
Pay attention to the orientation of the dish plate.
31667AA340 4.8 (0 .189)
uu
31667AA350 5.1 (0 .201)
` /` . 31667AA360 5.4 (0 .213)
31667AA370 5.7 (0 .224)
v -
31667AA380 6.0 (0 .236)
O 10) Install leaf spring of low and reverse brake.

CAUTION :
Pay attention to the direction and position of
0 leaf spring during installation .
B3M1081C
(A) Snap ring
8) Apply compressed air intermittently to check for

operation .
(A) Leaf spring
11) Install 2-4 brake piston, retainer and return

spring to transmission case . <Ref . to AT-106
INSTALLATION, 2-4 Brake.>
AT 121
12) Position snap ring in transmission . Using ST, 16) Install leaf spring of 2-4 brake .
press the snap ring into place . NOTE :
ST 498677100 COMPRESSOR Be careful not to mistake the location of the leaf
O(B) ~~
13) Install planetary gear and low clutch assembly I 1 ~ I ~ i B3M1104C
to transmission case. (A) Leaf spring

Install carefully while rotating the low clutch and (B) Retaining plate
attention not to damage the seal ring . <Ref . to 17) Install snap ring and thrust needle bearing .
AT-96 INSTALLATION, Planetary Gear and Low NOTE :
Clutch .> Install thrust needle bearing in the correct direc-
14) Install pressure plate, drive plate, driven plate, tion .
retaining plate and snap ring .
J
0 i 0
/ B3M1075
O
(A) Snap ring
15) After all 2-4 brake component parts have been (B) Thrust needle bearing
installed, blow in air intermittently and confirm the (C) Up side
operation of the brake. (D) Down side
AT- 1 22
18) Install front sun gear and thrust needle bear- 22) Secure the housing with two nuts and the bolt.
ing. Tightening torque:
NOTE: T.' 41 N~m (4.2 kgf-m, 30.4 ft-Ib)
tion.
0
0
B3M10681

(A) Front sun gear
Liquid gasket:
THREE BOND 1215
(C) Up side
(D) Down side NOTE:
19) Install the high clutch hub and thrust needle fitted in position.
bearing.
NOTE :
tion .

(B) Rubber seal

secure with six bolts and four nuts .
CAUTION:
(A) High clutch hub When installing, be careful not to damage the
(B) Thrust needle bearing torque converter clutch case bushing and oil
(C) Up side seal .
(D) Down side
Tightening torque:
20) Install the high clutch assembly. <Ref . to 41 N~m (4,2 kgf-m, 30.4 ft-Ib)
AT-90 INSTALLATION, High Clutch and Reverse 25) Install reduction drive gear. <Ref. to AT-48
Clutch .> INSTALLATION, Reduction Drive Gear.>
21) Install the oil pump housing assembly . 26) Install reduction driven gear.
WITHOUT VTD <Ref. to AT-48 WITHOUT VTD,
AT-1 23

case . <Ref . to AT-36 INSTALLATION, Extension
Case .>
28) Install the rear vehicle speed sensor .
Tightening torque:
7 N~m (0.7 kgf-m, 5.1 ft-Ib)
nector into stay.
(A )
B3M1054A

31) Install the oil cooler pipes . <Ref . to AT-29

hand .
CAUTION :
50 - 55 mm (1.97 - 2.17 in)

Clutch Assembly.>
C : INSPECTION S5,o594A,o
Check for the following .
~ Drive plate facing for wear or damage
~ Snap ring for wear and spring retainer for defor-
mation
AT-1 24
TRANSMISSION CONTROL DEVICE
28. Transmission Control 10) Remove the oil pan .

Device 5510274
NOTE :
Use a scraper to remove oil pan .
A: REMOVAL S5,o2,aA,8
NOTE :
9 Extract the torque converter clutch horizontally.
pump shaft.
U(0
2) Remove the input shaft . ~O[~
3) Disconnect transmission harness connector 0
from stay. B3M2022
NOTE : 11) Remove control valve body assembly. <Ref . to

Lift-up lever behind the connector and disconnect AT-83 REMOVAL, Control Valve Body Assembly.>
it from stay. 12) Pull off the straight pin of manual lever.
5) Disconnect the air breather hoses. <Ref . to
6) Wrap vinyl tape around the nipple attached to
the air breather hose .
8) Remove the inhibitor switch .
13) Remove bolts securing select lever, then

remove select lever, manual lever and parking rod.
CAUTION :
Be careful not to damage the lips of the press-
fitted oil seal in the case.
B3M1087~
9) Prepare a block of wood . Turn the transmission

case over, and support it with the block of wood .
NOTE :
Turn the transmission case in the direction the
inhibitor switch was installed .
(a,) Bolt
(B) Range select lever
(C) Manual lever
(D) Parking rod
AT-1 25
14) Remove the detention spring . 3) Insert manual lever and parking rod.
0 0
° ~o
O / o
-~- o 0 0
~~o
00
0
o
B3M1086
B : INSTALLATION SS,oz,4A (B) Range select lever

1) Install detention spring to transmission case. (C) Manual lever
(D) Parking rod
Tightening torque:
6 N~m (0.6 kgf-m, 4.3 ft-Ib) 41 Insert sorina nin to manual lever.
o
° ~o
-~- o
\ O o / o\ ~0 o o
0o
o
B3M1086
2) Insert range select lever, and tighten bolt. 5) Install control valve assembly. <Ref . to AT-84
Tiphteninq torque: INSTALLATION, Control Valve Body Assembly.>
entire oil pan mating surface .
Liquid gasket:
THREE BOND 12178

position .
8) Install pitching stopper bracket.
Tightening torque:
41 N~m (4.2 kgf-m, 30.4 ft-1b)
AT-1 26
9) Install air breather hose . <Ref. to AT-27

INSTALLATION, Air Breather Hose.>
10) Install inhibitor switch and adjust the inhibitor
switch by referring to Supplement AT section .
nector into stay.
(B
A)
- /
B3M1054A


hand .
CAUTION:
50-55 mm (1.97-2.17 in)

<Ref. to AT-34 INSTALLATION, Torque Converter
Clutch Assembly .>
C: INSPECTION
Make sure the manual lever and detention spring
are not worn or otherwise damaged.
AT-1 27
GENERAL DESCRIPTION
Body Structure
1. General Description S906001
A: PREPARATION TOOL S906001A17
TOOL NAME REMARKS

Tram tracking gauge Used for measuring dimen-
sion.
Tape measure Used for measuring dimen-
sion
BS-2
墌 00.5.31/68j/9bs 墍
DATUM POINTS
Body Structure
2. Datum Points S906540
A: LOCATION S906540A13
NOTE:
쐌 Datum points are specified for body repair.
쐌 Guide holes, locators, and indents are provided to facilitate panel replacement and to increase alignment
accuracy.
쐌 Both right and left reference points are symmetrical.
1. ROOM SECTION S906540A1301
B5M0847A
(13) Front fender attaching hole at (23) Rear quarter outer door switch (87) Six light upper retainer attaching
front pillar center portion M6 attaching hole 20 mm (0.79 in) hole 6.2 mm (0.244 in) dia.
(14) Front fender attaching hole at dia. (88) Retainer attaching square hole
front pillar lower portion M6 (64) Center pillar (LWR) gauge hole at side rail outer 8 × 8 mm (0.31
(19) Retainer attaching hole at side 13 mm (0.51 in) dia. × 0.31 in)
rail outer 3.2 mm (0.126 in) dia. (81) Rear shelf (UPR) center hole 8 (89) Retainer attaching square hole
(20) Center pillar outer hole 14 mm mm (0.31 in) dia. at rear quarter outer 8 × 8 mm
(0.55 in) dia. (82) Rear side bulk head (UPR) (0.31 × 0.31 in)
(21) Front seat belt adjust plate gauge hole 7 mm (0.28 in) dia. (92) Rear shelf (UPR) hole 6 mm
attaching hole M10 (85) Rear quarter outer gauge hole (0.24 in) dia.
(22) Side sill outer hole 20 mm (0.79 20 mm (0.79 in) dia.
in) dia.
BS-3
墌 00.5.31/68j/9bs 墍
DATUM POINTS
Body Structure
2. REAR SECTION S906540A1302
B5M0848A
(38) Front panel instrument panel (90) Roof trim attaching hole 8 mm (95) Rear bumper attaching hole 12.5
attaching hole 18 × 36 mm (0.71 (0.31 in) dia. × 17 mm (0.492 × 0.669 in) dia.
× 1.42 in) dia. oblong hole (91) Rear glass upper locating hole oblong hole
(46) Rear shock absorber attaching RH: 6.8 mm (0.268 in) dia., LH: (97) Trim attaching hole at rear skirt 7
hole 13 mm (0.51 in) dia. 6.8 × 10 mm (0.268 × 0.39 in) mm (0.28 in) dia.
(83) Rear skirt outer gauge hole 20 dia. oblong hole (98) Rear bumper side attaching hole
mm (0.79 in) dia. (93) Inner trim attaching hole (UPR) 8 6.2 mm (0.244 in) dia.
(84) Rear extension attaching hole mm (0.31 in) dia. (99) Rear combination light mounting
6.2 mm (0.244 in) dia. (94) Inner trim attaching hole (LWR) 8 hole 8 mm (0.31 in) dia.
(86) Skirt rear inner center location mm (0.31 in) dia. (100)Rear bumper beam attaching
hole 7 mm (0.28 in) dia. hole 8.2 mm (0.323 in) dia.
BS-4
墌 00.5.31/68j/9bs 墍
DATUM POINTS
Body Structure
3. UNDERBODY SECTION S906540A1303
B5M0849A
(50) Radiator panel (LWR) frame (54) Front side frame (Rr) gauge hole (58) Reinforcement crossmember B
gauge hole 15 mm (0.59 in) dia. 20 mm (0.79 in) dia. hole RH: 15 mm (0.59 in) dia.,
(51) Front side frame (Ft) gauge hole (55) Crossmember front floor gauge LH: 12 mm (0.47 in) dia.
20 mm (0.79 in) dia. hole M10 (59) Frame rear floor side gauge hole
(52) Front side frame (Ft) gauge hole (56) Side frame (Rr) gauge hole 18 30 mm (1.18 in) dia.
20 mm (0.79 in) dia. mm (0.71 in) dia.
(53) Front suspension attaching hole (57) Frame rear floor side gauge hole
M14 25 mm (0.98 in) dia.
BS-5
墌 00.5.31/68j/9bs 墍
DATUM POINTS
Body Structure
B5M0850A B5M0853A
B5M0851A B5M0854A
B5M0852A B5M0855A
B5M0856A B5M0860A
BS-6
墌 00.5.31/68j/9bs 墍
DATUM POINTS
Body Structure
B5M0857A
B5M0861A
B5M0858A B5M0862A
B5M0859A B5M0863A
B5M0864A B5M0868A
BS-7
墌 00.5.31/68j/9bs 墍
DATUM POINTS
Body Structure
B5M0865A B5M0869A
B5M0866A B5M0882A
B5M0867A B5M0871A
B5M0872A B5M0876A
BS-8
墌 00.5.31/68j/9bs 墍
DATUM POINTS
Body Structure
B5M0873A B5M0877A
B5M0874A B5M0880A
B5M0875A B5M0881A
BS-9
墌 00.5.31/68j/9bs 墍
DATUM DIMENSIONS
Body Structure
3. Datum Dimensions S906337
A: MEASUREMENT S906337A14
Refer to LOCATION for details on measurement

points. <Ref. to BS-3 LOCATION, Datum Points.>
NOTE:
쐌 Using a tram tracking gauge, measure all the
dimensions.
쐌 When using a tape measure, carefully measure
dimensions without letting the tape measure sag or
twist.
쐌 Measure the linear dimensions between cores
of holes.
쐌 Suffixes “RH” and “LH” indicate right-hand and
left-hand.
G5M0122
쐌 Measure at the center of the circle around the

outside of the body panel.
B5M1133A
BS-10
墌 00.5.31/68j/9bs 墍
DATUM DIMENSIONS
Body Structure
1. FRONT STRUCTURE S906337A1401
B5M1134A
Point to point Dimension Point to point Dimension

(11) to (1) 888 (34.96) (4) RH to (4) LH 1,320 (51.97)
(11) to (9) RH 519 (20.43) (5) RH to (4) LH 1,073 (42.24)
(11) to (9) LH 519 (20.43) (5) LH to (4) RH 1,073 (42.24)
(11) to (6) RH 950 (37.40) (60) RH to (13) RH 1,179 (46.42)
(11) to (6) LH 950 (37.40) (60) LH to (13) LH 1,179 (46.42)
(11) to (3) RH 1,008 (39.68) (60) RH to (14) RH 1,135 (44.68)
(11) to (3) LH 1,008 (39.68) (60) LH to (14) LH 1,135 (44.68)
(10) RH to (3) RH 897 (35.31) (10) RH to (3) LH 1,679 (66.10)
(10) RH to (8) RH 504 (19.84) (10) LH to (3) RH 1,679 (66.10)
(10) LH to (8) LH 504 (19.84) (8) RH to (8) LH 1,398 (55.04)
(9) RH to (9) LH 1,020 (40.16) (8) RH to (10) LH 1,519 (59.80)
(6) RH to (6) LH 870 (34.25) (8) LH to (10) RH 1,519 (59.80)
(6) RH to (10) LH 1,522 (59.92) (3) RH to (8) LH 1,439 (56.65)
(6) LH to (10) RH 1,522 (59.92) (3) LH to (8) RH 1,439 (56.65)
(8) RH to (3) RH 395 (15.55) (7) RH to (7) LH 860 (33.86)
(8) LH to (3) LH 395 (15.55) (7) RH to (6) LH 943 (37.13)
(10) RH to (10) LH 1,470 (57.87) (7) LH to (6) RH 943 (37.13)
(3) RH to (3) LH 1,370 (53.94) (7) RH to (10) LH 1,322 (52.05)
(5) RH to (5) LH 720 (28.35) (7) LH to (10) RH 1,322 (52.05)
Unit: mm (in)
BS-11
墌 00.5.31/68j/9bs 墍
DATUM DIMENSIONS
Body Structure
2. CENTER STRUCTURE S906337A1402
B5M0879A
BS-12
墌 00.5.31/68j/9bs 墍
DATUM DIMENSIONS
Body Structure
3. WINDSHIELD AND DOORS S906337A1403
B5M0870A
BS-13
墌 00.5.31/68j/9bs 墍
DATUM DIMENSIONS
Body Structure

(14) RH to (18) RH 1,425 (56.10) (12) to (10) RH 1,136 (44.72)
(14) LH to (18) LH 1,425 (56.10) (12) to (10) LH 1,136 (44.72)
(13) RH to (64) RH 1,031 (40.59) (11) to (17) RH 1,130 (44.49)
(13) LH to (64) LH 1,031 (40.59) (11) to (17) LH 1,130 (44.49)
(16) RH to (64) RH 966 (38.03) (81) to (82) RH 611 (24.06)
(16) LH to (64) LH 966 (38.03) (81) to (82) LH 611 (24.06)
(20) RH to (23) RH 864 (34.02) (81) to (21) RH 1,309 (51.54)
(20) LH to (23) LH 864 (34.02) (81) to (21) LH 1,309 (51.54)
(20) RH to (24) RH 863 (33.98) (81) to (23) RH 812 (31.97)
(20) LH to (24) LH 863 (33.98) (81) to (23) LH 812 (31.97)
(19) RH to (23) RH 899 (35.39) (82) LH to (21) LH 1,019 (40.12)
(19) LH to (23) LH 899 (35.39) (82) RH to (21) LH 1,606 (63.23)
(20) RH to (36) RH 1,548 (60.94) (82) RH to (82) LH 1,140 (44.88)
(20) LH to (36) LH 1,548 (60.94) (85) LH to (20) LH 1,548 (60.94)
(42) RH to (44) RH 1,037 (40.83) (85) LH to (64) LH 1,650 (64.96)
(42) LH to (44) LH 1,037 (40.83) (19) LH to (64) LH 1,029 (40.51)
(11) to (12) 989 (38.94) (20) LH to (87) LH 911 (35.87)
(67) RH to (67) LH 1,100 (43.31) (20) LH to (88) LH 842 (33.15)
(11) to (67) RH 1,119 (44.06) (20) LH to (64) LH 399 (15.71)
(11) to (67) LH 1,119 (44.06) (23) LH to (89) LH 552 (21.73)
(12) to (67) RH 551 (21.69) (88) LH to (64) LH 1,192 (46.93)
(12) to (67) LH 551 (21.69) (89) LH to (64) LH 1,204 (47.40)
Unit: mm (in)
BS-14
墌 00.5.31/68j/9bs 墍
DATUM DIMENSIONS
Body Structure
4. COMPARTMENT S906337A1404
B5M0883A

(21) RH to (21) LH 1,351 (53.19) (41) to (22) LH 738 (29.06)
(15) RH to (15) LH 1,455 (57.28) (41) to (26) RH 1,459 (57.44)
(22) RH to (22) LH 1,455 (57.28) (41) to (26) LH 1,459 (57.44)
(39) RH to (39) LH 1,385 (54.53) (41) to (25) 1,290 (50.79)
(40) RH to (40) LH 1,392 (54.80) (41) to (12) 1,228 (48.35)
(41) to (38) 1,639 (64.53) (41) to (21) RH 940 (37.01)
(41) to (39) RH 1,642 (64.65) (41) to (21) LH 940 (37.01)
(41) to (39) LH 1,642 (64.65) (41) to (17) RH 1,261 (49.65)
(41) to (40) RH 1,531 (60.28) (41) to (17) LH 1,261 (49.65)
(41) to (40) LH 1,531 (60.28) (65) RH to (65) LH 1,307 (51.46)
(41) to (15) RH 1,342 (52.83) (41) to (65) RH 969 (38.15)
(41) to (15) LH 1,342 (52.83) (41) to (65) LH 969 (38.15)
(41) to (22) RH 738 (29.06) Unit: mm (in)
BS-15
墌 00.5.31/68j/9bs 墍
DATUM DIMENSIONS
Body Structure
5. TRUNK LID AND REAR GATE S906337A1405
B5M1135A
BS-16
墌 00.5.31/68j/9bs 墍
DATUM DIMENSIONS
Body Structure

(45) to (48) 974 (38.35) (84) RH to (84) LH 1,410 (55.51)
(45) to (47) RH 797 (31.38) (100) RH to (84) LH 1,226 (48.27)
(45) to (47) LH 797 (31.38) (86) to (21) RH 2,073 (81.61)
(47) RH to (47) LH 1,289 (50.75) (86) to (21) LH 2,086 (82.13)
(49) RH to (49) LH 1,313 (51.69) (86) to (38) 3,143 (123.74)
(34) RH to (34) LH 700 (27.56) (86) to (46) RH 1,121 (44.13)
(41) to (45) 1,482 (58.35) (86) to (46) LH 1,140 (44.88)
(41) to (43) RH 1,206 (47.48) (86) to (96) 558 (21.97)
(41) to (43) LH 1,199 (47.20) (90) to (22) RH 1,319 (51.93)
(41) to (48) 1,663 (65.47) (90) to (22) LH 1,319 (51.93)
(48) to (46) RH 1,191 (46.89) (22) RH to (94) LH 1,710 (67.32)
(48) to (46) LH 1,191 (46.89) (22) LH to (94) RH 1,710 (67.32)
(70) RH to (70) LH 1,215 (47.83) (38) to (97) RH 3,100 (122.05)
(72) RH to (72) LH 1,320 (51.97) (38) to (97) LH 3,100 (122.05)
(81) to (38) 2,351 (92.56) (92) to (91) RH 776 (30.55)
(81) to (90) 444 (17.48) (92) to (91) LH 776 (30.55)
(81) to (93) RH 719 (28.31) (91) RH to (91) LH 976 (38.43)
(81) to (93) LH 719 (28.31) (46) LH to (97) LH 1,008 (39.68)
(81) to (94) RH 632 (24.88) (46) LH to (97) RH 1,374 (54.09)
(81) to (94) LH 632 (24.88) (46) LH to (46) RH 1,052 (41.42)
(38) to (82) RH 2,178 (85.75) (93) RH to (93) LH 1,099 (43.27)
(38) to (82) LH 2,419 (95.24) (94) RH to (94) LH 1,257 (49.49)
(83) RH to (83) LH 930 (36.61) (95) RH to (95) LH 1,115 (43.90)
(84) RH to (83) LH 1,216 (47.87) (97) RH to (97) LH 830 (32.68)
(99) RH to (83) LH 1,246 (49.06) (99) RH to (99) LH 1,370 (53.94)
(100) RH to (83) LH 991 (39.02) (100) RH to (100) LH 1,020 (40.16)
Unit: mm (in)
BS-17
墌 00.5.31/68j/9bs 墍
DATUM DIMENSIONS
Body Structure
MEMO:
BS-18
墌 00.5.31/68j/9bs 墍
BASIC DIAGNOSTIC PROCEDURE
Cruise Control System (DIAGNOSTICS)
1. Basic Diagnostic Procedure S003501
A: PROCEDURE S003501E45
No. Step Check Yes No

1 START DIAGNOSIS. Is cruise control main Go to step 2. Go to symptom 1.
1) Perform pre-inspection. <Ref. to CC-3 switch turned ON? <Ref. to CC-16
INSPECTION, General Description.> SYMPTOM
2) Check cruise control main switch operation. CHART, Diagnos-
tics Chart with
Symptom.>
2 PREPARE SUBARU SELECT MONITOR. Is the select monitor avail- Go to step 3. Go to step 4.
able?
3 PERFORM CRUISE CANCEL CONDITIONS Is trouble code indicated? Go to “Diagnos- Go to step 4.
DIAGNOSIS. tics Chart with
Perform cruise cancel conditions diagnosis. Trouble Code”.
<Ref. to CC-14 Subaru Select Monitor.>
4 CHECK CRUISE CONTROL SET OPERA- Can cruise control be set Go to step 5. Go to symptom 2.
TION. while driving at 40 km/h (25 <Ref. to CC-16
Check cruise control set operation. MPH)? SYMPTOM
CHART, Diagnos-
tics Chart with
Symptom.>
5 CHECK VEHICLE SPEED IS HELD WITHIN Is vehicle speed held within Go to step 6. Go to symptom 3.
SET SPEED. set speed ±3 km/h (±2 <Ref. to CC-16
Make sure vehicle speed is held within set MPH) ? SYMPTOM
speed. CHART, Diagnos-
tics Chart with
Symptom.>
6 CHECK RESUME/ACCEL OPERATION. Does vehicle speed Go to step 7. Go to symptom 4.
Check RESUME/ACCEL operation. increase or return to set <Ref. to CC-16
speed after RESUME/ SYMPTOM
ACCEL switch has been CHART, Diagnos-
pressed? tics Chart with
Symptom.>
7 CHECK SET/COAST OPERATION. Does vehicle speed Go to step 8. Go to symptom 5.
Check SET/COAST operation. decrease after SET/COAST <Ref. to CC-16
switch has been pressed? SYMPTOM
CHART, Diagnos-
tics Chart with
Symptom.>
8 CHECK CANCEL OPERATION. Is cruise control released Go to step 9. Go to symptom 6.
Check CANCEL operation. after CANCEL switch has <Ref. to CC-16
been pressed? SYMPTOM
CHART, Diagnos-
tics Chart with
Symptom.>
9 CHECK CRUISE CONTROL RELEASE Is cruise control released Go to step 10. Go to symptom 7.
OPERATION. after brake pedal has been <Ref. to CC-16
Check cruise control release operation. depressed? SYMPTOM
CHART, Diagnos-
tics Chart with
Symptom.>
10 CHECK CRUISE CONTROL RELEASE Is cruise control released Finish the diag- Go to symptom 8.
OPERATION. after clutch pedal has been nostics. <Ref. to CC-16
Check cruise control release operation. depressed? (MT) SYMPTOM
CHART, Diagnos-
tics Chart with
Symptom.>
CC-2
GENERAL DESCRIPTION

CAUTION:
쐌 All Airbag system wiring harness and con-
A: CAUTION S003001A03 nectors are colored yellow. Do not use electri-
1. SUPPLEMENTAL RESTRAINT SYSTEM cal test equipment on these circuits.
쐌 Be careful not to damage Airbag system wir-
“AIRBAG” S003001A0301
ing harness when servicing the cruise control
Airbag system wiring harness is routed near the module and cruise control command switch.
cruise control module and cruise control command
switch.
B: PREPARATION TOOL S003001A17
1. SPECIAL TOOLS S003001A1701

22771AA030 SELECT MONITOR Troubleshooting for electrical systems.
KIT 쐌 English:
22771AA030 (Without printer)
쐌 German:
쐌 French:
쐌 Spanish:
B2M3877
2. GENERAL TOOLS S003001A1702
TOOL NAME REMARKS

Circuit Tester Used for measuring resistance, voltage and ampere.
C: INSPECTION S003001A10 2. CRUISE CONTROL CABLE S003001A1003
1. BATTERY S003001A1002
Measure battery voltage and specific gravity of

electrolyte.
Standard voltage:
12 V, or more
Specific gravity:
Above 1.260
S6M0099A
Check the cruise control cable installation.

If NG, install the cable securely.
CC-3
墌 00.5.31/68j/0cc 墍
GENERAL DESCRIPTION
3. ACCELERATOR CABLE S003001A1004
S6M0099A
Check movement of the accelerator cable when

the cruise control throttle is moved by hand.
If NG, check throttle cam.
4. THROTTLE CAM S003001A1005
Check that the throttle cam moves smoothly.

If NG, repair throttle cam.
5. CABLE FREE PLAY S003001A1006
B6M0241A
Check that the throttle cam-to-lever clearance is

within specifications.
Throttle cam-to-lever clearance:
0 — 1 mm (0 — 0.04 in)
If NG, adjust the clearance with the adjust nut.
NOTE:
Check that the cap is positioned in the groove.
CC-4
墌 00.5.31/68j/0cc 墍
ELECTRICAL COMPONENTS LOCATION
3. Electrical Components Location S003507
B6M1398A
(1) Cruise control actuator

(2) Inhibitor switch (AT)
(3) Command switch
(4) Main switch
(5) Clutch switch (MT)
(6) Stop and brake switch
(7) Cruise control module
CC-5
墌 00.5.31/68j/0cc 墍
CRUISE CONTROL MODULE I/O SIGNAL
4. Cruise Control Module I/O Signal S003515
A: ELECTRICAL SPECIFICATION S003515A08
G6M0015
Content Terminal No. Measuring conditions and I/O signals (ignition switch ON and engine idling)
Main light 1 쐌 Battery voltage is present when main switch is turned OFF.
쐌 “0” volt is present when main switch is turned ON.
Inhibitor switch (AT) 4 쐌 Battery voltage is present when selector lever is other than “P” or “N” posi-
tion.
쐌 “0” volt is present when selector lever is set to “P” or “N” position.
Motor B 5 쐌 ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated
while cruise control is operating.
쐌 “0” volt is present when main switch is turned OFF.
Ground 6 —
Motor A 7 쐌 ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated
RESUME/ACCEL switch 9 쐌 Battery voltage is present when command switch is turned to RESUME/
ACCEL position.
쐌 “0” volt is present when command switch is released.
SET/COAST switch 10 쐌 Battery voltage is present when command switch is turned to SET/COAST
position.
쐌 “0” volt is present when command switch is released.
Main power supply 11 쐌 Battery voltage is present when main power is turned ON.
쐌 “0” volt is present when main power is turned OFF.
Ignition switch 12 쐌 Battery voltage is present when ignition switch is turned ON.
쐌 “0” volt is present when ignition switch is turned OFF.
Motor C 13 쐌 ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated
Motor clutch 14 쐌 ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated
쐌 “0” volt is present when vehicle is stopped.
Cruise control main switch 15 쐌 Battery voltage is present during pressing the cruise control main switch,
and then battery voltage is present while main switch is turned ON.
Brake switch 16 Leave clutch pedal released (MT), while cruise control main switch is turned
ON.
Then check that;
쐌 Battery voltage is present when brake pedal is released.
쐌 “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;
쐌 Battery voltage is present when clutch pedal is released.
쐌 “0” volt is present when clutch pedal is depressed.
Data link connector 17 —
CC-6
墌 00.5.31/68j/0cc 墍
Content Terminal No. Measuring conditions and I/O signals (ignition switch ON and engine idling)
Data link connector 18 —
Vehicle speed sensor (MT) 19 Lift-up the vehicle until all four wheels are raised off ground, and then rotate
TCM (AT) any wheel manually.
Approx. “5” and “0” volt pulse signals are alternately input to cruise control
module.
Stop light switch 20 Turn ignition switch to OFF.
Then check that;
쐌 Battery voltage is present when brake pedal is depressed.
쐌 “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-7
墌 00.5.31/68j/0cc 墍
B: SCHEMATIC S003515A21
1. CRUISE CONTROL 4 CYLINDER ENGINE MODEL S003515A2101
BU71-21A
CC-8
墌 00.5.31/68j/0cc 墍
BU71-21B
CC-9
墌 00.5.31/68j/0cc 墍
BU71-21C
CC-10
墌 00.5.31/68j/0cc 墍
2. CRUISE CONTROL 6 CYLINDER

ENGINE MODEL S003515A2102
CC-11 BU71-22A
墌 00.5.31/68j/0cc 墍
BU71-22B
CC-12
墌 00.5.31/68j/0cc 墍
BU71-22C
CC-13
墌 00.5.31/68j/0cc 墍
SUBARU SELECT MONITOR
5. Subaru Select Monitor S003503

2. CRUISE CANCEL CONDITIONS
DIAGNOSIS S003503A1605
A: OPERATION S003503A16
1) Prepare Subaru Select Monitor kit.
1. GENERAL S003503A1604
The on-board diagnosis function of the cruise con-

trol system uses an external Subaru Select Moni-
tor.
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 driv- S2M0285
ing although cruise cancel condition is not
entered). 2) Connect diagnosis cable to Subaru Select
(2) Cruise control module memory stores the Monitor.
cancel condition (Code No.) which occurred 3) Insert cartridge into Subaru Select Monitor.
during driving. When there are plural cancel NOTE:
conditions (Code No.), they are shown on the
Subaru Select Monitor cartridge:
Subaru Select Monitor.
No. 24082AA150
CAUTION:
쐌 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.
쐌 The content of memory is cleared when igni-
tion switch or cruise main switch is turned OFF.
2) Real-time diagnosis
The real-time diagnosis function is used to deter-
mine whether or not the input signal system is in S2M0286A
good order, according to signal emitted from
switches, sensors, etc. 4) Connect Subaru Select Monitor to data link
(1) Vehicle cannot be driven at cruise speed connector.
because problem occurs in the cruise control (1) Data link connector located in the lower por-
system or its associated circuits. tion of the instrument panel (on the driver’s
(2) Monitor the signal conditions from switches side).
and sensors.
B2M2960B
(2) Connect diagnosis cable to data link con-

nector.
CC-14
墌 00.5.31/68j/0cc 墍
5) Start engine and turn cruise control main switch 3. REAL-TIME DIAGNOSIS S003503A1606
to ON.
1) Connect select monitor.
6) Turn Subaru Select Monitor switch to ON.
2) Turn ignition switch and cruise control main
switch to ON.
3) Turn Subaru Select Monitor switch to ON.
4) On the ⰆMain MenuⰇ display screen, select
the {Each System Check} and press the [YES] key.
5) On the ⰆSystem Selection MenuⰇ display
screen, select the {Cruise Control} and press the
[YES] key.
6) Press the [YES] key after displayed the infor-
mation of engine type.
7) On the ⰆCruise Control DiagnosisⰇ display
S2M0288A screen, select the {Current Data Display & Save}
and press the [YES] key.
8) Make sure that normal indication is displayed
the {All System Diagnosis} and press the [YES]
when controls are operated as indicated below:
key.
쐌 Depress/release the brake pedal. (Stop light
NOTE: switch and brake switch turn ON.)
The diagnostic trouble code is also shown in the 쐌 Turn ON the “SET/COAST” switch.
{Each System Check} mode. This mode is called 쐌 Turn ON the “RESUME/ACCEL” switch.
up on the ⰆCruise Control DiagnosisⰇ screen by 쐌 Depress/release the clutch pedal. (MT)
selecting the item {Cancel Code(s) Display}. 쐌 Set the selector lever to P or N. (AT)
8) Drive vehicle at least 30 km/h (19 MPH) with NOTE:
cruise speed set. 쐌 For detailed operation procedure, refer to the
9) If cruise speed is canceled itself (without doing SUBARU SELECT MONITOR OPERATION
any cancel operations), a diagnostic trouble code MANUAL.
will appear on select monitor display. 쐌 For detailed concerning diagnostic trouble
CAUTION: codes, refer to the LIST OF DIAGNOSTIC
쐌 A diagnostic trouble code will also appear TROUBLE CODE.
when cruise cancel is effected by driver. Do not <Ref. to CC-30 LIST OF DIAGNOSTIC TROUBLE
confuse. CODE, Diagnostics Chart with Trouble Code.>
쐌 Have a co-worker ride in vehicle to assist in
diagnosis during driving.
NOTE:
Diagnostic trouble code will be cleared by turning
ignition switch or cruise control main switch to OFF.
CC-15
墌 00.5.31/68j/0cc 墍
DIAGNOSTICS CHART WITH SYMPTOM
6. Diagnostics Chart with Symptom S003619
A: SYMPTOM CHART S003619F22
Symptom Repair area Reference

Cruise control main switch is not (1) Check power supply. <Ref. to CC-18 CHECK POWER
turned ON. SUPPLY, Diagnostics Chart with Symp-
tom.>
1
(2) Check cruise control main switch. <Ref. to CC-20 CHECK CRUISE CON-
TROL MAIN SWITCH, Diagnostics Chart
with Symptom.>
Cruise control cannot be set. (1) Check SET/COAST switch. <Ref. to CC-22 CHECK CRUISE CON-
TROL COMMAND SWITCH, Diagnostics
Chart with Symptom.>
(2) Check stop light switch and brake <Ref. to CC-24 CHECK STOP LIGHT
switch. SWITCH AND BRAKE SWITCH, Diag-
nostics Chart with Symptom.>
(3) Check clutch switch (MT). <Ref. to CC-26 CHECK CLUTCH
SWITCH (MT), Diagnostics Chart with
Symptom.>
(4) Check inhibitor switch (AT). <Ref. to CC-28 CHECK INHIBITOR
SWITCH (AT), Diagnostics Chart with
2
Symptom.>
(5) Check vehicle speed sensor. <Ref. to CC-31 DIAGNOSTIC TROUBLE
CODE 22 - VEHICLE SPEED SENSOR
-, Diagnostics Chart with Trouble Code.>
(6) Check motor drive system. <Ref. to CC-35 DIAGNOSTIC TROUBLE
CODE 35 - ACTUATOR MOTOR -, Diag-
nostics Chart with Trouble Code.>
(7) Check motor clutch drive system. <Ref. to CC-37 DIAGNOSTIC TROUBLE
CODE 37 - ACTUATOR MOTOR
CLUTCH -, Diagnostics Chart with
Trouble Code.>
Vehicle speed is not held within set (1) Check vehicle speed sensor. <Ref. to CC-31 DIAGNOSTIC TROUBLE
speed ±3 km/h (±2 MPH). CODE 22 - VEHICLE SPEED SENSOR
3
(3) Check motor clutch drive system. <Ref. to CC-37 DIAGNOSTIC TROUBLE
Trouble Code.>
Vehicle speed does not increase or (1) Check RESUME/ACCEL switch. <Ref. to CC-22 CHECK CRUISE CON-
does not return to set speed after TROL COMMAND SWITCH, Diagnostics
RESUME/ACCEL switch has been Chart with Symptom.>
pressed. (2) Check motor drive system. <Ref. to CC-35 DIAGNOSTIC TROUBLE
4
(3) Check motor clutch drive system. Ref. to CC-37 DIAGNOSTIC TROUBLE
Trouble Code.>
CC-16
墌 00.5.31/68j/0cc 墍
Symptom Repair area Reference

Vehicle speed does not decrease (1) Check SET/COAST switch. <Ref. to CC-22 CHECK CRUISE CON-
after SET/COAST switch has been TROL COMMAND SWITCH, Diagnostics
pressed. Chart with Symptom.>
5
Trouble Code.>
Cruise control is not released after (1) Check CANCEL switch. <Ref. to CC-22 CHECK CRUISE CON-
CANCEL switch has been pressed. TROL COMMAND SWITCH, Diagnostics
Chart with Symptom.>
6
Trouble Code.>
Cruise control is not released after (1) Check stop light switch and brake <Ref. to CC-24 CHECK STOP LIGHT
brake pedal has been depressed. switch. SWITCH AND BRAKE SWITCH, Diag-
nostics Chart with Symptom.>
7
Trouble Code.>
Cruise control is not released after (1) Check clutch switch. <Ref. to CC-26 CHECK CLUTCH
clutch pedal has been depressed SWITCH (MT), Diagnostics Chart with
(MT). Symptom.>
8
Trouble Code.>
CC-17
墌 00.5.31/68j/0cc 墍
B: CHECK POWER SUPPLY S003619F23
WIRING DIAGRAM:
B6M1524
CC-18
墌 00.5.31/68j/0cc 墍

1 CHECK POWER SUPPLY. Is the voltage more than 10 Go to step 2. 쐌 Check fuse No.
1) Disconnect cruise control module harness V? 18 (in fuse & relay
connector. box).
2) Turn ignition switch ON. 쐌 Check harness
3) Measure voltage between harness connec- for open or short
tor terminal and chassis ground. between cruise
Connector & terminal control module
(B94) No. 12 (+) — Chassis ground (−): and fuse & relay
box.
2 CHECK GROUND CIRCUIT. Is the resistance less than Power supply and Repair harness.
Measure resistance between harness connec- 10 Ω? ground circuit are
tor terminal and chassis ground. OK.
Connector & terminal
(B94) No. 6 (+) — Chassis ground (−):
CC-19
墌 00.5.31/68j/0cc 墍
C: CHECK CRUISE CONTROL MAIN SWITCH S003619F24
WIRING DIAGRAM:
B6M1524
CC-20
墌 00.5.31/68j/0cc 墍

1 CHECK CRUISE CONTROL MAIN SWITCH Is the voltage more than 10 Go to step 2. 쐌 Check fuse No.
CIRCUIT. V? 18 (in fuse & relay
1) Disconnect cruise control main switch har- box).
ness connector. 쐌 Check harness
2) Turn ignition switch ON. for open or short
3) Measure voltage between harness connec- between cruise
tor terminal and chassis ground. control main
Connector & terminal switch and fuse &
(i19) No. 3 (+) — Chassis ground (−): relay box.
2 CHECK CRUISE CONTROL MAIN SWITCH Is the resistance less than Go to step 3. Repair harness.
CIRCUIT. 10 Ω?
1) Turn ignition switch OFF.
2) Disconnect cruise control module harness
connector.
3) Measure resistance between cruise control
module harness connector terminal and cruise
control main switch harness connector termi-
nal.
(B94) No. 15 (+) — (i19) No. 5 (−):
(B94) No. 1 (+) — (i19) No. 6 (−):
(B94) No. 11(+) — (i19) No. 1 (−):
3 CHECK CRUISE CONTROL MAIN SWITCH. Is cruise control main Replace cruise Replace cruise
Remove and check cruise control main switch OK? control module. control main
switch. <Ref. to CC-5 Cruise Control Main switch.
Switch.>
CC-21
墌 00.5.31/68j/0cc 墍
D: CHECK CRUISE CONTROL COMMAND SWITCH S003619F25
WIRING DIAGRAM:
B6M1525
CC-22
墌 00.5.31/68j/0cc 墍

1 CHECK SET/COAST SWITCH CIRCUIT. Is the voltage 0 V when Go to step 2. Go to step 4.
1) Disconnect cruise control module harness SET/COAST switch is not
connector. pressed? Is the voltage
2) Turn ignition switch ON. more than 10 V when SET/
3) Measure voltage between harness connec- COAST switch is pressed?
tor terminal and chassis ground when SET/
COAST switch is pressed and not pressed.
2 CHECK RESUME/ACCEL SWITCH CIRCUIT. Is the voltage 0 V when Go to step 3. Go to step 4.
Measure voltage between harness connector RESUME/ACCEL switch is
terminal and chassis ground when RESUME/ not pressed? Is the voltage
ACCEL switch is pressed and not pressed. more than 10 V when
Connector & terminal RESUME/ACCEL switch is
(B94) No. 9 (+) — Chassis ground (−): pressed?
3 CHECK CANCEL SWITCH CIRCUIT. Is the voltage 0 V when Cruise control Go to step 4.
Measure voltage between harness connector CANCEL switch is not command switch
terminal and chassis ground when CANCEL pressed? Is the voltage circuit is OK.
switch is pressed and not pressed. more than 10 V when
Connector & terminal CANCEL switch is
(B94) No. 9 (+) — Chassis ground (−): pressed?
4 CHECK POWER SUPPLY FOR COMMAND Does horn sound? Go to step 5. 쐌 Check fuse No.
SWITCH. 6 (in fuse & relay
Check horn operation. box).
쐌 Check horn
relay. <Ref. to
COM-4 HORN
RELAY,
INSPECTION,
Horn System.>
쐌 Check harness
for open or short
between cruise
control command
switch and fuse &
relay box.
5 CHECK CRUISE CONTROL COMMAND Is cruise control command Check harness Replace cruise
SWITCH. switch OK? between cruise control command
Remove and check cruise control command control command switch.
switch. <Ref. to CC-6 Cruise Control Com- switch and cruise
mand Switch.> control module.
CC-23
墌 00.5.31/68j/0cc 墍
E: CHECK STOP LIGHT SWITCH AND BRAKE SWITCH S003619F26
WIRING DIAGRAM:
B6M1526
CC-24
墌 00.5.31/68j/0cc 墍

1 CHECK STOP LIGHT SWITCH AND BRAKE Is the voltage more than 10 Go to step 2. 쐌 Check fuse No.
SWITCH CIRCUIT. V? 16 (in fuse & relay
1) Disconnect stop light switch and brake box).
switch harness connector. 쐌 Check harness
2) Turn ignition switch ON. for open or short
3) Turn cruise control main switch ON. between stop
4) Measure voltage between harness connec- light/brake switch
tor terminal and chassis ground. and fuse & relay
Connector & terminal box.
2 CHECK STOP LIGHT SWITCH AND BRAKE Is the voltage more than 10 Go to step 3. 쐌 Check harness
SWITCH CIRCUIT. V? for open or short
Measure voltage between harness connector between stop
terminal and chassis ground. light/brake switch
Connector & terminal and cruise control
(B65) No. 1 (+) — Chassis ground (−): module (AT).
쐌 Check clutch
switch and the
circuit (MT).
3 CHECK STOP LIGHT SWITCH AND BRAKE Is the resistance less than Go to step 4. Repair harness.
SWITCH CIRCUIT. 10 Ω?
1) Turn cruise control main switch and ignition
switch OFF.
2) Disconnect cruise control module harness
connector.
module harness connector terminal and stop
light switch and brake switch harness connec-
tor terminal.
(B94) No. 20 (+) — (B65) No. 3 (−):
(B94) No. 16 (+) — (B65) No. 4 (−):
4 CHECK STOP LIGHT SWITCH AND BRAKE Is stop light switch and Stop light switch Replace stop light
SWITCH. brake switch OK? and brake switch switch and brake
Remove and check stop light switch and circuit are OK. switch.
brake switch. <Ref. to CC-7 Stop and Brake
Switch.>
CC-25
墌 00.5.31/68j/0cc 墍
F: CHECK CLUTCH SWITCH (MT) S003619F27
WIRING DIAGRAM:
B6M1526
CC-26
墌 00.5.31/68j/0cc 墍

1 CHECK CLUTCH SWITCH CIRCUIT. Is the voltage more than 10 Go to step 2. Check harness for
1) Disconnect clutch switch harness connec- V? open or short
tor. between clutch
2) Turn ignition switch ON. switch and cruise
3) Turn cruise control main switch ON. control module.
4) Measure voltage between harness connec-
tor terminal and chassis ground.
2 CHECK CLUTCH SWITCH CIRCUIT. Is the resistance less than Go to step 3. Repair harness.
1) Turn cruise control main switch and ignition 10 Ω?
switch OFF.
2) Disconnect stop light switch and brake
switch harness connector.
3) Measure resistance between clutch switch
harness connector terminal and stop light
switch and brake switch harness connector
terminal.
(B107) No. 1 (+) — (B65) No. 1 (−):
3 CHECK CLUTCH SWITCH. Is clutch switch OK? Clutch switch cir- Replace clutch
Remove and check clutch switch. <Ref. to cuit is OK. switch.
CC-8 Clutch Switch.>
CC-27
墌 00.5.31/68j/0cc 墍
G: CHECK INHIBITOR SWITCH (A/T) S003619F28
WIRING DIAGRAM:
B6M1527
CC-28
墌 00.5.31/68j/0cc 墍

1 CHECK INHIBITOR SWITCH CIRCUIT. Is the voltage more than 10 Go to step 2. Check harness for
1) Disconnect inhibitor switch harness con- V? open or short
nector. between inhibitor
3) Turn cruise control main switch ON. control module.
4) Measure voltage between harness connec-
tor terminal and chassis ground.
(T7) No. 12 (+) — Chassis ground (−):
2 CHECK INHIBITOR SWITCH CIRCUIT. Is the resistance less than Go to step 3. Repair harness.
1) Turn cruise control main switch and ignition 10 Ω?
switch OFF.
2) Disconnect starter motor harness connec-
tor.
3) Measure resistance between inhibitor
switch harness connector terminal and chas-
sis ground.
(T7) No. 7 (+) — (B14) No. 1 (−):
3 CHECK INHIBITOR SWITCH. Is inhibitor switch OK? Inhibitor switch Replace inhibitor
Remove and check inhibitor switch. <Ref. to circuit is OK. switch.
CC-9 Inhibitor Switch.>
CC-29
墌 00.5.31/68j/0cc 墍
DIAGNOSTICS CHART WITH TROUBLE CODE
7. Diagnostics Chart with Trouble Code S003620
A: LIST OF DIAGNOSTIC TROUBLE CODE S003620E40
Diagnostic
trouble Item Contents of diagnosis Reference
code
21 Inner relay is seized. Cruise control module inner relay is <Ref. to CC-30 DIAGNOSTIC TROUBLE
seized when main switch is OFF. CODE 21, 24, 25 AND 2A - CRUISE
CONTROL MODULE BUILT-IN RELAY,
CPU RAM -, Diagnostics Chart with
Trouble Code.>
22 Vehicle speed sensor Vehicle speed signal changes more than <Ref. to CC-31 DIAGNOSTIC TROUBLE
10 km/h (6 MPH) within 350 ms. CODE 22 - VEHICLE SPEED SENSOR
24 Cruise control module is Two vehicle speed values stored in <Ref. to CC-30 DIAGNOSTIC TROUBLE
abnormal. cruise control module memory are not CODE 21, 24, 25 AND 2A - CRUISE
the same. CONTROL MODULE BUILT-IN RELAY,
Trouble Code.>
25 Cruise control module is Two output values stored in cruise con- <Ref. to CC-30 DIAGNOSTIC TROUBLE
abnormal. trol module memory are not the same. CODE 21, 24, 25 AND 2A - CRUISE
Trouble Code.>
28 Wiring harness opened. Open wiring harness circuit is detected <Ref. to CC-34 DIAGNOSTIC TROUBLE
via control module relay when main CODE 28 - WIRING HARNESS
switch is ON. OPENED. -, Diagnostics Chart with
Trouble Code.>
35 Motor drive system is 쐌 Motor output circuit is open or shorted. <Ref. to CC-35 DIAGNOSTIC TROUBLE
abnormal. 쐌 Motor drive circuit is open or shorted. CODE 35 - ACTUATOR MOTOR -, Diag-
37 Motor clutch drive system 쐌 Motor clutch output circuit is open or <Ref. to CC-37 DIAGNOSTIC TROUBLE
is abnormal. shorted. CODE 37 - ACTUATOR MOTOR
쐌 Motor clutch drive circuit is open or CLUTCH -, Diagnostics Chart with
shorted. Trouble Code.>
38 Motor drive shaft does not Motor drive gear engagement is not <Ref. to CC-39 DIAGNOSTIC TROUBLE
engage properly. properly adjusted. CODE 38 - MOTOR DRIVE SHAFT
DOES NOT ENGAGE PROPERLY. -,
Diagnostics Chart with Trouble Code.>
39 Motor is overloaded. Current flows through motor more fre- <Ref. to CC-40 DIAGNOSTIC TROUBLE
quently than under normal conditions. CODE 39 - MOTOR IS OVERLOADED.
-, Diagnostics Chart with Trouble Code>
2A Cruise control module is Cruise control module self-diagnosis <Ref. to CC-30 DIAGNOSTIC TROUBLE
abnormal. function senses abnormality. CODE 21, 24, 25 AND 2A - CRUISE
Trouble Code.>
B: DIAGNOSTIC TROUBLE CODE 21, 24, 25 AND 2A

— CRUISE CONTROL MODULE BUILT-IN RELAY, CPU RAM — S003620F29
DIAGNOSIS:
쐌 Poor welding of built-in relay of cruise control module.
쐌 Failure of built-in CPU RAM of cruise control module.
CC-30
墌 00.5.31/68j/0cc 墍
C: DIAGNOSTIC TROUBLE CODE 22

— VEHICLE SPEED SENSOR — S003620F30
DIAGNOSIS:
Disconnection or short circuit of vehicle speed sensor system.
WIRING DIAGRAM:
B6M1528
CC-31
墌 00.5.31/68j/0cc 墍

1 CHECK TRANSMISSION TYPE. Is the transmission type Go to step 2. Go to step 6.
MT?
2 CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 Go to step 3. Check harness for
AND VEHICLE SPEED SENSOR. V? open or short
1) Disconnect harness connector from vehicle between ignition
speed sensor. relay and vehicle
2) Turn ignition switch ON. speed sensor.
3) Measure voltage between vehicle speed
sensor harness connector terminal and chas-
sis ground.
3 CHECK HARNESS BETWEEN CRUISE Is the resistance less than Go to step 4. Repair harness.
CONTROL MODULE AND VEHICLE SPEED 10 Ω?
SENSOR.
1) Disconnect harness connector from cruise
control module.
2) Measure resistance between vehicle speed
sensor harness connector terminal and cruise
control module harness connector terminal.
(B17) No. 1 — (B94) No. 19:
4 CHECK HARNESS BETWEEN VEHICLE Is the resistance less than Go to step 5. Repair harness.
SPEED SENSOR AND ENGINE GROUND. 10 Ω?
sensor harness connector terminal and
engine ground.
(B17) No. 2 (+) — Engine ground (−):
5 CHECK VEHICLE SPEED SENSOR. Is the voltage more than Replace cruise Replace vehicle
1) Connect harness connector to vehicle 3.5 V? control module. speed sensor.
speed sensor. <Ref. to CC-4
2) Set the vehicle on free roller, or lift-up the Cruise Control
vehicle and support with safety stands. Module.>
WARNING:
Be careful not to be caught up by the run-
ning wheels.
3) Drive the vehicle at speed greater than 20
km/h (12 MPH).
4) Measure voltage between cruise control
module harness connector terminal and chas-
sis ground.
CC-32
墌 00.5.31/68j/0cc 墍

6 CHECK HARNESS BETWEEN CRUISE Is the resistance less than Go to step 7. Repair harness
CONTROL MODULE AND TRANSMISSION 10 Ω? connector
CONTROL MODULE. between cruise
1) Disconnect harness connector from trans- control module
mission control module and cruise control and transmission
module. control module.
module harness connector terminal and trans-
mission control module harness connector
terminal.
CAUTION:
To measure the voltage and/or resistance,
use a tapered pin with a diameter of less
than 0.64 mm (0.025 in). Do not insert the
pin more than 5 mm (0.20 in).
Without VDC:
(B94) No. 19 — (B55) No. 13:
With VDC:
(B94) No. 19 — (B56) No. 17:
7 CHECK TRANSMISSION CONTROL MOD- Is the voltage less than 1 V Replace cruise Replace transmis-
ULE. ←→ more than 4.5 V? control module. sion control mod-
1) Connect harness connector to transmission <Ref. to CC-4 ule. <Ref. to
control module. Cruise Control AT-42 Transmis-
2) Set the vehicle on free roller, or lift-up the Module.> sion Control Mod-
vehicle and support with safety stands. ule (TCM).>
WARNING:
Be careful not to be caught by the running
wheels.
3) Drive the vehicle faster than 10 km/h (6
MPH).
4) Measure voltage between transmission
control module harness connector terminal
and chassis ground.
CAUTION:
To measure the voltage and/or resistance,
use a tapered pin with a diameter of less
than 0.64 mm (0.025 in). Do not insert the
pin more than 5 mm (0.20 in).
Without VDC:
With VDC:
CC-33
墌 00.5.31/68j/0cc 墍
D: DIAGNOSTIC TROUBLE CODE 28

— WIRING HARNESS OPENED. — S003620F31

1 CHECK BATTERY. Is battery specific gravity Go to step 2. Charge or replace
Measure battery specific gravity of electrolyte. more than 1.250? battery. Go to step
2.
2 CHECK FUSES, CONNECTORS AND HAR- Is there anything unusual Repair or replace End of inspection.
NESSES. about the appearance of faulty parts.
Check the condition of the main and other main fuse, fuse, harness,
fuses, and harnesses and connectors. Also connector and grounding?
check for proper grounding.
CC-34
墌 00.5.31/68j/0cc 墍
E: DIAGNOSTIC TROUBLE CODE 35

— ACTUATOR MOTOR — S003620F32
DIAGNOSIS:
Open or poor contact of cruise control actuator motor.
WIRING DIAGRAM:
B6M1529
CC-35
墌 00.5.31/68j/0cc 墍

1 CHECK POWER SUPPLY. Is the voltage more than 10 Go to step 2. Check harness for
1) Turn ignition switch OFF. V? open or short
2) Disconnect harness connector from cruise between cruise
control actuator. control main
4) Turn cruise control main switch ON. control actuator.
actuator harness connector terminal and
chassis ground.
Terminals
2 CHECK GROUND CIRCUIT OF ACTUATOR. Is resistance less than 10 Go to step 3. Repair harness.
Measure resistance between cruise control Ω?
chassis ground.
Terminals
3 MEASURE RESISTANCE OF ACTUATOR. Is resistance approximately Go to step 4. Replace cruise
Measure resistance of cruise control actuator 5 Ω? control actuator.
motor. <Ref. to CC-3
Terminals Actuator.>
No. 4 — No. 1:
No. 4 — No. 2:
No. 4 — No. 5:
4 CHECK HARNESS BETWEEN ACTUATOR Is resistance less than 10 Go to step 5. Repair harness.
AND CRUISE CONTROL MODULE. Ω?
control module.
control actuator harness connector terminal.
(B7) No. 1 — (B94) No. 7:
5 CHECK HARNESS BETWEEN ACTUATOR Is resistance less than 10 Replace cruise Repair harness.
AND CRUISE CONTROL MODULE. Ω? control module.
Measure resistance between cruise control <Ref. to CC-4
module harness connector terminal and cruise Cruise Control
control actuator harness connector terminal. Module.>
(B7) No. 5 — (B94) No. 5:
CC-36
墌 00.5.31/68j/0cc 墍
F: DIAGNOSTIC TROUBLE CODE 37

— ACTUATOR MOTOR CLUTCH — S003620F33
DIAGNOSIS:
Open or poor contact of cruise control actuator motor clutch.
WIRING DIAGRAM:
B6M1529
CC-37
墌 00.5.31/68j/0cc 墍

1 CHECK POWER SUPPLY. Is the voltage more than 10 Go to step 2. Check harness for
1) Turn ignition switch OFF. V? open or short
2) Disconnect harness connector from cruise between cruise
control actuator. control main
4) Turn cruise control main switch ON. control actuator.
chassis ground.
Terminals
2 CHECK GROUND CIRCUIT OF ACTUATOR. Is resistance less than 10 Go to step 3. Repair harness.
Measure resistance between cruise control Ω?
chassis ground.
Terminals
(B7) No. 6 — Chassis ground:
3 MEASURE RESISTANCE OF ACTUATOR Is resistance approximately Go to step 4. Replace cruise
CLUTCH. 39 Ω? control actuator.
Measure resistance of cruise control actuator <Ref. to CC-3
clutch. Actuator.>
Terminals
No. 3 — No. 6:
4 CHECK HARNESS BETWEEN ACTUATOR Is resistance less than 10 Go to step 5. Repair harness.
AND CRUISE CONTROL MODULE. Ω?
control module.
control actuator harness connector terminal
(B7) No. 2 — (B94) No. 13:
5 CHECK HARNESS BETWEEN ACTUATOR Is resistance less than 10 Replace cruise Repair harness.
AND CRUISE CONTROL MODULE. Ω? control module.
Measure resistance between cruise control <Ref. to CC-4
module harness connector terminal and cruise Cruise Control
control actuator harness connector terminal. Module.>
(B7) No. 3 — (B94) No. 14:
CC-38
墌 00.5.31/68j/0cc 墍
G: DIAGNOSTIC TROUBLE CODE 38

— MOTOR DRIVE SHAFT DOES NOT ENGAGE PROPERLY. — S003620F34

1 CHECK ACTUATOR MOTOR. Are foreign particles caught Replace cruise Check the cruise
1) Disconnect harness connector from cruise in inner gear or does inner control actuator. control cable
control actuator. gear engage and disen- <Ref. to CC-3 adjustment. <Ref.
2) Remove cruise control actuator from gage improperly? Actuator.> to CC-3 CABLE
mounting bracket. FREE PLAY,
3) Pull cable by hand to check for looseness INSPECTION,
or status of inner gear engagement. General Descrip-
tion.>
CC-39
墌 00.5.31/68j/0cc 墍
H: DIAGNOSTIC TROUBLE CODE 39

— MOTOR IS OVERLOADED. — S003620F35

1 CHECK THE OPERATING CURRENT TO Is current flow more than Replace cruise Check the power
ACTUATOR MOTOR. 10A? control module. supply circuit.
1) Connect Subaru Select Monitor to data link <Ref. to CC-4 <Ref. to CC-18
connector. Cruise Control CHECK POWER
2) Try to drive the vehicle while operating the Module.> SUPPLY, Diag-
cruise control system. nostics Chart with
3) Check the operation current to the cruise Symptom.>
control actuator motor.
CC-40
墌 00.5.31/68j/0cc 墍
GENERAL DESCRIPTION
Cruise Control System
1. General Description S912001 A: COMPONENT S912001A05
B6M1398A
(1) Cruise control actuator (4) Main switch (7) Cruise control module
(2) Inhibitor switch (AT) (5) Clutch switch (MT)
(3) Command switch (6) Stop and brake switch
B: CAUTION S912001A03 쐌 Connect connectors and hoses securely during

reassembly.
쐌 Before disassembling or reassembling parts, 쐌 After reassembly, ensure functional parts oper-
always disconnect the battery ground cable. When ate properly.
repairing the radio, control module and other parts
with memory functions, make note of the memory C: PREPARATION TOOL S912001A17
before disconnecting the battery ground cable. All

memory will be erased. 1. GENERAL TOOLS S912001A1701
쐌 Reassemble parts in the reverse order of disas- TOOL NAME REMARKS

sembly unless otherwise indicated. Circuit Tester Used for measuring resistance
쐌 Adjust parts to specifications specified in this and voltage.
manual.
CC-2
墌 00.5.31/68j/9cc 墍
ACTUATOR
2. Actuator S912499
NOTE:
(A): Must be adjusted when cable end outer is fixed
A: REMOVAL S912499A18 in place, so that gap between throttle cam and
lever is 0 — 1 mm (0 — 0.04 in).
CAUTION: (Must be attached while throttle cam is being
쐌 Be careful not to apply excessive load to the pulled by wire cable.)
wire cable when adjusting and/or installing; (B): Must be coated evenly on cam end inner con-
otherwise, the actuator may be deformed or nection.
damaged. (C): Cover must be inserted securely, until tip of
쐌 Do not bend cable sharply with a radius less cable touches cover stopper.
than 100 mm (3.94 in); otherwise, cable may
bend permanently, resulting in poor perfor-
mance.
쐌 When installing cable, be careful not to
sharply bend or pinch the inner cable;
otherwise, the cable may break.
1) Remove clip bands from cruise control cable.
2) Loosen nut which secures cruise control cable
end to throttle cam and then remove cable from
throttle cam.
B6M1213A
C: INSPECTION S912499A10
S6M0088
3) Remove actuator attaching bolts.

4) Remove actuator while disconnecting connec- B6M1507
tor.
Measure resistance between cruise control actua-
tor terminals.
Tester connection Resistance (Ω)
1—5 Approx. 46
2—3 Approx. 46
If NG, replace cruise control actuator.
B6M1548
Install in the reverse order of removal.

Tightening torque:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
CC-3
墌 00.5.31/68j/9cc 墍
CRUISE CONTROL MODULE
3. Cruise Control Module S912500
1) Remove glove box. <Ref. to EI-34 REMOVAL,

Glove Box.>
2) Remove nut, then remove cruise control mod-
ule (A) and the other electrical control module (B)
while disconnecting connector.
B6M1338A
3) Disconnect cruise control module and the other

electrical control module.
Install is in the reverse order of removal.
CC-4
CRUISE CONTROL MAIN SWITCH
4. Cruise Control Main Switch

S912498
1) Remove switch panel (a) while disconnecting

connector.
B6M1336A
2) Remove main switch by pushing it outward.
B6M1337
Install is in the reverse order of removal.
G6M0244
Check continuity between cruise control main

switch terminals.
Specified condi-
Switch position Tester connection
tion
OFF 3—5 No continuity
ON 3—5 Continuity
If NG, replace cruise control main switch.
CC-5
CRUISE CONTROL COMMAND SWITCH
5. Cruise Control Command 7) Disconnect horn and cruise control command

switch connector, then remove cruise control com-
Switch S912497
mand switch.
WARNING:
Before servicing, be sure to read the notes in
the AB section for proper handling of the driv-
er’s airbag module. <Ref. to DRIVER’S AIRBAG
MODULE.>
1) Set front wheels in straight ahead position.
3) Disconnect battery ground cable from battery
S6M0096
and wait for at least 20 seconds before starting
work.
4) Using TORX姞 BIT T30 (Tamper resistant type), B: INSTALLATION S912497A11
loosen two TORX姞 bolts which secure driver’s air-

bag module. Install is in the reverse order of removal.
H5M0662A
5) Disconnect airbag module connector on back of B6M1406
airbag module. Check continuity between cruise control command

6) Remove horn switch from steering wheel as switch terminals.
shown.
Tester con- Specified
Switch Position
nection condition
ON 1 (+) — 2 (−) Continuity
CANCEL
ON 1 (+) — 3 (−) Continuity
OFF 1—3 No continuity
SET/COAST
ON 1—3 Continuity
RESUME/ OFF 1—2 No continuity
ACCEL ON 1—2 Continuity
If NG, replace cruise control command switch.

S6M0095
CC-6
墌 00.5.31/68j/9cc 墍
STOP AND BRAKE SWITCH
6. Stop and Brake Switch S912496
Disconnect connector from switch, and then

remove the switch. <Ref. to BR-64 REMOVAL,
Stop Light Switch.>
B6M1508A
Check continuity brake switch (1) and stop light

switch (2) between terminals.
Switch Pedal
nection condition
Released 1—4 Continuity
Brake
Depressed 1—4 No continuity
Released 2—3 No continuity
Stop light
Depressed 2—3 Continuity
If NG, replace stop and brake switch.
CC-7
CLUTCH SWITCH
7. Clutch Switch S912258
Disconnect the connector from the switch, and

then remove the switch. <Ref. to CL-21
DISASSEMBLY, Clutch Pedal.>
G6M0184
Check continuity between clutch switch terminals.

Switch Pedal
nection condition
Released 1—2 Continuity
Clutch
Depressed 1—2 No continuity
If NG, replace the clutch switch.
CC-8
INHIBITOR SWITCH
8. Inhibitor Switch S912243
Disconnect connector from switch, and then

remove the switch. <Ref. to AT-29 REMOVAL,
Inhibitor Switch.>
Installation is in the reverse order of removal.
B6M1530
Check continuity between inhibitor switch termi-

nals.
Selector lever Specified condi-
Tester connection
position tion
P Continuity
N 7 — 12 Continuity
Except P and N No continuity
If NG, replace inhibitor switch.
CC-9
INHIBITOR SWITCH
MEMO:
CC-10
GENERAL DESCRIPTION
Communication System
A: PREPARATION TOOL S904001A17
TOOL NAME REMARKS

Circuit Tester Used for measuring resistance and voltage.
COM-2
HORN SYSTEM
2. Horn System S904436
A: SCHEMATIC S904436A21
1. HORN S904436A2101
COM-3 BU74-21
HORN SYSTEM
B: INSPECTION S904436A10
1. HORN RELAY S904436A1001
Check continuity between terminals (indicated in

table below) when terminal No. 4 is connected to
battery and terminal No. 3 is grounded.
When current Between terminals
Continuity exists.
flows. No. 1 and No. 2
Between terminals Continuity does not
When current No. 1 and No. 2 exist.
does not flow. Between terminals
Continuity exists.
No. 3 and No. 4
S6M0048A
COM-4
HORN
3. Horn S904437
1) Remove horn bracket mounting bolt (A).

2) Disconnect harness connector and remove
horn assembly (B).
B6M1491A
With 12 V direct current supply between horn ter-

minal and case ground, check that the horn sounds
properly.
B6M1492
COM-5
HORN SWITCH
4. Horn Switch S904434
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, Gen-
eral Description.>
1) Remove the driver’s airbag module. <Ref. to
AB-12 Driver’s Airbag Module.>
2) Remove horn switch from steering wheel as
shown.
S6M0095
Check continuity between terminals.
B6M1493
Switch position Tester connection Specified condition

When horn
Continuity
switch is pushed.
When horn 1—Body ground
switch is not No continuity
pushed.
COM-6
GENERAL DESCRIPTION
Exterior Body Panels
A: SPECIFICATIONS S913001E49
B5M0711A
EB-2
墌 00.5.31/68j/9eb 墍
GENERAL DESCRIPTION
B: COMPONENT S913001A05
1. FRONT HOOD S913001A0501
B5M1064A
(1) Front hood (3) Hinge Tightening torque: N·m (kgf-m, ft-lb)
(2) Seal (Front hood)
T1: 24.5 (2.50, 18.1)
EB-3
墌 00.5.31/68j/9eb 墍
GENERAL DESCRIPTION
2. FRONT DOOR PANEL S913001A0502
B5M0923C
(1) Gusset (7) Sealing cover Tightening torque: N·m (kgf-m, ft-lb)
(2) Weatherstrip (8) Checker
T1: 7.4 (0.75, 5.4)
(3) Clip (Weatherstrip) (9) Lower hinge
T2: 18 (1.8, 13.0)
(4) Stabilizer (Lifter) (10) Upper hinge
T3: 30 (3.1, 22.4)
(5) Stabilizer (Outer) (11) Door panel
(6) Stabilizer (Inner)
EB-4
墌 00.5.31/68j/9eb 墍
GENERAL DESCRIPTION
3. REAR DOOR PANEL S913001A0503
B5M0713C
(1) Weatherstrip (7) Sealing cover Tightening torque: N·m (kgf-m, ft-lb)
(2) Clip (Weatherstrip) (8) Checker
T1: 7.4 (0.75, 5.4)
(3) Stabilizer (Outer) (9) Lower hinge
T2: 18 (1.8, 13.0)
(4) Stabilizer (Inner) (10) Upper hinge
T3: 30 (3.1, 22.4)
(5) Door panel
(6) Plate
EB-5
墌 00.5.31/68j/9eb 墍
GENERAL DESCRIPTION
4. TRUNK LID PANEL S913001A0504
B5M1065A
(1) Torsion bar (4) Hinge ASSY Tightening torque: N·m (kgf-m, ft-lb)
(2) Trunk lid (5) Cover
T: 18 (1.8, 13.0)
(3) Weatherstrip
EB-6
墌 00.5.31/68j/9eb 墍
GENERAL DESCRIPTION
5. REAR GATE PANEL S913001A0505
B5M1066B
(1) Gas stay (5) Buffer cover Tightening torque: N·m (kgf-m, ft-lb)
(2) Hinge (6) Buffer (Back door)
T1: 7.4 (0.75, 5.4)
(3) Rear gate
T2: 14 (1.4, 10.1)
(4) Buffer (Rear gate)
T3: 25 (2.5, 18.1)
EB-7
墌 00.5.31/68j/9eb 墍
GENERAL DESCRIPTION
C: CAUTION S913001A03 쐌 While removing mounting bolts, using assis-

tance devices such as a support jack will help sup-
쐌 Exterior body panels are heavy. Do not drop and port the panel.
damage the panels. During removal and
쐌 Be careful not to lose small parts.
installation, do not damage the panel painting sur-
face.
D: PREPARATION TOOL S913001A17

925610000 WRENCH Used for removing and installing door
hing.
B5M1117
927780000 REMOVER Used for removing and installing trunk
torsion bar.
B5M1118
2. GENERAL TOOL S913001A1702
TOOL NAME REMARKS

Support Jack Used for supporting door panel.
EB-8
墌 00.5.31/68j/9eb 墍
FRONT HOOD
2. Front Hood S913367

3) Rotate hood buffer to adjust lateral height.
1) Open front hood to remove washer nozzles.

2) Remove clips to remove hood insulator.
B5M0750
B5M1090
3) Remove bolts to disconnect hood from hinges.
B5M0747
1) Install in the reverse order of removal.

2) Adjust clearance between hood and fender.
Clearance must be equal at both sides.
C: ADJUSTMENT S913367A01
1) Use hinge mounting holes to align front hood

longitudinally and laterally.
B5M0747
2) Adjust height at front end of hood. <Ref. to

SL-46 ADJUSTMENT, Front Hood Lock Assem-
bly.>
EB-9
墌 00.5.31/68j/9eb 墍
FENDER PANEL
3. Fender Panel S913368
1) Disconnect ground (−) cable from battery.

2) Remove side spoilers. <Ref. to EI-29 Side Sill
Spoiler.> (If fitted)
3) Remove side protectors and fender protectors.
(OUTBACK)
4) Remove front bumper face. <Ref. to EI-14
REMOVAL, Front Bumper.>
5) Remove headlights. <Ref. to LI-25 REMOVAL,
Headlight Assembly.>
6) Remove mud guard. <Ref. to EI-23 REMOVAL,
Mud Guard.>
7) Remove bolts and clips to remove front fender.
B5M0760

2) When fender panel is installed, clearance
between fender panel and hood or front fender
must be equal.
EB-10
FRONT DOOR PANEL
4. Front Door Panel S913366

10) Remove door-side bolts for upper and lower
hinges to remove door.
1) Disconnect (−) cable from battery.

2) Remove front door trim. <Ref. to EI-32
REMOVAL, Front Door Trim.>
3) Remove outer mirror assembly. <Ref. to GW-40
REMOVAL, Outer Mirror Assembly.>
4) Remove front door regulator and motor. <Ref.
to GW-23 REMOVAL, Front Regulator and Motor.>
5) Remove front door latch assembly. <Ref. to
SL-36 REMOVAL, Front Door Latch Assembly.>
G5M0385
6) Remove front outer handle. <Ref. to SL-35
REMOVAL, Front Outer Handle.> 11) Using special tool, remove body-side bolts for
7) Remove front pillar lower trim to disconnect upper and lower hinges, and remove door hinges.
connector from body harness. ST 925610000 DOOR HINGE WRENCH
B5M0726 B5M0933A
8) Put wooden block on jack and place jack under CAUTION:

door. Support door with a jack to protect it from 쐌 During removal and installation of doors, do
damage. not damage body.
9) Remove checker bolts. 쐌 Doors are heavy. Be careful not to drop and
damage them.

2) Apply grease to sliding area of door hinges.
S5M0183
EB-11
墌 00.5.31/68j/9eb 墍
FRONT DOOR PANEL
1) Using special tool, loosen body-side bolts of

upper and lower hinges to align the position of front
door panel longitudinally and vertically.
ST 925610000 DOOR HINGE WRENCH
B5M0933A
2) Loosen door-side bolts of upper and lower

hinges to align the position of front door panel ver-
tically and laterally at the front end.
G5M0385
3) Loosen screw (A) and tap striker (B) using plas-

tic hammer to adjust striker.
B5M0934A
CAUTION:
Do not use impact wrench. Welding area on
striker nut plate is easily broken.
EB-12
墌 00.5.31/68j/9eb 墍
FRONT SEALING COVER
5. Front Sealing Cover S913564

REMOVAl, Front Door Trim.>
2) Remove front speaker. <Ref. to EI-11
REMOVAL, Front Speaker.>
3) Using a spatula, remove sealer.
CAUTION:
쐌 Carefully remove sealer. Excessive force will
easily break the cover.
쐌 If cover gets broken, replace it with a new
one.
G5M0391

2) When replacing sealing cover, use CEMEDINE
5430L sealer.
3) Press sealer-applied area firmly to prevent any
floating on surface.
Sealer:
CEMEDINE 5430L or equivalent
CAUTION:
쐌 Apply a uniform bead of sealer.
쐌 Attach sealing cover, keeping it from becom-
ing wrinkled.
쐌 Breaks in the bead will allow water leakage
and contamination.
If sealing cover is damaged, replace it with a new

one.
EB-13
REAR DOOR PANEL
6. Rear Door Panel S913364
1) Disconnect (−) cable from battery.

2) Remove rear door trim. <Ref. to EI-33
REMOVAL, Rear Door Trim.>
3) Remove rear door regulator and motor assem-
bly. <Ref. to GW-26 REMOVAL, Rear Regulator
and Motor Assembly.>
4) Remove rear door latch. <Ref. to SL-40 G5M0385
REMOVAL, Rear Door Latch Assembly.>
5) Remove rear outer handle. <Ref. to SL-39 11) Using special tool, remove body-side bolts for
REMOVAL, Rear Outer Handle.> upper and lower hinges, and remove door hinges.
6) Remove center pillar lower trim. <Ref. to EI-43 CAUTION:
REMOVAL, Lower Inner Trim.> 쐌 During removal and installation of doors, do
7) Remove seatbelt bracket and blind plug. not damage body.
Disconnect connector of door harness and remove 쐌 Doors are heavy. Be careful not to drop and
door hinge nut. damage them.

2) Apply grease to sliding area of door hinges.
B5M1062
8) Put a wooden block on the jack and place the

jack under the door. Support the door with the jack
to protect it.
9) Remove checker bolts.
S5M0183
10) Remove door-side bolts for upper and lower

hinges to remove door.
EB-14
墌 00.5.31/68j/9eb 墍
REAR DOOR PANEL
1) Using special tool, loosen body-side bolts of

upper and lower hinges to align the position of rear
door panel longitudinally and vertically.
B5M0933A
2) Loosen door-side bolts of upper and lower

hinges to align the position of rear door panel ver-
tically and laterally at front-end.
G5M0385
3) Loosen screw (A) and tap striker (B) using plas-

tic hammer to adjust striker.
B5M0934A
CAUTION:
Do not use an impact wrench. The welding area
on the striker nut plate is easily broken.
EB-15
墌 00.5.31/68j/9eb 墍
REAR SEALING COVER
7. Rear Sealing Cover S913565
1) Remove rear door trim. <Ref. to EI-33

2) Remove rear speaker. <Ref. to ET-12
REMOVAL, Rear Speaker.>
3) Using a spatula, remove sealer.
CAUTION:
쐌 Carefully remove sealer. Excessive force will
easily break the cover.
쐌 If cover gets broken, replace it with a new
one.
G5M0391

2) When replacing sealing cover, use CEMEDINE
5430L sealer.
3) Press sealer-applied area firmly to prevent any
floating on surface.
Sealer:
CEMEDINE 5430L or equivalent
CAUTION:
쐌 Apply an uniform bead of sealer.
쐌 Attach sealing cover, keeping it from becom-
ing wrinkled.
쐌 Breaks in the bead will allow water leakage
and contamination.
If sealing cover gets damaged, replace it with a

new one.
EB-16
TRUNK LID PANEL
8. Trunk Lid Panel S913365 B: INSTALLATION S913365A11
1. TRUNK LID S913365A1101

2) Install trunk lid with uniform clearance.
1) Open trunk lid.
2) Disconnect trunk lid connector. 2. TORSION BAR S913365A1102
3) Loosen trunk lid mounting bolts to remove trunk 1) Install in the reverse order of removal.
lid from hinges. 2) Apply grease to rotating area of hinges and
mating surface of torsion bar.
G5M0144
2. TORSION BAR S913365A1802
1) Open trunk lid.

2) Using special tool, remove torsion bar from
hinge link.
CAUTION:
During removal and installation, carefully
handle torsion bar. It will generate reactive
force.
G5M0145
3) Remove 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-17
REAR GATE PANEL
9. Rear Gate Panel S913363

2. GAS STAY S913363A1802
1) Open rear gate. Using a jack to support the rear

gate.
1) Open rear gate.

2) Remove rear gate outer handle. <Ref. to SL-42
REMOVAL, Rear Gate Outer Handle.>
3) Remove rear gate latch assembly. <Ref. to
SL-43 REMOVAl, Rear Gate Latch Assembly.>
4) Remove rear gate key lock cylinders. <Ref. to
SL-49 REMOVAL, Key Lock Cylinders.>
5) Remove rear finisher light assembly. <Ref. to
LI-34 REMOVAL, Rear Finisher Light Assembly.>
6) Remove rear wiper. <Ref. to WW-17 B5M1063
REMOVAL, Rear Wiper Motor.>
7) Disconnect connectors of rear wiper, rear CAUTION:
defogger, and other lighting devices. 쐌 After gas stay is removed, rear gate cannot
8) Disconnect washer hose. stay open. Supporting the rear gate with a jack,
9) Remove rubber duct (A) connection, and pull remove the bolts.
out harness and washer hose from rear gate. 쐌 Do not damage piston rods and oil seals.
쐌 Never disassemble cylinders: They contain
gas.
2) Loosen bolts to remove gas stay from rear gate.

2) Install rear gate panel with uniform clearance to
body.
B5M0733A
CAUTION:
10) Using a support, support the rear gate while Do not damage painted surfaces of body and
removing gas stay mounting bolts. rear gate.
2. GAS STAY S913363A1102

CAUTION:
쐌 Do not confuse right and left sides of gas
stay.
쐌 After supporting rear gate with a jack, start
operation.
B5M1063
CAUTION:
When the rear gate is released, it may hit and
damage the body. To prevent this, place a shop
cloth between body and gate.
11) Loosen rear gate bolts to remove rear gate.
EB-18
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REAR GATE PANEL
C: DISPOSAL S913363A07
1. GAS STAY S913363A0701
1) Cover with a vinyl case before drilling holes.
G5M0491
CAUTION:
Prevent the vinyl case from being caught by
drill cutting edge
2) Lift body side slightly with piston rods fully
extended, and secure body side on vise stand.
Drill a hole in 2 to 3 mm (0.08 to 0.12 in) diameter
at a point 10 to 200 mm (0.39 to 7.87 in) from door
side, and bleed gas stay completely.
CAUTION:
Gas is colorless, odorless, and harmless.
However, gas pressure may spray cutting pow-
der or oil. Be sure to wear dust-resistant
goggles.
B5M1145A
EB-19
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REAR GATE PANEL
MEMO:
EB-20
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GENERAL DESCRIPTION
Exterior/Interior Trim
A: COMPONENT S911001A05
1. FRONT BUMPER S911001A0501
B5M0885A
(1) Bumper face (5) Side bracket Tightening torque: N·m (kgf-m, ft-lb)
(2) E/A form (6) Cover (Tie down hook)
T: 33 (3.4, 25)
(3) Bumper beam (7) Cover
(4) Side stay
EI-2
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GENERAL DESCRIPTION
2. REAR BUMPER (SEDAN) S911001A0502
B5M0886A
(1) Bumper beam (5) Bumper face Tightening torque: N·m (kgf-m, ft-lb)
(2) Upper beam (6) Hook
T: 95 (9.7, 70)
(3) Resin beam (7) Side stay
(4) Side bracket
EI-3
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GENERAL DESCRIPTION
3. REAR BUMPER (WAGON) S911001A0503
B5M0887A
(1) Bumper beam (4) Bumper face Tightening torque: N·m (kgf-m, ft-lb)
(2) Resin beam (5) Hook
T: 95 (9.7, 70)
(3) Side bracket (6) Side stay
EI-4
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GENERAL DESCRIPTION
4. SIDE PROTECTOR S911001A0504
B5M0888A
(1) Side protector (Front fender) (4) Side protector (Rear quarter) (7) Side garnish (Rear door)
(2) Side protector (Front door) (5) Side garnish (Front fender) (8) Side garnish (Rear quarter)
(3) Side protector (Rear door) (6) Side garnish (Front door) (9) Side garnish (Side sill)
EI-5
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GENERAL DESCRIPTION
5. DOOR TRIM S911001A0505
B5M1146A
(1) Gusset cover (5) Pad (9) Upper trim

(2) Bracket (6) Trim panel (10) Side trim
(3) Weatherstrip upper (7) Power window switch cover (11) Lower trim
(4) Clip (8) Weatherstrip lower
EI-6
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GENERAL DESCRIPTION
6. INNER TRIM (SEDAN) S911001A0506
B5M0928A
(1) Front pillar upper trim (6) Trunk rear trim (11) Side sill rear lower cover
(2) Center pillar upper trim (7) Trunk side trim (12) Front pillar lower trim
(3) Rear pillar upper trim (8) Rear pillar lower trim (13) Side sill front lower cover
(4) Rear shelf trim (9) Side sill rear upper cover (14) Pad stopper A pillar
(5) Rear bulk trim (10) Center pillar lower trim (15) Pad B pillar upper
EI-7
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GENERAL DESCRIPTION
7. INNER TRIM (WAGON) S911001A0507
B5M0929A
(1) Front pillar upper trim (7) Lid (13) Front pillar lower trim
(2) Center pillar upper trim (8) Rear skirt trim (14) Side sill front lower cover
(3) Rear pillar upper trim (9) Hook (15) Pad stopper A pillar
(4) Rear rail trim (10) Side sill rear upper cover (16) Pad B pillar upper
(5) Pocket (11) Center pillar lower trim
(6) Rear quarter lower trim (12) Side sill rear lower cover
EI-8
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GENERAL DESCRIPTION
8. INSTRUMENT PANEL S911001A0508
B5M1147A
(1) Pad & frame (11) Front cover (MT) (21) Front cup holder
(2) Grille side (D) (12) Rear cup holder (22) Switch panel
(3) Hook (13) Console box (23) Meter visor
(4) Grille side (P) (14) Cap (24) Grille vent (D)
(5) Grille vent (P) (15) Console lid (25) Grille center
(6) Glove box panel (16) Console cover
(7) Glove box lid (17) Tray Tightening torque: N·m (kgf-m, ft-lb)
(8) Center panel side (D) (18) Ash tray T: 7 (0.7, 5.1)
(9) Center panel side (P) (19) Lower cover
(10) Front cover (AT) (20) Center panel
EI-9
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GENERAL DESCRIPTION
9. INNER ACCESSORIES S911001A0510
B5M1142A
(1) Hook (3) Pad side rail

(2) Sun visor (4) Assist grip
EI-10
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GENERAL DESCRIPTION
TOOL NAME REMARKS

Clip remover Used for trim removal.
Adhesive remover Used for side protector removal.
Primer Used for side protector installation.
Infrared lamp Used for removal/installation of side protector.
Tow-sided tape Used for side protector installation.
TORX姞 T30 Used for removal/installation of crossbar.
EI-11
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FRONT GRILLE
2. Front Grille S911379
1) Open hood.
2) Loosen bolts and nuts to remove front grill.
B5M0763
EI-12
FRONT UNDER COVER
3. Front Under Cover S911372
1) Lift-up the vehicle.

2) Loosen bolts and clips to remove under cover.
B5M0931
EI-13
FRONT BUMPER
4. Front Bumper S911371

CAUTION:
E/A FORM is easy to break. Do not apply exces-
A: REMOVAL S911371A18 sive force to it during removal.
CAUTION:
쐌 Handle bumper carefully to avoid damage to
bumper face.
쐌 Do not damage body during removal or
installation of bumper.
쐌 To avoid damage to bumper, lay removed
bumper on sheet spread on the floor. Do not lay
it directly on the floor.
1) Open hood.
2) Remove negative cable of battery. B5M0892
3) Pull off front side of front mud guard to remove
bolts. 8) Remove bumper beam.
B5M0756
B5M0754
4) Remove clip at bottom of bumper. B: INSTALLATION S911371A11

CAUTION:
bumper face.
B5M0994
5) Remove clip (A), and pull out bumper slightly.

6) Disconnect electrical connector of fog light to
remove bumper.
B5M0738A
7) Remove E/A FORM from bumper beam.
EI-14
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FRONT BUMPER
C: REPAIR S911371A19
1. COATING METHOD FOR PP BUMPER S911371A1901
Process
Process name Job contents
No.
Set bumper on paint worktable if required. Use

1 Bumper mounting paint worktable conforming to inner shape of
bumper when possible.
G5M0164
Mask specified part (black base) with masking tape. Use masking tape for PP (example,
2 Masking
Nichiban No. 533, etc.).
Degreasing, Clean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt, oil, fat,
3
cleaning etc.
4 Primer paint Apply primer one to all parts to be painted, using air gun. Use primer (clear).
Dry at normal temperature [10 to 15 min. at 20°C (68°F)].
5 Drying 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.
쐌 Paint in use (for each color): 쐌 Paint in use (for each color):
Solid paint Metallic paint
Hardener PB Hardener PB
Thinner T-301 Thinner T-306
6 Top coat paint (I)
쐌 Mixing ratio: 쐌 Mixing ratio:
Main agent vs. hardener = 4:1 Main agent vs. hardener = 10:1
쐌 Viscosity: 10 — 13 sec/20°C (68°F) 쐌 Viscosity: 10 — 13 sec/20°C (68°F)
쐌 Film thickness: 35 — 45µ 쐌 Film thickness: 15 — 20µ
쐌 Spraying pressure: 245 — 343 kPa 쐌 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
7 Drying Not required. 20°C (68°F)].
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.
쐌 Paint in use:
Metallic paint
Hardener PB
8 Top coat paint (II) Not required. Thinner T-301
쐌 Mixing ratio: Clear vs. hardener = 6:1
쐌 Viscosity: 14 — 16 sec/20°C (68°F)
쐌 Film thickness: 25 — 30µ
쐌 Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
60°C (140°F), 60 min. or 80°C (176°F), 30 min.
9 Drying If higher than 80°C (176°F), PP may be deformed. Keep maximum temperature of 80°C
(176°F).
10 Inspection Paint check.
11 Masking removal Remove masking in process No. 2.
EI-15
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FRONT BUMPER
2. REPAIR INSTRUCTIONS FOR COLORED PP BUMPER S911371A1902
NOTE:
All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be
restored to its former condition. Damage limited to shallow scratches that cause only a change in the lus-
tre 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.
쐌 Minor damage causing only a change in the lustre of the bumper due to a light touch
Almost restorable.
Process
No.
1 Cleaning Clean the area to be repaired using water.
2 Sanding 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). Recom- Perform either the same operation as for the
3 Finish mended wax: NITTO KASEI Soft 99 TIRE resin section or process No. 18 and subse-
WAX BLACK, or equivalent. quent operations in the “(3)” section, depend-
Polish the waxed area with a clean cloth after ing on the degree and nature of damage.
5 to 10 minutes.
쐌 Deep damage caused by scratching fences, etc.

A dent cannot be repaired but a whitened or swelled part can be removed.
Process
No.
1 Cleaning Clean damaged area with water.
Removal of dam-
2 Cut off protruding area, if any, due to collision, using a putty knife.
aged area
3 Sanding Grind the affected area with #100 to #500 sand paper.
Resin section Coated section
4 Finish Perform Process No. 12 and subsequent
Same as Process No. 3 in the “(1)” section.
operations in the “(3)” section.
EI-16
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FRONT BUMPER
쐌 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 Bumper removal Remove bumper as required.
2 Part removal Remove parts built into bumper as required.
Place bumper on a paint worktable as

required.
3 Bumper placement
It is recommended that contour of worktable
accommodate internal shape of bumper.
G5M0164
Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable sol-
4 Surface preparation
vent (NRM No. 900 Precleno, white gasoline, or alcohol).
If nature of damage are cracks or holes, cut a

guide slit of 20 to 30 mm (0.79 to 1.18 in) in
5 Cutting length along the crack or hole up to the
bumper’s base surface. Then, bevel or “vee-
out” the affected area using a knife or grinder.
G5M0165
6 Sanding (I) Grind beveled surface with sand paper (#40 to #60) to smooth finish.
7 Cleaning 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.
8 Temporary welding
G5M0166
NOTE:
쐌 Do not melt welding rod until it flows out. This results in reduced strength.
쐌 Leave the welded spot unattended until it cools completely.
EI-17
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FRONT BUMPER
Process
No.
Using a heater gun and PP welding rod, weld the beveled spot while melting the rod and dam-
aged area.
9 Welding
G5M0167
NOTE:
쐌 Melt the sections indicated by hatched area.
쐌 Do not melt welding rod until it flows out, in order to provide strength.
쐌 Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
쐌 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
Sand the welded spot smooth with #240 sand paper.
Mask the black substrate section using masking tape.
11 Masking
Recommended masking tape: Nichiban No. 533 or equivalent
Cleaning/
12 Completely clean the entire coated area, using solvent similar to that used in Process No. 4.
degreasing
Apply a coat of primer to the repaired surface and its surrounding areas. Mask these areas, if
necessary.
Recommended primer: Mp/ 364 PP Primer
13 Primer coating
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 20°C (68°F) for 10 to 15 minutes until primer is half-
dry.
14 Leave unattended. 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:
쐌 UPS 300 Flex Primer
Primer surfacer
15 쐌 No. 303 UPS 300 Exclusive hardener
coating
쐌 NPS 725 Exclusive Reducer (thinner)
쐌 Mixing ratio: 2 : 1 (UPS 300: No. 303)
쐌 Coated film thickness: 40 — 50µ
16 Drying Allow the coated surface to dry for 60 minutes at 20°C (68°F) [or 30 minutes at 60°C (140°F)].
17 Sanding (III) Sand the coated surface and its surrounding areas using #400 sand paper and water.
Cleaning/
18 Same as Process No. 12.
degreasing
EI-18
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FRONT BUMPER
Process
No.
Solid color Metallic color
Use a “block” coating method. Use a “block” coating method.
쐌 Recommended paint: 쐌 Recommended paint:
Suncryl (SC) Suncryl (SC)
No. 307 Flex Hardener No. 307 Flex Hardener
SC Reducer (thinner) SC Reducer (thinner)
19 Top coat (I)
쐌 Mixing ratio: 3 : 1 쐌 Mixing ratio: 3 : 1
Suncryl (SC) vs. No. 307 Flex Hardener Suncryl (SC) vs. No. 307 Flex Hardener
쐌 Viscosity: 11 — 13 sec/20°C (68°F) 쐌 Viscosity: 11 — 13 sec/20°C (68°F)
쐌 Coated film thickness: 40 — 50µ 쐌 Coated film thickness: 20 — 30µ
쐌 Spraying thickness: 245 — 343 kPa 쐌 Spraying thickness: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi) (2.5 — 3.5 kg/cm2, 36 — 50 psi)
Leave unattended at 20°C (68°F) for at least
10 minutes until the topcoated area is half-dry.
20 Leave unattended. Not required. NOTE:
Be careful to keep dust or dirt from coming in
contact with the affected area.
Apply a clear coat three times at an interval of
3 to 5 minutes.
쐌 Recommended paint:
SC710 Overlay Clear
No. 307 Flex Hardener
SC Reducer (thinner)
21 Top coat (II) Not required.
쐌 Mixing ratio: 3 : 1
Suncryl (SC) vs. No. 307 Flex Hardener
쐌 Coated film thickness: 20 — 30µ
쐌 Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
Allow the coated surface to dry at 20°C (68°F) for two hours or 60°C (140°F) for 30 minutes.
22 Drying NOTE:
Do not allow the temperature to exceed 80°C (176°F) since this will deform the PP substrate.
23 Inspection Carefully check the condition of the repaired area.
24 Masking removal Remove masking tape applied in Process No. 11 and 13.
25 Parts installation Install parts on bumper in reverse order of removal.
26 Bumper installation Install bumper.
EI-19
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REAR BUMPER
5. Rear Bumper S911370

4) Remove hook (A) to pull off rear side of trunk
side trim.
1. SEDAN S911370A1801
CAUTION:
bumper face.
it directly on the floor. B5M0799A
1) Lift-up the vehicle. 5) Remove two nuts from each side to remove
2) Remove bolts and clips. rear bumper.
B5M0800
6) Loosen clips to remove upper beam (A) from

bumper face.
B5M0797
3) Loosen clips to remove trunk rear trim.

B5M0796A
7) Remove resin beam.
B5M0798
B5M0893
EI-20
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REAR BUMPER
2. WAGON S911370A1802 6) Loosen bolts to remove rear bumper.

CAUTION:
bumper face.
it directly on the floor.
2) Remove trailer hitch. <Ref. to EI-31 REMOVAL, B5M0759
Trailer Hitch.>
3) Remove bolts and clips. 7) Loosen clip (A) to remove bumper beam (B)
from rear bumper face (C).
B5M0894A
8) Remove resin beam from bumper beam.
B5M0757
4) Remove rear floor box. <Ref. to EI-44 B5M0895

REMOVAL, Rear Quarter Trim.>
5) Pull off rear end of rear quarter lower trim to
remove cap.
B5M0758
EI-21
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REAR BUMPER
B: INSTALLATION S911370A11 C: REPAIR S911370A19
1. SEDAN S911370A1101 Refer to front bumper repair. <Ref. to EI-15

REPAIR, Front Bumper.>
CAUTION:
bumper face.
2) Fit slider (A) to guide pin (B) securely.
B5M0801A
2. WAGON S911370A1102
CAUTION:
bumper face.
2) Fit slider (A) to guide pin (B) securely.
B5M0801A
EI-22
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MUD GUARD
6. Mud Guard S911374
1) Jack-up the vehicle.

2) Loosen screws and clips to remove mud guard.
B5M0761A
Insert hook into body, and tighten it with screw and

clip.
EI-23
PROTECTOR
7. Protector S911380
1) Except OUTBACK:
B5M1150A
NOTE:
Paying attention to the position of clip (b).
OUTBACK:
Remove clip (a) and bolt (b).
B5M0897A
EI-24
墌 00.5.31/68j/9ei 墍
PROTECTOR
NOTE: Recommended adhesive remover:

Paying attention to the position of clip (c). SUMITOMO 3M4000 or equivalent
2) Attach masking tape to outer perimeter of side CAUTION:
protector. (If original side protector is re-installed, Do not apply adhesive remover to lacquer base
tape the entire protector.) coated body panels.
3) Insert fishing line [0.8 mm (0.31 in) dia.] 5) Attach plastic wrap to adhesive remover coated
between side protector and vehicle body. Cut (pull areas and heat to 40 to 60°C (104 to 140°F) for 5
the line) through two-sided tape along side protec- to 10 minutes using an infrared lamp.
tor on the body. Using a puller, remove clips from
vehicle body while pulling side protector towards CAUTION:
yourself as required. Do not overheat until plastic wrap is somewhat
white.
B5M0300A
B5M0301A
6) Using a plastic spatula, remove traces of two-

sided tape from body panel.
7) Remove masking tape and clean traces of two-
sided tape using a cloth dampened with white
gasoline.
8) Similarly, clean traces of adhesive from two-
sided tape on side protector.
CAUTION:
Make sure side protector is clean and free of
adhesive remover. Clean if necessary.
B5M0302A
B5M1151A
NOTE:
쐌 To increase adhesive remover strength, leave
two-sided tape on body and side protector.
쐌 If two-sided tape is too thick, use a putty knife to
cut it thin so that adhesive remover is ready for
use.
쐌 If two-sided tape is hard to remove, heat to
approximately 40°C (104°F).
4) Apply an even coat of adhesive remover to the
two-sided tape.
EI-25
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PROTECTOR
1) Apply primer to original side protector (if used),

and attach two-sided tape to side protectors as
shown.
Two-sided tape:
Thickness; 1.2 mm (0.047 in)
Width; 5 mm (0.20 in)
Recommended primer:
SUMITOMO 3MK-500 or equivalent
Recommended two-sided tape:
SUMITOMO 3M4210 or equivalent
B5M0303A
2) Using an infrared lamp, heat body panel to 40

to 60°C (104 to 140°F) and rear surface of side
protector to 20 to 30°C (68 to 86°F).
3) Remove tack paper from two-sided paper.
While aligning clips with holes in body panel,
attach two-sided tape to side protector and body
panel with a force of more than 49 N (5 kg, 11 lb)
with roller. Do not allow air to enter mating surface
of the two.
CAUTION:
쐌 To maintain adhesive power, do not wash the
vehicle for 24 hours after tape application.
쐌 Push clip in securely using hands.
(To prevent deformation, do not use excessive
force.)
EI-26
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COWL PANEL
8. Cowl Panel S911387
1) Open hood.
2) Remove wiper arm. <Ref. to WW-12
REMOVAL, Front Wiper Arm.>
3) Remove front panel seal.
B5M0995
4) Loosen clips to remove cowl panel.
B5M1152A
EI-27
SPOILER
9. Spoiler S911385
1) Open trunk lid.

2) Remove electrical connector (a) of high-
mounted stop light.
3) Remove mounting nut of rear spoiler to remove
rear spoiler.
CAUTION:
쐌 When removing nut, do not drop it into trunk
lid.
쐌 Pay attention to avoid damage during
removal or installation.
B5M0906A

2) Clean mounting surfaces of trunk lid and spoiler
before installation.
EI-28
SIDE SILL SPOILER
10. Side Sill Spoiler S911646
Remove clips F (1 on front, 6 on lower, 1 on side)

and remove side sill spoiler.
B5M1129
EI-29
CROSSBAR
11. Crossbar S911388 B: INSTALLATION S911388A11
1) Rotate lower clamp of each end support about
90 degrees downward.
1) Remove TORX姞 bolt T30 from each cross end 2) Set crossbar so that front direction arrow on the
support. right top face of crossbar points in the direction of
2) Rotate lower clamp of each end support about vehicle front, and place crossbar end support at
90 degrees downward to remove crossbar. position 152.4 mm (6.00 in) back from joint of front
roof rail support and roof rail.
Length A:
152.4 mm (6.00 in)
B5M0576A
CAUTION:
Do not damage roof panel during removal or
B5M0577A
installation.
3) Set crossbar so that front direction arrow on the
right top face of crossbar points in the direction of
vehicle front, and place crossbar end support at
position 152.4 mm (6.00 in) back from joint of rear
roof rail support and roof rail.
Length B:
152.4 mm (6.00 in)
B5M0579A
4) Tighten end support and lower clamp using

TORX姞 bolt T30.
EI-30
墌 00.5.31/68j/9ei 墍
TRAILER HITCH
12. Trailer Hitch S911389
CAUTION:
Because trailer hitch is heavy, two people are
required to remove it.
2) Remove rubber cushion from body.
NOTE:
If rubber cushion is hard to remove, apply
SUBARU CRC.
SUBARU CRC (Part No. 004301003 )
B2M3119
3) Remove strap (a).

4) Remove bolts. Remove trailer hitch while low-
ering muffler.
CAUTION:
Because trailer hitch is heavy, two people are
required to remove it.
2) For installation method of bolt, see the figure.
B5M0905A
(a) Bolt
(b) Spring washer
(c) Flat washer
(d) Plate
(e) Nut
EI-31
FRONT DOOR TRIM
13. Front Door Trim S911356

4) Remove three screws and clips.
CAUTION:
Do not apply excessive force to clip. Otherwise
the clip may be broken.
1) Pull up inner remote cover toward you to
remove upper hook. Pull down it to remove lower
claw. Remove inner remote cover.
B5M1009
5) Remove gusset cover. Disconnect electrical

connectors to remove speaker.
B5M1011
2) Remove two hooks of switch panel to remove

power window main switch.
B5M1010
6) Remove seven clips of trim panel using clip

remover to remove trim panel.
B5M1136A
3) Disconnect electrical connectors from power

window main switch and mirror switch.
B5M1012A
B5M1008
EI-32
墌 00.5.31/68j/9ei 墍
REAR DOOR TRIM
14. Rear Door Trim S911354

4) Remove seven clips of trim panel using clip
remover to remove trim panel.
CAUTION:
Do not apply excessive force to clip. Otherwise
the clip may be broken.
1) Pull up inner remote cover toward you to
remove upper hook. Pull down it to remove lower
claw. Remove inner remote cover.
B5M1014A
B5M1011

power window sub switch and disconnect electrical
connector.
B5M1017A
3) Remove three screws and clips.
B5M1013
EI-33
墌 00.5.31/68j/9ei 墍
GLOVE BOX
15. Glove Box S911558
1) Remove stoppers.
B5M1016
2) Loosen screws to remove glove box.
B5M1015
EI-34
ROOF RAIL
16. Roof Rail S911383
1) Remove roof trim. <Ref. to EI-47 REMOVAL, Roof Trim.>

2) Remove five mounting nuts and then detach roof rail carefully.
B5M1018

CAUTION:
Be careful not to scratch body panels with roof
rail stud bolts when removing and installing
them.
EI-35
墌 00.5.31/68j/9ei 墍
CONSOLE BOX
17. Console Box S911382 B: INSTALLATION S911382A11
1) Remove shift knob (A) (MT model) and front
cover (B).
B5M0844A
2) Remove tray (A) and console cover (B).
B5M0642A
3) Remove console box (A).
B5M0643A
EI-36
墌 00.5.31/68j/9ei 墍
INSTRUMENT PANEL ASSEMBLY
18. Instrument Panel Assembly 5) Remove stopper (A) then remove glove box.
S911381
Airbag system wiring harness is routed near the

combination meter.
WARNING:
쐌 All airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuits.
쐌 Be careful not to damage airbag system har-
ness when servicing the instrument panel.
1) Disconnect GND cable from battery.
2) Remove lower cover.
B5M0640A
6) Remove side panel of both sides.

B5M0639A
3) Remove lower column cover and disconnect

harness connectors to steering column.
B5M0641A
7) Remove passenger’s airbag module. <Ref. to

AB-14 Passenger’s Airbag Module.>
8) Remove console box. <Ref. to EI-36
B6M1184
REMOVAL, Console Box.>
4) Remove steering column assembly (with steer- 9) Remove front pillar upper trim of both sides.
ing wheel). <Ref. to PS-20 REMOVAL, Tilt Steer-
ing Column.>
B5M0644A
EI-37
墌 00.5.31/68j/9ei 墍
10) Remove front pillar lower trim of passenger NOTE:

side. Do not move the switch and link when installing.
B5M0649A B5M0645A
11) Set temperature control switch (A) to “FULL

HOT” and then disconnect temperature control
cable from bottom of heater unit. (Manual A/C
equipped model)
12) Remove instrument panel mounting bolts.
EI-38
墌 00.5.31/68j/9ei 墍
B5M1019
EI-39
墌 00.5.31/68j/9ei 墍
13) Disconnect harness connectors and remove instrument panel carefully.

CAUTION:
Do not pull the harness when disconnecting the connector.
NOTE:
If necessary, make matching marks for easy reassembly.
B5M0846A
(1) SMJ/White (4) 8P/White (7) Antenna feeder

(2) 2P/Blue (5) 1P/Black (8) 16P/Blue
(3) 10P/White (6) 1P/Black
CAUTION:
쐌 Take care not to scratch the instrument panel
and related parts.
쐌 When storing the removed instrument panel,
place it standing up on the floor.
G5M0602
EI-40
墌 00.5.31/68j/9ei 墍

CAUTION:
쐌 Be careful not to snag the harness.
쐌 Make sure to connect harness connector.
쐌 Take care not to scratch the instrument panel
and related parts.
NOTE:
When setting the instrument panel into position,
push the three hooks into grommet (A) on the body
panel.
B5M1020A
EI-41
墌 00.5.31/68j/9ei 墍
UPPER INNER TRIM
19. Upper Inner Trim S911384
1) Remove front mole (A).

2) Remove front pillar upper trim (B).
3) Detach front seat belt shoulder anchor, then
remove center pillar upper trim (C).
B5M1021A

CAUTION:
Be sure to securely hook pawls of inner trim
panel to body flange.
NOTE:
When installing center pillar upper trim and front
pillar upper trim, be sure to set front mole as shown
in figure.
B5M0673A
EI-42
LOWER INNER TRIM
20. Lower Inner Trim S911369
1) Remove front pillar lower trim (A).

2) Remove side sill front lower cover (B).
3) For sedan: Remove rear seat cushion <Ref. to
SE-16 REMOVAL, Rear Seat.>, then remove side
sill rear upper cover (C).
For wagon: Rise rear seat cushion, then remove
side sill rear upper cover (C).
4) Remove side sill rear lower cover (D).
5) Remove center pillar lower trim (E).
B5M1022A

CAUTION:
EI-43
REAR QUARTER TRIM
21. Rear Quarter Trim S911358

2. WAGON S911358A1802
1) Remove side sill rear upper cover. <Ref. to

EI-43 REMOVAL, Lower Inner Trim.>
1. SEDAN S911358A1801 2) Remove luggage floor mat. <Ref. to EI-54
REMOVAL, Luggage Floor Mat.>
1) Remove rear mole (A).
3) Remove rear skirt trim (A).
2) Remove rear shelf trim. <Ref. to EI-50
4) Remove rear quarter lower trim mounting volts,
REMOVAL, Rear Shelf Trim.>
screws and clips, then remove the trim (B).
3) Remove side sill rear upper cover. <Ref. to
5) Remove rear mole (C).
EI-43 REMOVAL, Lower Inner Trim.>
6) Remove rear quarter upper trim mounting
4) Remove rear pillar lower trim (B).
screw, then remove the trim (D).
5) Remove rear pillar upper trim (C).
7) Remove rear rail trim (E).
B5M0806B
B5M1023A
EI-44
墌 00.5.31/68j/9ei 墍
REAR QUARTER TRIM

CAUTION:
NOTE:
When installing rear quarter upper trim, be sure to
set rear mole as shown in the figure.
B5M0673A
EI-45
墌 00.5.31/68j/9ei 墍
SUN VISOR
22. Sun Visor S911359
Remove mounting screws then detach sun visor

(A) and hook (B).
B5M1024A
EI-46
ROOF TRIM
23. Roof Trim S911360

10) Remove rear quarter upper trim (C) of both
sides.
CAUTION:
When removing clip, use great care not to dam-
age the roof trim.
1. SEDAN S911360A1801

2) Remove sunroof switch. (Sunroof equipped
model) <Ref. to SR-15 REMOVAL, Sunroof
Switch.>
B5M1026A
3) Remove room light. <Ref. to LI-41 REMOVAL,
Room Light.> 11) Remove clips, and then remove roof trim.
4) Remove sun visor and hook of both sides.
<Ref. to EI-46 REMOVAL, Sun Visor.>
5) Remove assist grips (A).
B5M0807A
B5M1025A 2. WAGON S911360A1802
1) Open the rear sunroof, and then remove four

6) Remove sunroof garnish (A).
clips. (Sunroof equipped model)
B5M0899A
B5M0674
7) Remove upper inner trim. <Ref. to EI-42

REMOVAL, Upper Inner Trim.>
3) Remove sunroof switch. (Sunroof equipped
8) Remove rear window mole (A) of both sides.
model) <Ref. to SR-15 REMOVAL, Sunroof
9) Remove screw (B) of rear quarter lower trim
Switch.>
shown in the figure.
4) Remove room light and luggage room light.
<Ref. to LI-41 REMOVAL, Room Light.> and <Ref.
to LI-42 REMOVAL, Luggage Room Light.>
5) Remove sun visor and hook of both sides.
<Ref. to EI-46 REMOVAL, Sun Visor.>
EI-47
墌 00.5.31/68j/9ei 墍
ROOF TRIM
6) Remove assist grips (A). 12) Remove cover (B) while detaching snap lock
carefully. Put the rear center seat belt tongue (A)
out to the other side of the trim through the hole.
B5M1025A
7) Remove upper inner trim. <Ref. to EI-42 B5M0675A

REMOVAL, Upper Inner Trim.>
8) Remove rear window mole of both sides (A). 13) Remove clips and then remove roof trim.
9) Remove screws (B) and clips (C) of rear quar-
ter lower trim shown in the figure.
10) Remove rear quarter upper trim (D) of both
sides.
B5M0658A
B5M1161A
EI-48
墌 00.5.31/68j/9ei 墍
REAR GATE TRIM
24. Rear Gate Trim S911357
CAUTION:
Be careful not to damage clips or their holes.
1) Remove clips and detach rear gate lower trim
(A).
B6M1191A
2) Remove caps and screws, and then detach

high-mounted stop light cover (A).
B5M1027A
3) Remove rear gate upper trim (A).
B5M1028A
EI-49
墌 00.5.31/68j/9ei 墍
REAR SHELF TRIM
25. Rear Shelf Trim S911361
1) Remove high-mounted stop light.
B5M0816
2) Remove rear seat backrest. <Ref. to SE-16

REMOVAL, Rear Seat.>
3) Remove inner seat belt RH, then disconnect
inner seat belt RH (A) and outer seat belt center
(B).
B5M0815A
4) Detach rear shelf trim through each rear outer

seat belt from slits (A) and hole (B) of rear shelf
trim.
B5M0930A
EI-50
墌 00.5.31/68j/9ei 墍
TRUNK TRIM
26. Trunk Trim S911352
1) Remove clips, and then detach trunk rear trim

(A).
2) Remove luggage hook (B) and clips, then
detach trunk side trim (C).
B5M0808A
EI-51
TRUNK LID TRIM
27. Trunk Lid Trim S911355
Remove clips and detach trunk lid trim (A).
B5M1092
EI-52
FLOOR MAT
28. Floor Mat S911362
1) Remove front seats. <Ref. to SE-6 REMOVAL,

Front Seat.>
2) Remove rear seat cushion. <Ref. to SE-16
3) Remove console box. <Ref. to EI-36 Console
Box.>
4) Remove front pillar lower trim, side sill rear
upper cover and center pillar lower trim. <Ref. to
EI-43 Lower Inner Trim.>
5) Remove clips from floor mat.
NOTE:
When pulling out edge, do not pull mat alone; pull
mat together with edge. Ply off two steel clips on
side sill front cover and one on side sill rear cover
using screwdriver.
6) Remove mat hook.
7) Remove mat from toe board area.
8) Remove mat from rear heater duct.
9) Roll mat, and then take it out of opened rear
door.
S5M0240

NOTE:
쐌 Secure mat firmly with hook and Velcro tape.
쐌 Insert mat edge firmly into the groove of side sill
cover.
EI-53
LUGGAGE FLOOR MAT
29. Luggage Floor Mat S911353
Remove clips, then detach rear floor mats and

boxes.
B5M0657A
EI-54
TRUNK ROOM MAT
30. Trunk Room Mat S911351
Draw out trunk room mat, and detach box.
B5M1091
EI-55
墌 00.5.31/68j/9ei 墍
GENERAL DESCRIPTION
Entertainment
A: CAUTION S901001A03
쐌 Before disassembling or reassembling parts,

always disconnect battery ground cable. When
replacing radio, control module, and other parts
provided with memory functions, record memory
contents before disconnecting the battery ground
cable. Otherwise, the memory will be erased.
쐌 Reassemble in reverse order of disassembly,
unless otherwise indicated.
쐌 Adjust parts to the given specifications.
쐌 Connect connectors and hoses securely during
reassembly.
쐌 After reassembly, make sure functional parts
operate smoothly.
TOOL NAME REMARKS

Circuit Tester Used for measuring resis-
tance and voltage.
Conductive Silver Composi- Used for repairing antenna
tion wire.
(DUPONT NO. 4817 or
equivalent)
ET-2
RADIO SYSTEM
Entertainment
2. Radio System S901467

1. AUDIO EXCEPT MCINTOSH SYSTEM
S901467A2101
ET-3
BU76-21A
墌 00.5.31/68j/9et 墍
RADIO SYSTEM
Entertainment
BU76-21B
ET-4
墌 00.5.31/68j/9et 墍
RADIO SYSTEM
Entertainment
2. AUDIO MCINTOSH SYSTEM S901467A2102
BU76-22A
ET-5
墌 00.5.31/68j/9et 墍
RADIO SYSTEM
Entertainment
BU76-22B
ET-6
墌 00.5.31/68j/9et 墍
RADIO SYSTEM
Entertainment
BU76-22C
ET-7
墌 00.5.31/68j/9et 墍
RADIO SYSTEM
Entertainment
Symptom Repair order

No power coming in (No display and no sound from speakers) (1) Check fuse and power supply for radio.
(2) Check radio ground.
(3) Remove radio for repair.
A specific speaker does not operate. (1) Check speaker.
(2) Check output circuit to speaker
쐌 between radio and speaker (except McIntosh system).
쐌 between speaker amplifier and speaker (McIntosh system).
Radio controls are operational, but sound is not heard from (1) Check fuse and power supply for speaker amplifier.
speakers. (McIntosh system) (2) Check speaker amplifier ground.
Woofer does not operate (McIntosh system). Check output circuit to woofer from speaker amplifier.
Radio generates noise with engine running (1) Check radio ground.
(2) Check generator.
(3) Check ignition coil.
AM and FM modes are weak or noisy (1) Check antenna.
(2) Check antenna amplifier.
(3) Check radio ground.
ET-8
墌 00.5.31/68j/9et 墍
CIGARETTE LIGHTER SYSTEM
Entertainment
3. Cigarette Lighter System S901494

1. CIGARETTE LIGHTER S901494A2101
ET-9
BU97-20
RADIO BODY
Entertainment
4. Radio Body S901469
1) Remove front cover (A).

2) Remove two screws (B) and then remove cen-
ter panel (C) while disconnecting connector.
B6M1209A
3) Remove fitting screws, and slightly pull radio

out from center console.
B6M1210
4) Disconnect electric connectors and antenna

feeder cord and then disconnect heater control
unit.
ET-10
FRONT SPEAKER
Entertainment
5. Front Speaker S901466

2) Remove front speaker mounting screws.
B6M1211

front speaker.
ET-11
REAR SPEAKER
Entertainment
6. Rear Speaker S901470
1) Remove rear door trim. <Ref. to EI-33>

REMOVAL, Rear Door Trim.
2) Remove rear speaker mounting screws.
B6M1211
3) Disconnect harness connector and remove rear

speaker.
ET-12
WOOFER
Entertainment
7. Woofer S901612
1) Remove trim of woofer.
B6M1511A
2) Remove woofer mounting screws.
B6M1512
3) Disconnect harness connector, and then

remove woofer.
ET-13
SPEAKER AMPLIFIER
Entertainment
8. Speaker Amplifier S901613
1) Remove passenger’s seat. <Ref. to SE-6

REMOVAL, Front Seat.>
2) Disconnect harness connector.
3) Remove mounting nuts, and then detach
speaker amplifier.
B6M1513
ET-14
ANTENNA
Entertainment
9. Antenna S901463 B: REPAIR S901463A19
A: INSPECTION S901463A10
1) Clean antenna wire and the surrounding area
with a cloth dampened by alcohol.
Check continuity between antenna terminal and 2) Paste a thin masking film on glass along the
each antenna wire. broken wire.
If an antenna wire is OK, continuity should exist. If 3) Deposit conductive silver composition
an antenna wire is broken, no continuity should (DUPONT NO. 4817) on the broken portion with a
exist. drawing pen.
NOTE:
When checking continuity, wind a piece of tin foil
around the tip of the tester probe and press the foil
against the wire with your finger.
G6M0138
4) Dry out the deposited portion.

5) After repair has been completed, check
repaired wire for continuity.
B6M1494A
To locate the broken point, move the probe along

the antenna wire.
B6M1495
ET-15
ANTENNA AMPLIFIER
Entertainment
10. Antenna Amplifier S901460 B: INSTALLATION S901460A11
1. SEDAN S901460A1801 C: INSPECTION S901460A10
1) Remove rear pillar upper trim (left side). <Ref. 1. SEDAN S901460A1001
to EI-44 REMOVAL, Rear Quarter Trim.>
2) Disconnect harness connector and terminal.
3) Remove mounting screw and detach antenna
amplifier.
B6M1545A
Measure resistance between terminal and ampli-

fier body.
B6M1328
Tester connection Resistance
A — Amplifier body 0 Ω (Continuity)
2. WAGON S901460A1802
B — Amplifier body More than 100 kΩ
1) Remove rear quarter lower trim (left side). <Ref. a — Amplifier body 0 Ω (Continuity)
to EI-44 REMOVAL, Rear Quarter Trim.> b — Amplifier body More than 100 kΩ
2) Disconnect harness connector and terminal. c — Amplifier body More than 100 kΩ
3) Remove mounting screw and detach antenna A—a 0 Ω (Continuity)
amplifier.
2. WAGON S901460A1002
B6M1212
B6M1546A
Measure resistance between terminal and ampli-

fier body.
Tester connection Resistance (Ω)
A — Amplifier body More than 100 kΩ
B — Amplifier body More than 100 kΩ
a — Amplifier body More than 100 kΩ
b — Amplifier body More than 100 kΩ
ET-16
CIGARETTE LIGHTER
Entertainment
11. Cigarette Lighter S901461
1) Remove center panel. <Ref. to ET-10

REMOVAL, Radio Body.>
2) Disconnect harness connectors and remove
cigarette lighter.
B6M1510
ET-17
CIGARETTE LIGHTER
Entertainment
MEMO:
ET-18
GENERAL DESCRIPTION
Glass/Windows/Mirrors
1. FIXED GLASS (SEDAN) S905001A0501
B5M0817B
(1) Windshield glass (4) Rearview mirror mount (7) 6 light glass
(2) Dam rubber (5) Locate pin
(3) Molding (6) Rear window glass
GW-2
墌 00.5.31/68j/9gw 墍
GENERAL DESCRIPTION
2. FIXED GLASS (WAGON) S905001A0502
B5M1043A
(1) Windshield glass (4) Rearview mirror mount (7) Rear quarter glass
(2) Dam rubber (5) Locate pin (8) Locate pin
(3) Molding (6) Fastener (9) Glass
GW-3
墌 00.5.31/68j/9gw 墍
GENERAL DESCRIPTION
3. FRONT DOOR GLASS S905001A0503
B5M0714A
(1) Glass (5) Motor ASSY Tightening torque: N·m (kgf-m, ft-lb)
(2) Door sash (Front)
T1: 7.35 (0.75, 5.4)
(3) Door sash (Rear)
T2: 14 (1.4, 10.1)
(4) Regulator ASSY
GW-4
墌 00.5.31/68j/9gw 墍
GENERAL DESCRIPTION
4. REAR DOOR GLASS S905001A0504
B5M0715A
(1) Glass (5) Motor ASSY Tightening torque: N·m (kgf-m, ft-lb)
(2) Door sash (Front)
T1: 7.35 (0.75, 5.4)
(3) Door sash (Rear)
T2: 14 (1.4, 10.1)
(4) Regulator ASSY
GW-5
墌 00.5.31/68j/9gw 墍
GENERAL DESCRIPTION
5. MIRRORS S905001A0505
B5M1057B
(1) Outer mirror (3) Mount (5) Mirror

(2) Inner rearview mirror (4) Spring
GW-6
墌 00.5.31/68j/9gw 墍
GENERAL DESCRIPTION
B: CAUTION S905001A03 쐌 Avoid impact and damage to the glass.

쐌 When electrical connectors are disconnected, C: PREPARATION TOOL S905001A17
always conduct an operational check after con-
necting them again.
TOOL NAME REMARKS

Circuit tester Used for checking voltage and continuity.
Piano wire Used for window glass removal.
Windshield knife Used for window glass removal.
GW-7
墌 00.5.31/68j/9gw 墍
POWER WINDOW SYSTEM
2. Power Window System S905456
GW-8
墌 00.5.31/68j/9gw 墍
POWER WINDOW SYSTEM
1. POWER WINDOW S905456A2101
BU70-21A
GW-9
墌 00.5.31/68j/9gw 墍
POWER WINDOW SYSTEM
BU70-21B
GW-10
墌 00.5.31/68j/9gw 墍
POWER WINDOW SYSTEM
BU70-21C
GW-11
墌 00.5.31/68j/9gw 墍
POWER WINDOW SYSTEM
BU70-21D
GW-12
墌 00.5.31/68j/9gw 墍
POWER WINDOW SYSTEM

(1) Fuse (SBF-6) (F/B No. 18)
(2) Power window circuit breaker
All power windows does not operate.
(3) Power window relay
(4) Wire harness
(1) Power window main switch
(2) Power window sub switch
One window does not operate.
(3) Power window motor
(4) Wire harness
“Window Lock” does not operate. (1) Power window main switch
GW-13
墌 00.5.31/68j/9gw 墍
REAR WINDOW DEFOGGER SYSTEM
3. Rear Window Defogger System S905455
1. REAR WINDOW DEFOGGER S905455A2101
BU52-21
GW-14
墌 00.5.31/68j/9gw 墍
REAR WINDOW DEFOGGER SYSTEM

(1) Fuse (M/B No. 1)
(2) Rear defogger relay
(3) Defogger switch
Rear window defogger does not operate.
(4) Rear defogger condenser
(5) Deffogger wire
(6) Wire harness
GW-15
墌 00.5.31/68j/9gw 墍
WINDSHIELD WIPER DEICER SYSTEM
4. Windshield Wiper Deicer System S905457
1. WINDSHIELD WIPER DEICER S905457A2101
BU78-20
GW-16
WINDSHIELD WIPER DEICER SYSTEM

(1) Fuse (F/B No. 18, 19)
(2) Wiper deicer relay
Wiper deicer does not operate.
(3) Wiper deicer switch
(4) Wire harness
GW-17
REMOTE CONTROL MIRROR SYSTEM
5. Remote Control Mirror System S905458
1. REMOTE CONTROL MIRROR S905458A2101
BU79-21
GW-18
墌 00.5.31/68j/9gw 墍
REMOTE CONTROL MIRROR SYSTEM

(1) Fuse (F/B No. 4)
All function does not operate. (2) Mirror switch
(3) Wire harness
(1) Mirror switch
One side of the mirror motor does not operate. (2) Mirror motor
(3) Wire harness
(1) Mirror switch
Mirror heater does not operate. (2) Mirror heater
(3) Wire harness
GW-19
墌 00.5.31/68j/9gw 墍
FRONT DOOR GLASS
6. Front Door Glass S905452

7) Operate the power window switch to move
glass to the position shown in the figure, and then
A: REMOVAL S905452A18 remove the two nuts from service holes.
1) Remove door trim. <Ref. to EI-32 REMOVAL,
Front Door Trim.>
2) Remove sealing cover. <Ref. to EB-13
REMOVAL, Front Sealing Cover.>
3) Remove outer weatherstrip.
4) Remove inner stabilizer.
B5M1046
8) Take out glass door panel upward.
B5M1044
5) Remove outer mirror. <Ref. to GW-40

REMOVAL, Outer Mirror Assembly.>
6) Remove gusset.
B5M1047
CAUTION:
쐌 Do not turn regulator in the closing direction
after removal of the glass. Otherwise gear may
be disengaged.
쐌 Avoid impact and damage to the glass.

CAUTION:
Make sure that glass stay is placed securely in
sash.
2) Adjust front door glass. <Ref. to GW-21
ADJUSTMENT, Front Door Glass.>
B5M1045
GW-20
墌 00.5.31/68j/9gw 墍
FRONT DOOR GLASS
C: ADJUSTMENT S905452A01 5) For adjustment of upper and lower ends of cen-

ter pillar, loosen adjusting nut (A) of B-channel (B).
NOTE:
Before adjustment, ensure that all adjusting bolts
of stabilizer, upper stopper, and sash are loose and
door glass is raised so that it is in contact with
weatherstrip.
1) Temporarily tighten one adjusting bolt on one
side of rear sash at the midpoint of slotted hole in
the inner panel.
2) Temporarily tighten regulator B-channel in a
position slightly lower than midpoint of slotted hole.
3) Lower door glass 10 to 15 mm (0.39 to 0.59 in)
B5M0729A
from fully closed position. While applying outward
pressure of 49.0±4.9 N (5.0±0.5 kg, 11.0±1.1 lb) 6) Adjust so that upper and lower ends of center
(F) to upper edge of glass above midpoint of two pillar are the same size.
outer stabilizers, press inner stabilizer until it just
touches the glass, then secure it.
G5M0421
4) For adjustment of clearance between front and

rear glasses, loosen nuts (A) and (B), and move
glass sash back and forth until clearance becomes
the value shown.
B5M0728A
7) For glass stroke adjustment, close door, raise

glass until positional relationship between glass
and weatherstrip becomes as shown. And secure
the glass so that upper stopper lightly touches the
B5M0731A glass holder.
B5M0732A
B5M0730A
GW-21
墌 00.5.31/68j/9gw 墍
FRONT DOOR GLASS
8) After stabilizer adjustment, carry out glass part of gusset to prevent generation of wind noise.
crimp adjustment. First, visually ensure positional 13) During adjustments, loosen other three clamp-
relationship between retainer & molding and glass ing bolts.
of the roof side, and then begin with rear sash
adjustment. Adjust two adjusting bolts alternately
step by step to obtain dimensions shown below
(cross-section A).
NOTE:
If two nuts are loosened at the same time, sash
moves back and forth. Therefore, when one nut is
adjusted, secure the other.
9) Make the same adjustment of two adjusting
bolts of rear sash.
B5M0732A
B5M1048A
CAUTION: 14) After adjustment, tighten bolts and nuts.

Do not tilt sash bracket to inner panel during
adjustment. Otherwise smooth regulator
operation cannot be achieved.
S5M0201A
10) Make adjustment of front sash in the same

manner as that of rear sash.
CAUTION:
Although front and rear sashes must, as a rule,
be adjusted in the same manner, in some door
installation, the adjustment in a different man-
ner 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.
11) After adjustments, tighten nuts.
12) After adjustment of glass, if there is a gap
between outer lip of gusset and glass surface,
adjust the gap with adjusting bolt (A) in lower fitting
GW-22
墌 00.5.31/68j/9gw 墍
FRONT REGULATOR AND MOTOR ASSEMBLY
7. Front Regulator and Motor

Assembly S905449

Front Door Trim.>
2) Remove sealing cover. <Ref. to EB-13
3) Remove inner remote. <Ref. to SL-34
REMOVAL, Front Inner Remote.>
4) Remove door glass. <Ref. to GW-20
REMOVAL, Front Door Glass.>
5) Disconnect electrical connector.
6) Loosen four bolts and two nuts to pull out regu-
lator assembly.
B5M1049
7) Loosen screws to remove motor assembly.
B5M1050

2) Adjust front door glass. <Ref. to GW-21
ADJUSTMENT, Front Door Glass.>
1) Make sure that power window motor rotates

properly when battery voltage is applied to termi-
nals of motor connector.
2) Change polarity of battery connections to termi-
nals to ensure that motor rotates in reverse direc-
tion.
GW-23
REAR DOOR GLASS
8. Rear Door Glass S905450 B: INSTALLATION S905450A11
1) Remove door trim. <Ref. to EI-33 REMOVAL, CAUTION:
Rear Door Trim.> Make sure that glass stay is placed securely in
2) Remove sealing cover. <Ref. to EB-16 sash.
REMOVAL, Rear Sealing Cover.> 2) Adjust rear door glass. <Ref. to GW-24
3) Remove stabilizer. ADJUSTMENT, Rear Door Glass.>
NOTE:
Rear door glass, as a rule, should be adjusted in
the same manner as front glass, although they are
different in dimension. Special notes for rear glass
are given below.
1) Adjust glass position using the following dimen-
sions as a guide line.
B5M1044
4) Operate power window switch to move glass as

shown in the figure, and remove two nuts.
B5M0935A
CAUTION:
쐌 If dimensions are smaller than the given
B5M1046
dimensions, glass may get caught in weather-
5) Loosen two screws to remove weatherstrip. strip during lifting/lowering operation. In the
worst case, it may cause glass not to be
opened fully.
쐌 After adjustment, move glass up and down
to check whether it is caught.
2) Adjust crimp of glass using the following dimen-
sions as a guide line.
B5M1051
6) Pull out glass.

CAUTION:
Avoid impact and damage to the glass.
B5M0936A
CAUTION:
쐌 If crimp of rear glass is higher than
necessary, glass may get caught in weather-
strip of center pillar corner, resulting in early
GW-24
墌 00.5.31/68j/9gw 墍
REAR DOOR GLASS
wear of weatherstrip. Be careful when adjust-

ing.
쐌 After adjustment, move glass up and down
to check whether it is caught.
GW-25
墌 00.5.31/68j/9gw 墍
REAR REGULATOR AND MOTOR ASSEMBLY
9. Rear Regulator and Motor B: INSTALLATION S905451A11
Assembly S905451 1) Install in the reverse order of removal.

2) Adjust rear door glass. <Ref. to GW-24
ADJUSTMENT, Rear Door Glass.>
Rear Door Trim.> C: INSPECTION S905451A10
2) Remove sealing cover. <Ref. to EB-16 1) Make sure that power window motor rotates
REMOVAL, Rear Sealing Cover.> properly when battery voltage is applied to termi-
3) Remove door glass. <Ref. to GW-24 nals of motor connector.
REMOVAL, Rear Door Glass.> 2) Change polarity of battery connections to termi-
4) Secure bolts using screwdriver to remove front nals to ensure that motor rotates in reverse direc-
sash adjusting nut. tion.
B5M1052
5) Remove front sash.

6) Disconnect electrical connector.
7) Loosen four bolts and two nuts to remove regu-
lator assembly.
B5M1049
8) Loosen screws to remove motor assembly.
B5M1050
GW-26
WINDSHIELD GLASS
10. Windshield Glass S905448

NOTE:
Because matching pins are bonded to the corners
A: REMOVAL S905448A18 of glass, use piano wire to cut the pin.
1. USING WINDSHIELD KNIFE S905448A1801
1) Remove cowl panel. <Ref. to EI-27 REMOVAL,

Cowl Panel.>
2) Remove front side molding and upper front
molding.
3) Tape body side of the circumference of wind-
shield glass for protection.
4) Apply sufficient amount of soapy water to adhe-
sive layer.
5) Insert windshield knife into the adhesive layer. G5M0412
6) While holding the knife edge and windshield
glass edge at a right angle, move windshield knife 2. USING PIANO WIRE S905448A1802
in parallel to windshield glass edge along face and
edge of windshield glass to cut the adhesive layer. 1) Remove cowl panel. <Ref. to EI-27 REMOVAL,
Cowl Panel.>
CAUTION: 2) Remove roof molding and upper front molding.
쐌 Do not twist windshield knife. 3) Tape the body side of the circumference of
쐌 Cutting of adhesive layer shall be started windshield glass for protection.
with wider gap between windshield glass and 4) Make a hole in adhesive layer using drill or
body. knife.
5) Pass piano wire through the hole, and attach
securely both the wire ends to pieces of wood.
G5M0494
6) Pull the wire ends alternately to cut off the

adhesive layer.
CAUTION:
쐌 Do not tightly pull the piano wire against the
windshield glass edge.
쐌 Be careful not to damage interior and exte-
rior parts.
쐌 When removal is made with area close to
G5M0418
instrument panel, place a protection plate over
it. Pay particular attention to the removal.
쐌 Do not cross piano wires. Otherwise they
may be cut.
GW-27
墌 00.5.31/68j/9gw 墍
WINDSHIELD GLASS
B: INSTALLATION S905448A11 8) Fit molding mark (B) to notch (A) of ceramic

print.
1) Clean external circumference of windshield
glass with alcohol or white gasoline.
2) Remove adhesive layer on the body using cut-
ter 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 body with alcohol or white gasoline to

remove thoroughly chips, dusts, and dirts from
body face. B5M0734A
4) Place glass on body.
5) Adjust glass position to make uniform clear- 9) Apply primer to adhesive layer of glass using
ance between body and glass in four corners. sponge.
6) Place matching pins and body on glass. 10) Apply primer to adhesive layer of body.
CAUTION:
쐌 Primer once attached to the painted surface
of the body and internal trim is hard to wipe off.
Mask the circumference of such areas.
쐌 Let primer dry for about ten minutes before
installing the glass.
쐌 Do not touch surface coated with primer.
G5M0407
7) Remove glass from body.
G5M0495
GW-28
墌 00.5.31/68j/9gw 墍
WINDSHIELD GLASS
11) Cut off cartridge nozzle tip and set it in seal-

ant gun as shown.
G5M0408
12) Apply adhesive to glass end surface as

shown.
13) Fit matching pins using suction rubber cup to
install windshield glass.
G5M0409
14) Lightly press windshield glass for tight fit.

15) Make adhesive surface flush using spatula.
CAUTION:
쐌 When door is opened/closed after glass is
bonded, always lower door glass and then
open/close it carefully.
쐌 Move vehicle slowly.
16) After completion of all work, allow vehicle to
stand for about 24 hours.
NOTE:
For minimum drying time and time the vehicle must
be left standing before driving after bonding, follow
instructions or instruction manual from the adhe-
sive manufacturer.
17) After curing of adhesive, pour water on exter-
nal surface of vehicle to check that there are no
water leaks.
CAUTION:
When a vehicle is returned to the user, tell him
or her that the vehicle should not be subjected
to heavy impact for at least three days.
18) Install cowl panel. <Ref. to EI-27
INSTALLATION, Cowl Panel.>
GW-29
墌 00.5.31/68j/9gw 墍
REAR GATE GLASS
11. Rear Gate Glass S905376

CAUTION:
A: REMOVAL S905376A18 or her that the vehicle should not be subjected
1) Remove real wiper motor. <Ref. to WW-17
REMOVAL, Rear Wiper Motor.> 5) Connect rear defogger terminals.
2) Remove electrical connector from rear defog- 6) Install rear wiper. <Ref. to WW-17
ger terminal. INSTALLATION, Rear Wiper Motor.>
3) Remove glass in the same procedure as for
windshield glass. <Ref. to GW-27 REMOVAL,
Windshield Glass.>
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.
S5M0209A
CAUTION:
NOTE:
sive manufacturer.
GW-30
REAR QUARTER GLASS
12. Rear Quarter Glass S905453
1. SEDAN S905453A1801
Remove glass in the same procedure as for windshield glass. <Ref. to GW-27 REMOVAL, Windshield
Glass.>
Rear quarter glass Body panel
Matching pin
Matching pin Trim panel Matching pin
Section A B5M0819A
2. WAGON S905453A1802
Remove glass in the same procedure as for windshield glass. <Ref. to GW-27 REMOVAL, Windshield
Glass.>
B: INSTALLATION S905453A11 CAUTION:

1) Cut off nozzle tip as shown in the figure. or her that the vehicle should not be subjected
G5M0414
2) Install glass in the same procedure as for wind-

shield glass. <Ref. to GW-28 INSTALLATION,
Windshield Glass.>
CAUTION:
NOTE:
sive manufacturer.
4) After curing of adhesive, pour water on external
surface of vehicle to check that there are no water
leaks.
GW-31
REAR WINDOW GLASS
13. Rear Window Glass S905454

CAUTION:
A: REMOVAL S905454A18 or her that the vehicle should not be subjected
1) Disconnect electrical connectors from rear
defogger terminals.
2) Remove glass in the same procedure as for
windshield glass. <Ref. to GW-27 REMOVAL,
Windshield Glass.>
1) Bond dam rubber and matching pin.
12.5 (0.492)
Matching pin
Fastener
Dam rubber
12.5 (0.492)
R15
16.5 (0.650)
Unit: mm (in)
B5M0818A
2) Install glass in the same procedure as for wind-

shield glass. <Ref. to GW-28 INSTALLATION,
Windshield Glass.>
3) Connect rear defogger terminals.
CAUTION:
open/close door carefully.
NOTE:
sive manufacturer.
5) After curing of adhesive, pour water on external
surface of vehicle to check that there are no water
leaks.
GW-32
ROOF WINDOW GLASS
14. Roof Window Glass S905339
<Ref. to SR-7 REMOVAL, Sunroof Lid.>
<Ref. to SR-7 INSTALLATION, Sunroof Lid.>
<Ref. to SR-7 ADJUSTMENT, Sunroof Lid.>
GW-33
INNER REARVIEW MIRROR
15. Inner Rearview Mirror S905340
1) Turn mirror base 90 degrees clockwise or coun-

terclockwise to remove it.
B5M1059
2) Remove spring from mirror base.
B5M1060
CAUTION:
Be careful not to damage the mirror surface.
Do not let mirror be damaged.

Do not let spring deteriorate.
GW-34
POWER WINDOW CONTROL SWITCH
16. Power Window Control 2. SUB-SWITCH S903621A1802
Switch S905621 Remove two hooks of switch panel to remove

power window sub-switch and disconnect electrical
A: REMOVAL S903621A18 connector.
1. MAIN SWITCH S903621A1801

power window main switch.
B5M1017
B5M1136A
2) Disconnect electrical connectors from power

window main switch and mirror switch.
2. SUB-SWITCH S903621A1102
B5M1008
Check continuity between connector terminals.

Driver’s switch:

AUTO UP 3 — 9, 7 — 1 Continuity
UP 3 — 9, 7 — 1 Continuity
OFF 3—7—1 Continuity
DOWN 7 — 9, 3 —1 Continuity
AUTO DOWN 7 — 9, 3 — 1 Continuity
Front passenger’s switch:

OFF 1—5—4 Continuity
DOWN 9 — 4, 1 — 5 Continuity
GW-35
POWER WINDOW CONTROL SWITCH
Rear left switch:

OFF 1 — 13 — 8 Continuity
Rear right switch:

OFF 1 — 16 — 14 Continuity
If NG, replace the main switch.

2. SUB-SWITCH S903621A1002

Front passenger’s door switch and rear door switch:

UP 5— 1, 6 — 2 Continuity
OFF 4— 1, 6 — 2 Continuity
DOWN 5— 2, 4 — 1 Continuity
If NG, replace the sub-switch.
GW-36
REAR WINDOW DEFOGGER SWITCH
17. Rear Window Defogger <Ref. to AC-30 REMOVAL, Control Unit.>

SwitchS905559
A: REMOVAL S905559A18 <Ref. to AC-30 INSTALLATION, Control Unit.>
GW-37
REAR WINDOW DEFOGGER SWITCH
Check continuity between connectors at the back

of heater control unit.
AUTO A/C:

OFF — No continuity
ON (i48) 13 — (i49) 12 Continuity
MANUAL A/C:

OFF (i17) 14 — (i17) 10 Continuity
GW-38
REAR WINDOW DEFOGGER
18. Rear Window Defogger S905341 B: REPAIR S905341A11
1) Clean broken portion with alcohol or white
gasoline.
CAUTION: 2) Mask both side of wire with thin film.
When wiping stain on glass off with cloth, use 3) Apply conductive silver composition (DUPONT
a dry and soft cloth and move it in the direction No. 4817) to broken portion.
of the heat wire extension to avoid damage to
the heat wire.
1) Turn ignition switch to ON.
2) Turn defogger switch to ON.
3) Wrap tips of tester pins with aluminum foil to
avoid damage to heat wire.
G6M0138
4) After repair, check wire.
G6M0136
4) Measure voltage at wire center with DC voltme-

ter.
Standard voltage:
Approx. 6 volts
B5M1053A
Voltage Criteria
Approx. 6 V OK
Approx. 12 V or 0 V Broken
NOTE:
쐌 If the measured value is 12 volts, heat wire is
open between wire center and positive (+) end.
쐌 If zero volt, heat wire is open between wire cen-
ter and ground.
5) Apply positive lead of voltmeter to positive ter-
minal of voltmeter, and then move negative lead
along the wire up to the negative terminal end. If
voltage changes from zero to several volts during
movement of lead, heat wire is open at the voltage
change point.
GW-39
OUTER MIRROR ASSEMBLY
19. Outer Mirror Assembly S905338

3) Loosen screws to remove mirror assembly.

Front Door Trim.>
2) Pull off sealing cover to disconnect mirror elec-
trical connector.
B5M1055
B5M1054
GW-40
墌 00.5.31/68j/9gw 墍
OUTER MIRROR ASSEMBLY
Check to ensure that rearview mirror moves prop-

erly when battery voltage is applied to terminals.
Switch position Terminal connection

OFF
UP 1 (+) — 3 (−)
DOWN 3 (+) — 1 (−)
LEFT 2 (+) — 3 (−)
RIGHT 3 (+) — 2 (−)
If NG, replace the mirror.
GW-41
OUTER MIRROR
20. Outer Mirror S905658
A: REPLACEMENT S905658A20
1) Remove the door mirror assembly. <Ref. to

GW-40 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 mir-
rors with heaters.)
B5M1144A
4) Warm the area around the mirror holder with a

hair drier until the edges of the mirror holder
become soft (about 2 or 3 minutes with a 1,000 W
drier.)
5) Remove the backing of the new two-sided tape,
and push the mirror in to install it.
CAUTION:
Unless the mirror holder is warmed sufficiently,
the mirror holder edges may be damaged or the
mirror cracked.
GW-42
REMOTE CONTROL MIRROR SWITCH
21. Remote Control Mirror B: INSTALLATION S905342A11
Switch S905342 Install in the reverse order of removal.

1) Remove power window main switch panel.
B5M1136A
2) Remove four hook to remove remote control

mirror switch.
B5M1056
GW-43
REMOTE CONTROL MIRROR SWITCH
Move rearview mirror switch to each position and

check continuity between terminals.
B5M1132
Change over switch left position:

LEFT 9 — 4, 2 — 1 Continuity
RIGHT 9 — 2, 4 — 1 Continuity
Change over switch right position:

LEFT 8 — 4, 2 — 1 Continuity
RIGHT 8 — 2, 4 — 1 Continuity
If NG, replace the switch.
GW-44
WIPER DEICER
22. Wiper Deicer S905622
Refer to INSPECTION under Rear Window Defog-

ger. <Ref. to GW-39 INSPECTION, Rear Window
Defogger.>
B: REPAIR S905622A11
Refer to REPAIR under Rear Window Defogger.

<Ref. to GW-39 REPAIR, Rear Window Defog-
ger.>
GW-45
WIPER DEICER SWITCH
23. Wiper Deicer Switch S905623
Remove driver side switch panel, and then remove

wiper deicer switch.
B5M1119
Move wiper deicer switch to each position and

check continuity between terminals.
Specified condi-
tion
ON 3—5 Continuity
If NG, replace the switch.
GW-46
GENERAL DESCRIPTION
Lighting System
12 V — 65 W/55 W (Except GT, OUTBACK)

Headlight
12 V — 60 W/55 W (GT, OUTBACK)
Front turn signal light 12 V — 27 W (2 pieces)
Side marker, parking light 12 V — 8 W
12 V — 55 W (Except OUTBACK),
Front fog light
12 V — 51 W (OUTBACK)
Tail/Stop light 12 V — 8/27 W
Rear combination light Turn signal light 12 V — 21 W
Back-up light 12 V — 27 W
License plate light 12 V — 5 W
Sedan 12 V — 16 W
High-mounted stop light
Wagon 12 V — 13 W (4 pieces)
Room light 12 V — 8 W
Spot light 12 V — 8 W
Step light 12 V — 3.4 W
Luggage room light 12 V — 13 W
Trunk room light 12V — 5W
B: PRECAUTIONS S914001E59 tem wiring harnesses and connectors are yel-

low. Do not use electric test equipment on
쐌 Before disassembling or reassembling parts, these circuits.
always disconnect battery ground cable. When 쐌 Be careful not to damage the air bag system
wiring harness when servicing electrical parts
contents before disconnecting the battery ground and switches.
cable. Otherwise, the memory will be erased. C: PREPARATION TOOL S914001A17
unless otherwise indicated. 1. GENERAL TOOLS S914001A1701

TOOL NAME REMARKS
reassembly. Circuit Tester Used for measuring resistance and
voltage.
operate smoothly.
WARNING:
쐌 Air bag system wiring harness is routed near
electrical parts and switches. All air bag sys-
LI-2
HEADLIGHT AND TAIL LIGHT SYSTEM
Lighting System
2. Headlight and Tail Light System S914415
1. HEADLIGHT 2-LIGHT MODEL S914415A2101
BU18-21
LI-3
墌 00.5.31/68j/9li 墍
Lighting System
2. HEADLIGHT 4-LIGHT MODEL S914415A2102
BU18-22
LI-4
墌 00.5.31/68j/9li 墍
Lighting System
3. CLEARANCE LIGHT AND ILLUMINATION LIGHT S914415A2103
BU21-21A
LI-5
墌 00.5.31/68j/9li 墍
Lighting System
BU21-21B
LI-6
墌 00.5.31/68j/9li 墍
Lighting System
BU21-21C
LI-7
墌 00.5.31/68j/9li 墍
Lighting System
1. HEADLIGHT RELAY S914415A1001
Check continuity between terminals when terminal

No. 4 is connected to battery and terminal No. 3 is
grounded.
Continuity exists.
Continuity exists.
No. 3 and No. 4
S6M0048A
2. TAIL AND ILLUMINATION RELAY S914415A1002

Continuity exists.
Continuity exists.
No. 3 and No. 4
S6M0048A
LI-8
墌 00.5.31/68j/9li 墍
FRONT FOG LIGHT SYSTEM
Lighting System
3. Front Fog Light System S914473
1. FRONT FOG LIGHT 4 CYLINDER ENGINE MODEL S914473A2101
LI-9 BU22-21
墌 00.5.31/68j/9li 墍
Lighting System
2. FRONT FOG LIGHT 6 CYLINDER ENGINE MODEL S914473A2102
BU22-22
LI-10
墌 00.5.31/68j/9li 墍
Lighting System
1. FRONT FOG LIGHT SWITCH S914473A1001
B6M1482
Check continuity between terminals when operat-

ing the switch.
Specified condi-
tion
ON 3-5 Continuity
2. FRONT FOG LIGHT RELAY S914473A1002

Continuity exists.
Continuity exists.
No. 3 and No. 4
S6M0048A
LI-11
墌 00.5.31/68j/9li 墍
TURN SIGNAL AND HAZARD LIGHT SYSTEM
Lighting System
4. Turn Signal and Hazard Light System S914481
1. TURN SIGNAL LIGHT AND HAZARD LIGHT S914481A2101
BU26-21A
LI-12
墌 00.5.31/68j/9li 墍
Lighting System
BU26-21B
LI-13
墌 00.5.31/68j/9li 墍
Lighting System
1. TURN SIGNAL SWITCH S914481A1001
<Ref. to LI-24 INSPECTION, Combination Switch

(Light).>
2. HAZARD SWITCH S914481A1002
B6M1483

ing the switch.
Specified condi-
tion
OFF 6-7 Continuity
ON 1 - 3 - 4, 7 - 8 Continuity
3. TURN SIGNAL & HAZARD MODULE

S914481A1003
B6M1484
Connect battery and turn signal light bulb to the

module, as shown in the figure. The module is
properly functioning if it blinks when power is sup-
plied to the circuit.
LI-14
墌 00.5.31/68j/9li 墍
BACK-UP LIGHT SYSTEM
Lighting System
5. Back-up Light System S914414
1. BACK-UP LIGHT S914414A2101
LI-15 BU29-21
墌 00.5.31/68j/9li 墍
BACK-UP LIGHT SYSTEM
Lighting System
1. BACK-UP LIGHT SWITCH (M/T) S914414A1001

Specified condi-
tion
When shift lever
is set in reverse Continuity
1-2
position
Other positions No continuity
2. INHIBITOR SWITCH (A/T) S914414A1002
B6M1485

Specified condi-
tion
When select lever
is set in “R” posi- Continuity
tion 1-2
Other positions No continuity
LI-16
墌 00.5.31/68j/9li 墍
STOP LIGHT SYSTEM
Lighting System
6. Stop Light System S914417
1. STOP LIGHT SEDAN MODEL S914417A2101
LI-17 BU25-22
墌 00.5.31/68j/9li 墍
STOP LIGHT SYSTEM
Lighting System
2. STOP LIGHT WAGON MODEL S914417A2102
BU25-23
LI-18
墌 00.5.31/68j/9li 墍
STOP LIGHT SYSTEM
Lighting System
1. STOP LIGHT SWITCH S914417A1001
B6M1486A

Specified condi-
tion
When brake pedal 1 - 2: Without Continuity
is depressed cruise control
When brake pedal 2 - 3: With cruise
No continuity
is released control
LI-19
墌 00.5.31/68j/9li 墍
INTERIOR LIGHT SYSTEM
Lighting System
7. Interior Light System S914418
1. INTERIOR LIGHT S914418A2101
LI-20 BU23-21A
墌 00.5.31/68j/9li 墍
Lighting System
BU23-21B
LI-21
墌 00.5.31/68j/9li 墍
Lighting System
BU23-21C
LI-22
墌 00.5.31/68j/9li 墍
Lighting System
1. DOOR SWITCH S914418A1001
B6M1487A

Specified condi-
tion
When door is
Continuity
opened
1-3
When door is
No continuity
closed
2. REAR GATE LATCH SWITCH S914418A1002

Specified condi-
tion
When rear gate is
Continuity
opened
1-2
When rear gate is
No continuity
closed
3. TRUNK ROOM LIGHT SWITCH S914418A1003

Specified condi-
tion
When trunk lid is
Continuity
opened
1-2
When trunk lid is
No continuity
closed
LI-23
墌 00.5.31/68j/9li 墍
COMBINATION SWITCH (LIGHT)
Lighting System
8. Combination Switch (Light) C: INSPECTION S914411A10
S914411
1) Remove instrument panel lower cover. <Ref. to

EI-37 REMOVAL, Instrument Panel Assembly.>
2) Remove screws which secure upper column
cover to lower column cover.
B6M1184
3) Disconnect connector from combination switch.

4) Remove screws which secure switch and
remove switch.
B6M1488A
Move combination switch to respective positions

and check continuity between terminals.
1. LIGHTING SWITCH S914411A1001
Specified condi-
tion
Tail 14 - 16 Continuity
Head 13 - 14 - 16 Continuity
S6M0046
2. DIMMER AND PASSING SWITCH S914411A1002
Specified condi-
Install in the reverse order of removal. tion
Passing 7 - 8 - 16 Continuity
Low beam 16 - 17 Continuity
High beam 7 - 16 Continuity
3. TURN SIGNAL SWITCH S914411A1003
Specified condi-
tion
Left 1-2 Continuity
Neutral — No continuity
Right 2-3 Continuity
4. PARKING SWITCH S914411A1004
Specified condi-
tion
OFF 2-4 Continuity
ON 1-4 Continuity
LI-24
HEADLIGHT ASSEMBLY
Lighting System
9. Headlight Assembly S914409 B: INSTALLATION S914409A11
1) Remove duct (A) (when right side headlight is C: ADJUSTMENT S914409A01
removed).
1. HEADLIGHT AIMING S914409A0101
NOTE:
As this headlight is the “VISUAL AIMING TYPE”, it
is possible to adjust aiming only in the vertical
direction. It cannot be adjusted in the horizontal
direction.
CAUTION:
Turn off the light before adjusting headlight
aiming. If the light is necessary to check
B6M1186A
aiming, do not turn on for more than two min-
utes.
2) Disconnect headlight bulb connector.
NOTE:
Before checking the headlight aiming, be sure of
the following:
쐌 The area around the headlight has not sustained
any accident, damage or other type of deformation.
쐌 Vehicle is parked on level ground.
쐌 The inflation pressure of tires is correct.
쐌 Vehicle’s gas tank is fully charged.
쐌 Bounce the vehicle several times to normalize
the suspension.
쐌 Make certain that someone is seated in the driv-
er’s seat.
B6M1313A
3) Remove three bolts and disconnect connectors,

and then detach headlight assembly.
B6M1189
LI-25
墌 00.5.31/68j/9li 墍
HEADLIGHT ASSEMBLY
Lighting System
Turn the headlight on and then adjust the low

beam pattern to the following positions on the
screen.
NOTE:
Adjust the headlight aiming by turning the adjust-
ing screw (a).
B6M1311A
LI-26
墌 00.5.31/68j/9li 墍
HEADLIGHT ASSEMBLY
Lighting System
B6M1312A
LI-27
墌 00.5.31/68j/9li 墍
HEADLIGHT BULB
Lighting System
10. Headlight Bulb S914410
CAUTION:
쐌 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.
쐌 Do not leave the headlight without a bulb for B6M1187A
a long time. Dust, moisture, etc. entering the
headlight may affect its the performance. 3) Disconnect harness connector.
4) Push to remove spring retainer (A) (low beam)
1. SINGLE-BULB TYPE S914410A1801 or turn bulb assembly (B) counterclockwise (high
1) Remove duct (A) (when right side headlight is beam) , and then detach headlight bulb.
removed).
B6M1468A
B6M1186A

3) Remove rubber cover. Install in the reverse order of removal.

4) Push to remove spring retainer, and then
detach the headlight bulb.
2. DUAL-BULB TYPE S914410A1802
1) Remove duct (A) (when right side headlight is

removed).
B6M1186A
2) Remove back cover (A).
LI-28
墌 00.5.31/68j/9li 墍
FRONT TURN SIGNAL LIGHT BULB
Lighting System
11. Front Turn Signal Light

Bulb S914412
1) Remove headlight assembly. <Ref. to LI-25

REMOVAL, Headlight Assembly.>
2) Turn the socket and remove the bulb.
B6M1469
LI-29
PARKING LIGHT BULB AND SIDE MARKER LIGHT BULB
Lighting System
12. Parking Light Bulb and

Side Marker Light Bulb S914413
1) Remove headlight assembly. <Ref. to LI-25

REMOVAL, Headlight Assembly.>
B6M1470
LI-30
FRONT FOG LIGHT ASSEMBLY
Lighting System
13. Front Fog Light Assembly

S914427
1. EXCEPT OUTBACK S914427A1801
1) Remove two clips and lower the mudguard.
B6M1333
3) Remove two clips and lower the mudguard.
B6M1471

3) Remove mounting bolts , and then detach fog
light assembly.
B6M1471
4) Disconnect harness connector (a).

5) Remove nut (b) then detach fog light assembly.
B6M1473
2. OUTBACK S914427A1802
1) Turn stone guard counterclockwise, and then B6M1334A

remove it.
B6M1332
2) Remove mounting bolts.
LI-31
墌 00.5.31/68j/9li 墍
FRONT FOG LIGHT BULB
Lighting System
14. Front Fog Light Bulb S914428
1. EXCEPT OUTBACK S914428A1801
1) Remove the two clips and lower the mudguard.
B6M1471
2) Remove back cover (A).
B6M1473

4) Remove spring retainer then detach fog light
bulb.
2. OUTBACK S914428A1802
1) Remove fog light assembly. <Ref. to LI-31

OUTBACK, REMOVAL, Front Fog Light Assem-
bly.>
3) Loosen screws and turn the bulb assembly
counterclockwise, and then detach the bulb.
LI-32
REAR COMBINATION LIGHT ASSEMBLY
Lighting System
15. Rear Combination Light 2) Remove two nuts and then remove rear combi-
nation light while disconnecting connector.
Assembly S914426
NOTE:
A: REMOVAL S914426A18 Before removing the nuts, apply a few turns of
butyl tape to the tip of the service tool. This pre-
1. SEDAN S914426A1801
vents the nuts from falling during removal.
1) Remove clips and then detach trunk rear trim.
B5M0798
2) Remove hook (A) and then turn over the trunk

side trim of rear portion.
B6M1190
B5M0799A Install in the reverse order of removal.

3) Remove harness clip (A).
4) Remove three nuts and then detach rear com-
bination light while disconnecting connector.
B6M1292A
2. WAGON S914426A1802
1) Remove two rear quarter trim covers.
LI-33
墌 00.5.31/68j/9li 墍
REAR FINISHER LIGHT ASSEMBLY
Lighting System
16. Rear Finisher Light B: INSTALLATION S914429A11
Assembly S914429 Install in the reverse order of removal.
1. SEDAN S914429A1801
1) Open the trunk lid.

2) Remove cover (A).
3) Disconnect connector (B) from rear finisher
light.
4) Remove ten nuts and then detach rear finisher
light from trunk lid.
B6M1293A
2. WAGON S914429A1802
1) Remove rear gate lower trim. <Ref. to EI-49

REMOVAL, Rear Gate Trim.>
2) Remove rear gate trim lower (A).
B6M1191A
3) Disconnect connector from rear finisher light.

4) Remove nuts (A) and then remove rear finisher
light from rear gate.
B6M1541A
LI-34
BRAKE/TAIL LIGHT BULB
Lighting System
17. Brake/Tail Light Bulb S914430
1. SEDAN (COMBINATION LIGHT) S914430A1801
1) Open trunk lid and remove cover.
B6M1476

B6M1501A

2. SEDAN (FINISHER LIGHT) S914430A1802
B6M1502A

3. WAGON (COMBINATION LIGHT) S914430A1803
1) Remove rear combination light assembly. <Ref.

to LI-33 WAGON, REMOVAL, Rear Combination
Light Assembly.>
B6M1475
4. WAGON (FINISHER LIGHT) S914430A1804
1) Open rear gate lower trim cover.
LI-35
BACK-UP LIGHT BULB
Lighting System
18. Back-up Light Bulb S914424
1. SEDAN S914424A1801
B6M1502A

2. WAGON S914424A1802
1) Open rear gate lower trim cover.
B6M1476
LI-36
REAR TURN SIGNAL LIGHT BULB
Lighting System
19. Rear Turn Signal Light Bulb

S914421
1. SEDAN S914421A1801
B6M1501A

2. WAGON S914421A1802
1) Remove rear combination light assembly. <Ref.

to LI-33 WAGON, REMOVAL, Rear Combination
Light Assembly.>
2) Remove the light cover mounting screws then
detach the cover.
B6M1477
LI-37
LICENSE PLATE LIGHT
Lighting System
20. License Plate Light S914420
1) Remove license plate light mounting screw (A)

and then remove the lens (B)
B6M1478A
2) Remove the bulb.
LI-38
HIGH-MOUNTED STOP LIGHT
Lighting System
21. High-mounted Stop Light

S914425
1. SEDAN WITHOUT REAR SPOILER

S914425A1801
1) Disconnect connector of high-mounted stop

light from body harness.
2) Remove bolts, then detach high-mounted stop
light assembly.
B5M0816
2. SEDAN WITH REAR SPOILER S914425A1802
1) Remove two screws and then detach high-

mounted stop light assembly while disconnecting
connector.
3. WAGON S914425A1803
1) Remove cap (a) by prying on the edge with a

screwdriver.
2) Remove screws (b) and then detach cover (c).
3) Remove screws (d) and then detach high-
mounted stop light while disconnecting connector.
B6M1343A
LI-39
SPOT LIGHT
Lighting System
22. Spot Light S914398
1) Remove lens (A) and spot light mounting screw

(B).
B5M1041A

spot light.

Specified condi-
tion
ON 1-2 Continuity
LI-40
ROOM LIGHT
Lighting System
23. Room Light S914397
1) Remove lens (A) and room light mounting

screws (B).
B6M1479A

the light.
B6M1489

Specified condi-
tion
ON 1-3 Continuity
DOOR 1-2 Continuity
LI-41
LUGGAGE ROOM LIGHT
Lighting System
24. Luggage Room Light S914399
1) Remove lens (A) and luggage room light

mounting screws (B).
B6M1480A

luggage room light.
B6M1490A
Turn the switch each position and check continuity

between terminals.
Specified condi-
tion
ON (A) - (C) Continuity
DOOR (A) - (B) Continuity
LI-42
TRUNK ROOM LIGHT
Lighting System
25. Trunk Room Light S914393
Disconnect harness connectors and remove trunk

room light.
B6M1503
LI-43
GLOVE BOX LIGHT
Lighting System
26. Glove Box Light S914396

Glove Box.>
3) Remove glove box light.
B6M1514
LI-44
DOOR STEP LIGHT
Lighting System
27. Door Step Light S914390
Remove the lens then detach the bulb.
B6M1481
LI-45
DOOR STEP LIGHT
Lighting System
MEMO:
LI-46
GENERAL DESCRIPTION
Seats
1. FRONT SEAT S908001A0501
B5M0907A
(1) Front seat ASSY (5) Slide rail IN Tightening troque:N·m (kgf-m, ft-lb)
(2) Rail cover IN
T1: 30 (3.1, 22)
(3) Rail cover OUT
T2: 53 (5.4, 39)
(4) Slide rail OUT
SE-2
墌 00.5.31/68j/9se 墍
GENERAL DESCRIPTION
Seats
2. REAR SEAT (SEDAN) S908001A0502
B5M0908A
(1) Backrest (3) Cushion Tightening torque:N·m (kgf-m, ft-lb)

(2) Head restraint
T: 24.5 (2.5, 18.1)
SE-3
墌 00.5.31/68j/9se 墍
GENERAL DESCRIPTION
Seats
3. REAR SEAT (WAGON) S908001A0503
B5M0909A
(1) Cover (5) Backrest LH Tightening torque:N·m (kgf-m, ft-lb)

(2) Cushion (6) Head restraint
T1: 10 (1.0, 7.2)
(3) Hook (7) Striker
T2: 24.5 (2.5, 18.1)
(4) Backrest RH
SE-4
墌 00.5.31/68j/9se 墍
GENERAL DESCRIPTION
Seats
B: CAUTION S908001A03 쐌 When removing front seat from a side airbag

loaded vehicle, follow cautions given in the airbag
쐌 Take care not to contaminate or damage seat section.
surface.
쐌 While loading to or unloading to vehicle, take
care not to contact body.
C: PREPARATION TOOL S908001A17
1. GENERAL TOOL S908001A1701
TOOL NAME REMARKS

Long nose pliers Used for removing and installing hog ring
SE-5
墌 00.5.31/68j/9se 墍
FRONT SEAT
Seats
2. Front Seat S908343

10) Remove two bolts at front side of seat rail.
1. STANDARD S908343A1801
1) Disconnect battery (−) terminal.

2) While pressing headrest lock button, remove
headrest.
G5M0344
11) Remove front seat from vehicle.

CAUTION:
When removing seat form vehicle, take care
not to damage body, seat, or trim.
H5M0704
2. POWER S908343A1802
1) While pressing headrest lock button, remove

3) Tilt forward backrest. headrest.
4) Move seat to full front end.
5) Remove bolt cover at rear end of slide rail.
H5M0704
B5M0975 2) Tilt forward backrest.

3) Move seat to full front end.
6) Disconnect side airbag connector under the 4) Remove bolt cover at rear end of slide rail.
seat. (Side airbag equipped vehicle)
7) Disconnect connectors of seat heater and seat
belt warning. (Seat heater equipped vehicle)
8) Remove two bolts at rear side of seat rail.
B5M0975
H5M0705
9) Move seat to full rear end.
SE-6
墌 00.5.31/68j/9se 墍
FRONT SEAT
Seats
5) Remove two bolts at rear side of seat rail. B: INSTALLATION S908343A11

2) Place slide rail rear inner on location bolts.
H5M0705
6) Move seat to full rear end.

7) Remove two bolts at front side of seat rail.
B5M0661A
3) Tighten the four bolts of slide rail.

CAUTION:
Confirm that seat can move smoothly and be
locked securely at any position.
2. POWER S908343A1102

2) Place slide rail rear inner on location bolts.
G5M0344
8) Disconnect battery (−) terminal.

CAUTION:
쐌 Wait for 20 seconds or more after discon-
necting the batter
쐌 The air bag system has a backup power
source. The air bag might deploy if you do not
wait for 20 seconds or more before starting.
9) Disconnect side airbag connector under the
seat. (Side airbag equipped vehicle) B5M0661A
10) Disconnect connectors of seat heater and
seat belt warning. (Seat heater equipped vehicle) 3) Tighten the four bolts of slide rail.
CAUTION:
Confirm that seat can move smoothly.
B5M1073
11) Remove front seat from vehicle.

CAUTION:
When removing seat form vehicle, take care
not to damage body, seat, or trim.
SE-7
墌 00.5.31/68j/9se 墍
FRONT SEAT
Seats
C: DISASSEMBLY S908343A06 6) Remove clamp of seat heater wire harness.

(Seat heater equipped vehicle)
1) Remove seats from vehicle. <Ref. to SE-6

2) Remove lumber lever cover.
B5M0980
7) Turn cover and cushion, and remove the two

bolts from hinge.
B5M0976
3) Remove hook at bottom, and then remove seat

back board.
B5M0979
8) Remove hinge screw cover and screws, and

remove seat back from hinge.
B5M0957
4) Remove hook on back side of seat, and remove

hog rings using a plier.
B5M0978
9) While picking up tip with a plier, remove head-

rest lock bushing.
B5M0966
5) Remove clamp of side airbag wire harness.

(Side airbag equipped vehicle)
B5M0977
SE-8
墌 00.5.31/68j/9se 墍
FRONT SEAT
Seats
10) Remove hog ring on front face of seat. 14) Remove clamp of airbag wire harness on back
side of seat. (Side airbag equipped vehicle)
B5M0972
15) Remove the two cap nuts, and then remove

side airbag module assembly. (Side airbag
equipped vehicle)
B5M0974A
Side airbag equipped vehicle:
B5M0971
16) Remove reclining cover and hinge cover.

(Non-tilt type vehicle)
B5M1126A
11) Remove hog rings, and then remove seat

heater. (Seat heater equipped vehicle)
B5M0970
17) Remove the 4 bolts of seat hinge assembly,

and then remove seat cushion.
Tilt type vehicle:
B5M0973
12) Remove seat cover.

13) Remove backrest pad.
B5M0967
SE-9
墌 00.5.31/68j/9se 墍
FRONT SEAT
Seats
Non-tilt type vehicle: Non-tilt type vehicle:
B5M1123A
Leather type vehicle:
B5M0969
18) Remove hook clips on back side of seat B5M1124A

cushion, and remove wire rings.
19) Remove clamp of seat heater wire harness. 21) Remove cushion cover.
(Seat heater equipped vehicle) 22) Remove cushion pad.
23) Remove clip pins, and remove seat lifter lever.
B5M0968
B5M0964
20) Remove hog rings.
Tilt type vehicle: 24) Remove reclining lever cover.
B5M0963
B5M0965A
SE-10
墌 00.5.31/68j/9se 墍
FRONT SEAT
Seats
25) Remove hinge cover cap and screws. 28) Remove 4 screws, and then remove hinge.
B5M0962
B5M0959
26) Remove seat hinge cover and hinge spring
cover. 29) Remove 2 bolts, and then remove slide rail.
B5M0961
B5M0958A
27) Remove 2 bolts, and then remove slide rail.
30) Remove connecting wire.
2. POWER S908343A0602
1) Remove seats from vehicle. <Ref. to SE-6

2) Remove lumber lever cover.
B5M0976
B5M0960
SE-11
墌 00.5.31/68j/9se 墍
FRONT SEAT
Seats
3) Remove hook at bottom, and then remove seat 8) Remove hinge screw cover and screws, and
back board. remove seat back from hinge.
B5M0957 B5M0978
4) Remove hook on back side of seat, and remove 9) While picking up tip with a plier, remove head-
wire rings using a plier. rest lock bushing.
B5M0966
B5M0977
5) Remove clamp of side airbag wire harness.

10) Remove wire ring on front face of seat.
(Side airbag equipped vehicle)
6) Remove clamp of seat heater wire harness.
B5M0980
7) Turn cover and cushion, and remove the two

bolts from hinge.
B5M0974A
B5M0979
SE-12
墌 00.5.31/68j/9se 墍
FRONT SEAT
Seats
Side airbag equipped vehicle: 16) Remove the 4 bolts of seat hinge assembly,
and then remove seat cushion.
B5M1126A
B5M0967
11) Remove wire rings, and then remove seat
heater. (Seat heater equipped vehicle) 17) Remove hook clips on back side of seat
cushion, and remove wire rings.
18) Remove clamp of seat heater wire harness.
B5M0973
12) Remove seat cover.

13) Remove backrest pad. B5M0968
14) Remove clamp of airbag wire harness on back
side of seat. (Side airbag equipped vehicle) 19) Remove wire rings.
B5M0972 B5M0965A
15) Remove the two cap nuts, and then remove Leather type vehicle:
side airbag module assembly. (Side airbag
equipped vehicle)
B5M1124A
B5M0971
20) Remove cushion cover.
21) Remove cushion pad.
SE-13
墌 00.5.31/68j/9se 墍
FRONT SEAT
Seats
22) Remove the screw and then remove the 24) Remove the cover on the underside of the
cover. seat hinge, remove the two bolts, and remove the
seat hinge.
B5M1078
23) 8-way power:

Remove the screw, disconnect the seat switch
connector on the underside of the cover, and
remove the hinge cover.
B5M1076
B5M1075
6-way power:
Remove the reclining lever cover and screw, dis-
connect the seat switch connector on the under-
side of the cover, and remove the hinge cover.
B5M1077
SE-14
墌 00.5.31/68j/9se 墍
FRONT SEAT
Seats
D: ASSEMBLY S908343A02
1) Assemble in the reverse order of disassembly.

NOTE:
쐌 Do not contaminate or damage cover.
쐌 While installing hog rings, prevent seat from get-
ting wrinkled.
2) Attach seat cover end hole to hinge inner. (Only
non-tilt type standard seat)
2. POWER S908343A0202

NOTE:
쐌 While installing hog rings, prevent seat from get-
ting wrinkled.
쐌 Make sure the connector is firmly connected.
쐌 Make sure the wire harness is not pinched.
2) Attach seat cover end hole to hinge inner. (Only
non-tilt type standard seat)
SE-15
墌 00.5.31/68j/9se 墍
REAR SEAT
Seats
3. Rear Seat S908350

5) Remove bolts and nuts of bracket hinge.
1. WAGON S908350A1801
1) Remove cushion, and then remove bolt covers.
B5M0665
B5M0915A
2) Remove bolts, and then remove rear seat cush-

ion.
B5M0811
6) Remove rear seat backrest.

2. SEDAN S908350A1802
1) Slightly raise front of cushion while pushing

down on cushion in the direction of “A”. With cush-
B5M0916 ion held in that position, move it forward until it is
unhooked.
3) Remove headrest.
4) Remove clips, and then remove rear floor front
mat.
B5M0914A
B5M0664A
SE-16
墌 00.5.31/68j/9se 墍
REAR SEAT
Seats
2) Remove bolts securing lower portion of back- B: INSTALLATION S908350A11

rest and then open the center trunk through lid.
1. WAGON S908350A1101

2. SEDAN S908350A1102
1) Hook and fasten the upper-back side of the rear

seat backrest to the body hook.
B5M0811
3) Lift rear seat backrest and then remove it.
G5M0348
2) Tighten the bolt and install the backrest.
B5M0811
3) Hook and fasten the seat cushion to the hook

on the lower part of the rear seat backrest.
B5M0914A
SE-17
墌 00.5.31/68j/9se 墍
REAR SEAT
Seats
C: DISASSEMBLY S908350A06 6) Remove backrest hook.

1. WAGON S908350A0601
1) Remove rear seat. <Ref. to SE-16 REMOVAL,

Rear Seat.>
2) Remove bolts, and then remove bracket hinge.
B5M0984
7) Remove hook at bottom.
B5M0981
3) Remove rear backrest lock cover.
B5M0985
8) Remove 4 pawls.
B5M0983
4) While turning counterclockwise rear backrest

knob, remove it.
5) While picking up tip with pliers, remove head-
rest lock bushings.
B5M0986
9) Remove 8 hog rings.
B5M0982
B5M0987
10) Remove the hog rings on front side of cushion

pad.
SE-18
墌 00.5.31/68j/9se 墍
REAR SEAT
Seats
Armrest not-equipped vehicle: 12) Remove bolts, and then remove cushion
hinge.
B5M1111A
B5M1079
Armrest-equipped vehicle:
13) Remove rear cushion mat.
B5M1112A
B5M0989
Child seat-equipped vehicle:
14) Remove hook, and then remove frame.
B5M1113A
B5M0992
Child seat cushion: 15) Remove hog rings, and then remove cover.
B5M1127 B5M1080A
11) Remove cover. When disassembly of rear seat

cushion is required, proceed to the following steps.
SE-19
墌 00.5.31/68j/9se 墍
REAR SEAT
Seats
2. SEDAN S908350A0602
1) Remove the rear seat from the vehicle.<Ref. to

SE-16 REMOVAL, Rear Seat.>
2) Remove the wiring from around the seat back-
rest.
3) Remove the two nuts and remove the armrest
assembly.
B5M1084A
1. WAGON S908350A0201

NOTE:
B5M1081 쐌 Do not contaminate or damage cover.
쐌 While installing wire rings, prevent seat from
4) Remove the wiring, and then remove the seat getting wrinkled.
cover.
2. SEDAN S908350A0202

NOTE:
쐌 While installing wire rings, prevent seat from
getting wrinkled.
B5M1082A
5) Remove the wiring around the seat cushion.
B5M1083
6) Remove the wiring, and then remove the seat

cover
SE-20
墌 00.5.31/68j/9se 墍
GENERAL DESCRIPTION
Security and Locks
1. General Description S909001 B: COMPONENT S909001A05
1. DOOR LOCK ASSEMBLY S909001A0501
B5M1089A
(1) Inner remote ASSY (6) Striker Tightening torque: N·m (kgf-m, ft-lb)
(2) Inner remote cover (7) Door outer handle
T1: 6.4 (0.65, 4.7)
(3) Bell crank (8) Key cylinder
T2: 7.5 (0.76, 5.5)
(4) Auto-door lock actuator
T3: 18 (1.8, 13.0)
(5) Door latch
SL-2
墌 00.5.31/68j/9sl 墍
GENERAL DESCRIPTION
Security and Locks
2. TRUNK LID AND REAR GATE LOCK

S909001A0502
B5M1086A
(1) Key cylinder (6) Rear gate outer handle Tightening torque: N·m (kgf-m, ft-lb)
(2) Cable (7) Rear gate actuator
T1: 7.5 (0.75, 5.4)
(3) Striker (8) Rear gate latch
T2: 25 (2.5, 18.1)
(4) Trunk lid lock ASSY
T3: 18 (1.8, 13.0)
(5) Trunk lid lock cover
SL-3
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GENERAL DESCRIPTION
Security and Locks
3. HOOD LOCK AND REMOTE OPENERS

S909001A0503
B5M1087A
(1) Hood lock ASSY (5) Pull handle ASSY Tightening torque: N·m (kgf-m, ft-lb)
(2) Lever ASSY
T1: 7.4 (0.75, 5.4)
(3) Cable
T2: 32 (33, 23.9)
(4) Cover
SL-4
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GENERAL DESCRIPTION
Security and Locks
4. SECURITY SYSTEM S909001A0504
B6M1359A
(1) Horn (6) Horn relay (in main fuse box) (11) Passive arm connector
(2) Security horn (7) Trunk room light switch (Sedan),
(3) Keyless entry control module rear gate latch switch (Wagon)
(4) Security control module (8) Interrupt relay
(5) Security indicator light (in combi- (9) Security horn relay
nation meter) (10) Door switch
SL-5
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GENERAL DESCRIPTION
Security and Locks
5. KEYLESS ENTRY SYSTEM S909001A0505
B6M1345A
(1) Horn (3) Horn relay (in main fuse box) (4) Trunk room light switch (Sedan),
(2) Keyless entry control module rear gate latch switch (Wagon)
(5) Door switch
C: CAUTION S909001A03

repairing radio, control module, etc. which are
provided with memory functions, record
memory contents before disconnecting battery
ground cable. Otherwise, these contents are
cancelled upon disconnection.
쐌 Reassemble parts in reverse order of disas-
sembly procedure unless otherwise indicated.
쐌 Adjust parts to specifications contained in
this manual if so designated.
쐌 Connect connectors and hoses securely dur-
ing reassembly.
쐌 After reassembly, ensure functional parts
operate smoothly.
쐌 Airbag system wiring harness is routed near
the electrical parts and switch.
쐌 All airbag system wiring harness and con-
ing harness when servicing the ignition key
cylinder.
SL-6
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GENERAL DESCRIPTION
Security and Locks

925580000 PULLER Used for removing trim clip
B5M1120
TOOL NAME REMARKS

Circuit tester Used for measuring resistance and voltage
Drill Used for replacing ignition key lock
SL-7
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DOOR LOCK CONTROL SYSTEM
Security and Locks
2. Door Lock Control System S909348
SL-8
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Security and Locks
1. DOOR LOCK WITHOUT KEYLESS ENTRY S909348A2101
BU73-21
SL-9
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Security and Locks
2. DOOR LOCK WITH KEYLESS ENTRY

S909348A2102
SL-10 BU73-22
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Security and Locks
1. SYMPTOM CHART S909348A1001
Symptom Repair order Reference

The door lock control system does 1. Check the fuse. <Ref. to SL-11 CHECK FUSE,
not operate. INSPECTION, Door Lock Control
System.>
2. Check the power supply and ground circuit for <Ref. to SL-11 CHECK POWER
the door lock timer (without keyless entry) or SUPPLY AND GROUND CIRCUIT,
keyless entry control module (with keyless entry). INSPECTION, Door Lock Control
System.>
3. Check the door lock switch and the circuit. <Ref. to SL-12 CHECK DOOR
LOCK SWITCH AND CIRCUIT,
INSPECTION, Door Lock Control
System.>
4. Check the door lock actuator and the circuit. <Ref. to SL-13 CHECK DOOR
LOCK ACTUATOR AND CIRCUIT,
System.>
The driver side or passenger side Check the door lock switch and the circuit. <Ref. to SL-12 CHECK DOOR
door lock switch does not operate. LOCK SWITCH AND CIRCUIT,
System.>
A specific door lock actuator does not Check the door lock actuator and the circuit. <Ref. to SL-13 CHECK DOOR
operate. LOCK ACTUATOR AND CIRCUIT,
System.>
2. CHECK FUSE S909348A1002

1 CHECK FUSE. Is the fuse blown (15A)? Replace the fuse Check power sup-
Remove and visually check fuse No. 3 (in the with a new one. ply and ground
fuse and relay box). circuit. <Ref. to
SL-11 CHECK
POWER SUPPLY
AND GROUND
CIRCUIT,
INSPECTION,
Door Lock Control
system.>
3. CHECK POWER SUPPLY AND

GROUND CIRCUIT S909348A1003
1 CHECK POWER SUPPLY. Is the voltage more than 10 Go to step 2. Check the har-
1) Disconnect the door lock timer or keyless V? ness for open cir-
entry control module harness connector. cuits and shorts
2) Measure the voltage between the harness between the door
connector terminal and chassis ground. lock timer or key-
Connector & terminal less entry control
Without keyless entry: module and the
(B92) No. 4 (+) — chassis ground (–): fuse.
With keyless entry:
(B176) No. 3 (+) — chassis ground (–):
SL-11
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Security and Locks

2 CHECK GROUND CIRCUIT. Is the resistance less than Power supply and Repair harness.
Measure the resistance between the harness 10 Ω? ground circuit is
connector terminal and chassis ground. OK.
Without keyless entry:
With keyless entry:
4. CHECK DOOR LOCK SWITCH AND

CIRCUIT S909348A1004
1 CHECK DOOR LOCK SWITCH CIRCUIT. Is the resistance less than Go to step 2. Go to step 3.
1) Disconnect the door lock timer or keyless 10 Ω?
entry control module harness connector.
2) Measure the resistance between the har-
ness connector terminal and chassis ground
when moving the door lock switch to LOCK.
With keyless entry:
2 CHECK DOOR LOCK SWITCH CIRCUIT. Is the resistance less than The door lock Go to step 3.
Measure the resistance between the harness 10 Ω? switch is OK.
connector terminal and chassis ground when
the door lock switch is moved to UNLOCK.
(B92) No. 7 — chassis ground:
With keyless entry:
(B176) No. 15 (+) — chassis ground
(–):
3 CHECK DOOR LOCK SWITCH. Does continuity exist? Go to step 4. Replace the door
1) Disconnect the door lock switch harness lock switch.
connector.
2) Check the continuity between the door lock
switch terminals when moving the door lock
switch to LOCK.
Terminal
Driver side No. 1 — No. 2:
Passenger side No. 2 — No. 5:
4 CHECK DOOR LOCK SWITCH. Does continuity exist? Check the har- Replace the door
Check the continuity between the door lock ness for open cir- lock switch.
switch terminals when moving the door lock cuits and shorts
switch to UNLOCK. between the door
Terminal lock timer or key-
Driver side No. 1 — No. 6: less entry control
Passenger side No. 1 — No. 5: module and the
door lock switch.
SL-12
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Security and Locks
5. CHECK DOOR LOCK ACTUATOR AND

1 CHECK OUTPUT SIGNAL. Is the voltage more than 10 Go to step 2. Replace the door
Measure the voltage between the harness V? lock timer or key-
connector terminal and chassis ground when less entry control
moving the door lock switch to LOCK. module.
With keyless entry:
2 CHECK OUTPUT SIGNAL. Is the voltage more than 10 Go to step 3. Replace the door
Measure the voltage between the harness V? lock timer or key-
connector terminal and chassis ground when less entry control
moving the door lock switch to UNLOCK. module.
With keyless entry:
(B176) No. 1, No. 9 (+) — chassis
ground (–):
3 CHECK DOOR LOCK ACTUATOR. Is the door lock actuator Check the har- Replace the door
Check the door lock actuator. OK? ness for open cir- lock actuator.
Front door lock actuator: <Ref. to SL-37 Front cuits and shorts
Door Lock Actuator.> between the door
Rear door lock actuator: <Ref. to SL-41 Rear lock timer or key-
Door Lock Actuator.> less entry control
Rear gate latch lock actuator: <Ref. to SL-44 module and the
Rear Gate Latch Lock Actuator.> door lock actuator.
SL-13
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KEYLESS ENTRY SYSTEM
Security and Locks
3. Keyless Entry System S909345
SL-14 BU77-20A
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Security and Locks
BU77-20B
SL-15
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Security and Locks
BU77-20C
SL-16
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Security and Locks
B: ELECTRICAL SPECIFICATION
S909345A08
B6M0957
Content Terminal No. Measuring condition

Door and rear gate lock actuator Battery voltage is present when pressing the transmitter UNLOCK/
1 (OUTPUT)
(Except driver side) DISARM button two times.
Battery voltage is present when pressing the transmitter LOCK/ARM
Door and rear gate lock actuator 2 (OUTPUT)
button one time.
Power supply (Back-up) 3 Battery voltage is constantly present.
0 V is present when pressing the transmitter UNLOCK/DISARM but-
Room light 4 (OUTPUT)
ton one time.
Door lock switch 5 (INPUT) 0 V is present when operating the door lock switch.
Trunk room light switch (Sedan),
6 (INPUT) 0 V is present when opening the trunk lid or rear gate.
rear gate latch switch (Wagon)
Door switch 7 (INPUT) 0 V is present when any door is open.
Ground 8 —
Battery voltage is present when pressing the transmitter UNLOCK/
Door lock actuator (Driver side) 9 (OUTPUT)
DISARM button one time.
Security control module 10 —
0 V is present when pressing the transmitter UNLOCK/DISARM or
Horn relay 12 (OUTPUT)
LOCK/ARM button.
Ignition switch (ON) 14 (INPUT) Battery voltage is present when ignition switch is turned ON.
Door unlock switch 15 (INPUT) 0 V is present when operating the door lock switch.
Battery voltage is present when inserting the key into the ignition
Key warning switch 16 (INPUT)
switch.
SL-17
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Security and Locks

None of the functions of the keyless 1. Check the transmitter battery and function. <Ref. to SL-20 CHECK TRANSMIT-
entry system operate. TER BATTERY AND FUNCTION,
INSPECTION, Keyless Entry Sys-
tem.>
2. Check the fuse. <Ref. to SL-21 CHECK FUSE,
tem.>
3. Check the keyless entry control module <Ref. to SL-21 CHECK POWER
power supply and ground circuit. SUPPLY AND GROUND CIRCUIT,
INSPECTION, Keyless Entry sys-
tem.>
4. Replace the keyless entry control module. <Ref. to SL-54 Keyless Entry Control
Module.>
The transmitter cannot be pro- 1. Check the transmitter battery and function. <Ref. to SL-20 CHECK TRANSMIT-
grammed. TER BATTERY AND FUNCTION,
tem.>
2. Check the ignition switch circuit. <Ref. to SL-21 CHECK IGNITION
SWITCH CIRCUIT, INSPECTION,
Keyless Entry System.>
3. Check the door switch. <Ref. to SL-21 CHECK DOOR
SWITCH, INSPECTION, Keyless
Entry System.>
Module.>
The door lock or unlock does not 1. Check the transmitter battery and function. <Ref. to SL-20 CHECK TRANSMIT-
operate. TER BATTERY AND FUNCTION,
NOTE: INSPECTION, Keyless Entry Sys-
If the door lock control system does tem.>
not operate when using the door lock 2. Check the key warning switch. <Ref. to SL-22 CHECK KEY WARN-
switch, check the door lock control ING SWITCH, INSPECTION, Keyless
system. <Ref. to SL-11 Entry System.>
INSPECTION, Door Lock Control 3. Check the door switch. <Ref. to SL-21 CHECK DOOR
System.> SWITCH, INSPECTION, Keyless
Entry System.>
4. Replace the keyless entry control module. <Ref. to SL- 54 Keyless Entry Control
Module.>
The panic alarm does not operate. 1. Check the transmitter battery and function. <Ref. to SL-20 CHECK TRANSMIT-
TER BATTERY AND FUNCTION,
tem.>
2. Check the horn operation. <Ref. to SL-23 CHECK HORN
OPERATION, INSPECTION, Keyless
Entry System.>
Module.>
SL-18
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Security and Locks

The horn chirp does not operate. 1. Check the horn chirp function. <Ref. to SL-20 CHECK HORN
CHIRP SETTING, INSPECTION,
2. Check the transmitter battery and function. <Ref. to SL-20 CHECK TRANSMIT-
tem.>
3. Check the key warning switch. <Ref. to SL-22 CHECK KEY WARN-
ING SWITCH, INSPECTION, Keyless
Entry System.>
Entry System.>
Entry System.>
Module.>
The room light operation does not 1. Check the transmitter battery and function. <Ref. to SL-20 CHECK TRANSMIT-
activate. TER BATTERY AND FUNCTION,
tem.>
2. Check the room light operation. <Ref. to SL-23 CHECK ROOM
LIGHT OPERATION, INSPECTION,
3. Check the key warning switch. <Ref. to SL-22 CHECK KEY WARN-
ING SWITCH, INSPECTION, Keyless
Entry System.>
Entry System.>
Module.>
The door warning does not operate. 1. Check the transmitter battery and function. <Ref. to SL-20 CHECK TRANSMIT-
tem.>
Entry System.>
Entry System.>
Module.>
SL-19
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Security and Locks
2. CHECK TRANSMITTER BATTERY AND

FUNCTION S909345A1002
1 CHECK TRANSMITTER BATTERY. Is the voltage more than 2 Go to step 2. Replace the trans-
1) Remove the battery from the transmitter. V? mitter battery.
<Ref. to SL-55 REMOVAL, Keyless Transmit-
ter.>
2) Check the battery voltage. <Ref. to SL-55
INSPECTION, Keyless Transmitter.>
2 CHECK LED OF TRANSMITTER. Does the LED blink one Go to step 3. Replace the trans-
1) Press the LOCK/ARM or UNLOCK/ time? mitter. <Ref. to
DISARM button six times to synchronize with SL-55
the keyless entry control module. REPLACEMENT,
2) Press the LOCK/ARM button. Keyless Transmit-
ter.>
Keep the LOCK/ARM button pressed. time and then turn on? mitter. <Ref. to
SL-55
REPLACEMENT,
Keyless Transmit-
ter.>
Press the UNLOCK/DISARM button. time? mitter. <Ref. to
SL-55
REPLACEMENT,
Keyless Transmit-
ter.>
5 CHECK LED OF TRANSMITTER. Does the LED blink two The transmitter is Replace the trans-
Keep the UNLOCK/DISARM button pressed. times? OK. mitter. <Ref. to
SL-55
REPLACEMENT,
Keyless Transmit-
ter.>
3. CHECK HORN CHIRP SETTING S909345A1003

1 CHECK HORN CHIRP SETTING. Does the horn signal chirp? The horn chirp Go to step 2.
Check the current setting of the horn chirp. function is OK.
1) Remove the key from the ignition switch.
2) Close all doors and the rear gate or trunk
lid.
3) Press the LOCK/ARM or UNLOCK/
DISARM button.
2 CHECK HORN CHIRP SETTING. Does the horn signal chirp? The horn chirp Check the trans-
1) Press both the LOCK/ARM and UNLOCK/ function is OK. mitter function.
DISARM button for more than 2 seconds. <Ref. to SL-20
2) Press the LOCK/ARM or UNLOCK/ CHECK TRANS-
DISARM button. MITTER BAT-
TERY AND
FUNCTION,
INSPECTION,
Keyless Entry
System.>
SL-20
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Security and Locks

1 CHECK FUSE. Is the fuse blown? (15 A Replace the fuse Check power sup-
Remove and visually check fuse No. 3 (in the and 30 A) with a new one. ply and ground
fuse and relay box) and SBF-6 (in the main circuit. <Ref. to
fuse box) SL-21 CHECK
POWER SUPPLY
AND GROUND
CIRCUIT,
INSPECTION,
Keyless Entry
system.>

1) Disconnect the keyless entry control mod- V? ness for open cir-
ule harness connector. cuits and shorts
2) Measure the voltage between the harness between the key-
connector terminal and chassis ground. less entry control
Connector & terminal module and fuse.
2 CHECK GROUND CIRCUIT. Is the resistance less than The power supply Repair the har-
Measure the resistance between the harness 10 Ω? and ground circuit ness.
connector terminal and chassis ground. are OK.
6. CHECK IGNITION SWITCH CIRCUIT

S909345A1006

1 CHECK IGNITION SWITCH SIGNAL. Is the voltage more than 10 The ignition Check the har-
1) Disconnect the keyless entry control mod- V? switch circuit is ness for open cir-
ule harness connector. OK. cuits and shorts
2) Turn the ignition switch ON. between the key-
3) Measure the voltage between the harness less entry control
connector terminal and chassis ground. module and igni-
Connector & terminal tion relay.
(–):
7. CHECK DOOR SWITCH S909345A1007

1 CHECK DOOR SWITCH CIRCUIT. Is the voltage 0 V when Go to step 2. Go to step 3.
Measure the voltage between the keyless each door, rear gate and
entry control module harness connector termi- trunk lid is opened?
nal and chassis ground.
Front and rear door:
Rear gate or trunk lid:
SL-21
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Security and Locks

2 CHECK DOOR SWITCH CIRCUIT. Is the voltage approx. 10 V The door switch is Go to step 3.
Measure the voltage between the keyless when each door, rear gate OK.
entry control module harness connector termi- and trunk lid is closed?
nal and chassis ground.
3 CHECK DOOR SWITCH. Does continuity exist when Replace the door Go to step 4.
1) Disconnect the door switch harness con- the door switch is pushed? switch.
nector.
2) Check the continuity between the door
switch terminals.
Terminal
Front LH No. 1 — No. 3:
Front RH No. 1 — No. 3:
Rear LH No. 1 — No. 3:
Rear RH No. 1 — No. 3:
Rear gate No. 1 — No. 2:
Trunk lid No. 1 — No. 2:
4 CHECK DOOR SWITCH. Does continuity exist when Check the har- Replace the door
Check continuity between the door switch ter- the door switch is ness for open cir- switch.
minals. released? cuits and shorts
Terminal between the key-
Front LH No. 1 — No. 3: less entry control
Front RH No. 1 — No. 3: module and door
Rear LH No. 1 — No. 3: switch.
8. CHECK KEY WARNING SWITCH S909345A1008

1 CHECK FUSE. Is the fuse blown? (15A) Replace the fuse Go to step 2.
Remove and visually check fuse No. 6 (in the with a new one.
main fuse box).
2 CHECK KEY WARNING SWITCH CIRCUIT. Is the voltage approx. 10 Go to step 3. Go to step 4.
1) Disconnect the keyless entry control mod- V?
ule harness connector.
2) Insert the key into the ignition switch.
(LOCK position)
3) Measure the voltage between the harness
connector terminal and chassis ground.
(–):
3 CHECK KEY WARNING SWITCH CIRCUIT. Is the voltage 0 V? The key warning Go to step 4.
1) Remove the key from the ignition switch. switch is OK.
2) Measure the voltage between the harness
connector terminal and chassis ground.
(–):
SL-22
墌 00.5.31/68j/9sl 墍
Security and Locks

4 CHECK KEY WARNING SWITCH. Does continuity exist? Go to step 5. Replace key
1) Disconnect the key warning switch harness warning switch.
connector.
2) Insert the key into the ignition switch.
(LOCK position)
3) Check the continuity between the key
warning switch terminals.
Terminal
No. 1 — No. 2:
5 CHECK KEY WARNING SWITCH. Does continuity exist? Replace key Check the fol-
1) Remove the key from the ignition switch. warning switch. lowing:
2) Check the continuity between the key 쐌 Harness for
warning switch terminals. open circuits and
Terminal shorts between
No. 1 — No. 2: the key warning
switch and fuse
쐌 Harness for
open circuits and
shorts between
the keyless entry
control module
and key warning
switch
9. CHECK HORN OPERATION S909345A1009

1 CHECK HORN OPERATION. Does the horn sound? Go to step 2. Check the horn
Make sure the horn sounds when the horn circuit.
switch is pushed.
2 CHECK HORN OPERATION. Does the horn sound? Replace the key- Check the har-
1) Disconnect the keyless entry control mod- less entry control ness for open cir-
ule harness connector. module. cuits and or
2) Ground the harness connector terminal shorts between
with a suitable wire. the keyless entry
Connector & terminal control module
(B176) No. 12 — chassis ground: and horn relay.
10. CHECK ROOM LIGHT OPERATION

S909345A1010

1 CHECK ROOM LIGHT OPERATION. Does the room light illumi- Go to step 2. Check the room
Make sure the room light illuminates when the nate? light circuit.
room light switch is turned ON.
2 CHECK HARNESS BETWEEN ROOM Is resistance less than 10 The room light Check the har-
LIGHT AND KEYLESS ENTRY CONTROL Ω? operation circuit is ness for open cir-
MODULE. OK. cuits and or
1) Disconnect the keyless entry control mod- shorts between
ule harness connector and room light harness the keyless entry
connector. control module
2) Measure the resistance between the key- and room light.
less entry control module harness connector
terminal and the room light harness connector
terminal.
(B176) No. 4 — (R52) No. 2:
SL-23
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SECURITY SYSTEM
Security and Locks
4. Security System S909347
BU94-22A
SL-24
墌 00.5.31/68j/9sl 墍
SECURITY SYSTEM
Security and Locks
BU94-22B
SL-25
墌 00.5.31/68j/9sl 墍
SECURITY SYSTEM
Security and Locks
BU94-22C
SL-26
墌 00.5.31/68j/9sl 墍
SECURITY SYSTEM
Security and Locks
B: ELECTRICAL SPECIFICATION
S909347A08
B6M0972
Content Terminal No. Measuring condition

Empty 1 —
Ignition switch (ON) 2 (INPUT) Battery voltage is present when ignition switch is turned ON.
Passive arm 3 —
Trunk room light switch (Sedan), 0 V is present when trunk room light switch or rear gate latch switch is
4 (INPUT)
rear gate latch switch (Wagon) turned ON.
Door switch 5 (INPUT) 0 V is present when any door is open.
Empty 6 —
Keyless entry control module 7 —
Security indicator light 9 (OUTPUT) 0 V is present when activating the alarm operation.
Power supply for clearance light
11 Battery voltage is constantly present.
(Back-up)
Clearance light 12 (OUTPUT) Battery voltage is present when activating the alarm operation.
Power supply (Back-up) 13 Battery voltage is constantly present.
Ground 14 —
Interrupt relay 15 (OUTPUT) Battery voltage is present when activating the alarm operation.
Security horn relay 16 (INPUT) Battery voltage is present when activating the alarm operation.
Security horn 17 (OUTPUT) Battery voltage is present when activating the alarm operation.
Security horn relay 18 (INPUT) Battery voltage is present when activating the alarm operation.
SL-27
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SECURITY SYSTEM
Security and Locks
1. BASIC DIAGNOSTIC PROCEDURE

S909347A1001

1 CHECK SECURITY SYSTEM SET OPERA- Can security system be Go to step 2. Go to symptom 1.
TION. set? <Ref. to SL-29
1) Before starting this diagnosis, open all win- SYMPTOM
dows. CHART,
2) Remove key from ignition key cylinder, and INSPECTION,
then close all doors and rear gate or trunk lid. Security System.>
3) Press LOCK/ARM button of transmitter.
2 CHECK SECURITY INDICATOR LIGHT AND Do security indicator light Go to step 3. Go to symptom 2.
CLEARANCE LIGHT BLINKING. and clearance light blink? <Ref. to SL-29
Check security indicator light and clearance SYMPTOM
light blinking. CHART,
INSPECTION,
Security System.>
3 CHECK SECURITY ALARM OPERATION. Does security system not Go to symptom 3. Go to step 4.
1) Unlock all doors using door lock switch on alarm when one of the <Ref. to SL-29
front door. doors is opened? SYMPTOM
2) Open any door, rear gate or trunk lid. CHART,
INSPECTION,
Security System.>
4 CHECK SECURITY ALARM OPERATION. Does security alarm (horn, Go to step 5. Go to symptom 4.
Check security alarm operation. clearance light and security <Ref. to SL-29
indicator light) operate? SYMPTOM
And is starter motor deacti- CHART,
vated? INSPECTION,
Security System.>
5 CHECK SECURITY ALARM CANCEL Does security alarm (horn Go to step 6. Go to symptom 5.
OPERATION. and clearance light) stop? <Ref. to SL-29
Press UNLOCK/DISARM button of transmitter. And is starter motor acti- SYMPTOM
vated? CHART,
INSPECTION,
Security System.>
6 CHECK BATTERY DISCONNECT PROTEC- Is battery disconnect pro- Go to step 7. Replace security
TION. tection OK? control module.
Check battery disconnect protection. <Ref. to
SL-28 CHECK BATTERY DISCONNECT
PROTECTION, INSPECTION, Security Sys-
tem.>
7 PERFORM IMPACT SENSITIVITY TEST. Is impact sensitivity OK? Press UNLOCK/ Replace security
Perform impact sensitivity test. <Ref. to SL-50 DISARM button of control module.
IMPACT SENSITIVITY TEST, INSPECTION, transmitter, and
Security Control Module.> finish the diagno-
sis.
2. CHECK BATTERY DISCONNECT If NG, replace the security control module.

PROTECTION S909347A1002
2) Close all the doors and rear gate or trunk lid.
3) Open the front hood.
4) Press the LOCK/ARM button of the transmitter.
5) Disconnect the ground cable from the battery.
6) Reconnect the cable to the battery.
7) Check that the security indicator light blinks
after reconnecting the battery cable.
SL-28
墌 00.5.31/68j/9sl 墍
SECURITY SYSTEM
Security and Locks

1 The security system cannot be set. 1. Check the transmitter func- <Ref. to SL-20 CHECK TRANS-
tion. MITTER BATTERY AND
FUNCTION, INSPECTION, Keyless
Entry System.>
2. Check the fuse. <Ref. to SL-30 CHECK FUSE,
INSPECTION, Security System.>
3. Check the security control <Ref. to SL-30 CHECK POWER
module power supply and SUPPLY AND GROUND CIRCUIT,
ground circuit. INSPECTION, Security System.>
SWITCH, INSPECTION, Security
System.>
5. Replace the security control <Ref. to SL-50 Security Control
module. Module.>
2 The security system can be Security indicator Check the security indicator light <Ref. to SL-31 CHECK SECURITY
set, but the security indicator light circuit. INDICATOR LIGHT CIRCUIT,
light or clearance light does INSPECTION, Security System.>
not blink. Clearance light Check the clearance light opera- <Ref. to SL-32 CHECK CLEAR-
tion. ANCE LIGHT OPERATION,
3 The security system does not alarm when one of Check the door switch. <Ref. to SL-30 CHECK DOOR
the door is opened. SWITCH, INSPECTION, Security
System.>
4 The security alarm does not All functions Check the door switch. <Ref. to SL-30 CHECK DOOR
activate. SWITCH, INSPECTION, Security
System.>
Security indicator Check the security indicator light <Ref. to SL-31 CHECK SECURITY
light circuit. INDICATOR LIGHT CIRCUIT,
Security horn Check the security horn. <Ref. to SL-31 CHECK SECURITY
HORN, INSPECTION, Security
System.>
Clearance light Check the clearance light opera- <Ref. to SL-32 CHECK CLEAR-
tion. ANCE LIGHT OPERATION,
Starter motor Check the interrupt relay circuit. <Ref. to SL-33 CHECK INTER-
deactivation RUPT RELAY CIRCUIT,
5 The security system cannot be Transmitter Check the transmitter function. <Ref. to SL-28 CHECK TRANS-
canceled. MITTER BATTERY AND
FUNCTION, INSPECTION, Keyless
Entry System.>
Ignition switch Check the ignition switch circuit. <Ref. to SL-33 CHECK IGNITION
SWITCH CIRCUIT, INSPECTION,
Security System.>
SL-29
墌 00.5.31/68j/9sl 墍
SECURITY SYSTEM
Security and Locks

1 CHECK FUSE. Is the fuse blown? (15 A Replace the fuse Check power sup-
Remove and visually check fuse No. 2 and 7 and 20 A) with a new one. ply and ground
(in main fuse box). circuit. <Ref. to
SL-30 CHECK
POWER SUPPLY
AND GROUND
CIRCUIT,
INSPECTION,
Security System.>

1) Disconnect the security control module har- V? ness for open cir-
ness connector. cuits and shorts
2) Measure the voltage between the harness between the secu-
connector terminal and chassis ground. rity control module
Connector & terminal and fuse.
1) Disconnect the security control module har- V? ness for open cir-
2) Measure the voltage between harness con- between the secu-
nector terminal and chassis ground. rity control module
Connector & terminal and fuse.
3 CHECK GROUND CIRCUIT. Is the resistance less than The power supply Repair the har-
Measure the resistance between the harness 10 Ω? and ground circuit ness.
connector terminal and chassis ground. are OK.
6. CHECK DOOR SWITCH S909347A1007

1 CHECK DOOR SWITCH CIRCUIT. Is voltage 0 V when each Go to step 2. Go to step 3.
Measure the voltage between the security door, rear gate or trunk lid
control module harness connector terminal is opened?
and chassis ground.
2 CHECK DOOR SWITCH CIRCUIT. Is the voltage approx. 10 V Door switch is Go to step 3.
Measure voltage between security control when each door, rear gate OK.
module harness connector terminal and chas- or trunk lid is closed?
sis ground.
SL-30
墌 00.5.31/68j/9sl 墍
SECURITY SYSTEM
Security and Locks

3 CHECK DOOR SWITCH. Does continuity exist when Replace the door Go to step 4.
1) Disconnect door switch harness connector. the door switch is pushed? switch.
2) Check continuity between door switch ter-
minals.
Terminal
Front RH No. 1 — No. 3:
4 CHECK DOOR SWITCH. Does continuity exist when Check the har- Replace the door
Check continuity between the door switch ter- the door switch is ness for open cir- switch.
minals. released? cuits and shorts
Terminal between the secu-
Front LH No. 1 — No. 3: rity control module
Front RH No. 1 — No. 3: and door switch.
7. CHECK SECURITY INDICATOR LIGHT

1 CHECK SECURITY INDICATOR LIGHT. Does the security indicator Replace the secu- Go to step 2.
1) Disconnect the security control module har- light illuminate? rity control mod-
ness connector. ule.
2) Ground the harness connector terminal
with a suitable wire.
2 CHECK POWER SUPPLY FOR SECURITY Is voltage more than 10 V? Go to step 3. Check the har-
INDICATOR LIGHT. ness for open cir-
1) Disconnect the connector from the combi- cuits and shorts
nation meter. between the com-
2) Measure the voltage between the combina- bination meter
tion meter harness connector terminal and and the fuse.
chassis ground.
(i12) No. 7 (+) — chassis ground (–):
3 CHECK SECURITY INDICATOR LIGHT CIR- Is resistance less than 10 Replace the com- Check the har-
CUIT. Ω? bination meter ness for open cir-
Measure the resistance between the combina- printed circuit. cuits and shorts
tion meter harness connector terminal and between the com-
security control module harness connector bination meter
terminal. and security con-
Connector & terminal trol module.
(i12) No. 1 — (B93) No. 9:
8. CHECK SECURITY HORN S909347A1009

1 CHECK SECURITY HORN RELAY. Is the security horn relay Go to step 2. Replace the secu-
Remove and check the security horn relay. OK? rity horn relay.
<Ref. to SL-52 Security Horn Relay.>
SL-31
墌 00.5.31/68j/9sl 墍
SECURITY SYSTEM
Security and Locks

2 CHECK POWER SUPPLY FOR SECURITY Is the voltage more than 10 Go to step 3. Check the har-
HORN RELAY. V? ness for open cir-
Measure the voltage between the security cuits and shorts
horn relay harness connector terminal and between the secu-
chassis ground. rity horn relay and
Connector & terminal horn relay.
HORN RELAY. V? ness for open cir-
Measure the voltage between the security cuits and shorts
horn relay harness connector terminal and between the secu-
chassis ground. rity horn relay and
Connector & terminal the fuse.
4 CHECK HARNESS BETWEEN SECURITY Is the resistance less than Go to step 5. Check the har-
HORN RELAY AND SECURITY CONTROL 10 Ω? ness for open cir-
MODULE. cuits and shorts
1) Disconnect the security control module har- between the secu-
ness connector. rity horn relay and
2) Measure the resistance between the secu- security control
rity horn relay harness connector terminal and module.
security control module harness connector
terminal.
(B243) No. 3 — (B93) No. 18:
HORN RELAY AND SECURITY CONTROL 10 Ω? ness for open cir-
MODULE. cuits and shorts
Measure the resistance between the security between the secu-
horn relay harness connector terminal and rity horn relay and
security control module harness connector security control
terminal. module.
(B243) No. 4 — (B93) No. 16:
CONTROL MODULE AND SECURITY 10 Ω? ness for open cir-
HORN. cuits and shorts
1) Disconnect the security horn harness con- between the secu-
nector. rity control module
2) Measure the resistance between the secu- and security horn.
rity control module harness connector terminal
and security horn harness connector terminal.
(B93) No. 17 — (B204) No. 1:
7 CHECK SECURITY HORN. Is the security horn OK? Replace the secu- Replace the secu-
Remove and check the security horn. <Ref. to rity control mod- rity horn.
SL-51 Security Horn.> ule.
9. CHECK CLEARANCE LIGHT

OPERATION S909347A1010
1 CHECK CLEARANCE LIGHT OPERATION. Does the clearance light Go to step 2. Check the clear-
Turn the parking switch ON and check if the illuminate? ance light circuit.
clearance light illuminates.
SL-32
墌 00.5.31/68j/9sl 墍
SECURITY SYSTEM
Security and Locks

CONTROL MODULE. V? ness for open cir-
1) Turn the parking switch OFF. cuits and shorts
2) Disconnect the security control module har- between the secu-
ness connector. rity control module
3) Measure the voltage between the security and the fuse.
control module harness connector terminal
and chassis ground.
3 CHECK HARNESS BETWEEN SECURITY Is the resistance less than Replace the secu- Check the har-
CONTROL MODULE AND FUSE BOX. 10 Ω? rity control mod- ness for open cir-
1) Disconnect the fuse box harness connector ule. cuits and shorts
(B152). between the secu-
2) Measure the resistance between the security control module
rity control module harness connector terminal and the fuse.
and fuse box harness connector terminal.
(B93) No. 12 — (B152) No. 11:
10. CHECK INTERRUPT RELAY CIRCUIT

S909347A1011

1 CHECK INTERRUPT RELAY. Is the interrupt relay OK? Go to step 2. Replace the inter-
Remove and check the interrupt relay. <Ref. rupt relay.
to INTERRUPT RELAY.>
2 CHECK POWER SUPPLY FOR INTERRUPT Is the voltage more than 10 Go to step 3. Check the har-
RELAY. V when the ignition switch ness for open cir-
Measure the voltage between the interrupt is turned to START? cuits and shorts
relay harness connector terminal and chassis between the inter-
ground. rupt relay and
Connector & terminal ignition switch.
3 CHECK HARNESS BETWEEN INTERRUPT Is the resistance less than Replace the secu- Check the har-
RELAY AND SECURITY CONTROL MOD- 10 Ω? rity control mod- ness for open cir-
ULE. ule. cuits and shorts
Measure the resistance between the interrupt between the inter-
relay harness connector terminal and security rupt relay and
control module harness connector terminal. security control
Connector & terminal module.
(B59) No. 4 — (B93) No. 15:
11. CHECK IGNITION SWITCH CIRCUIT

S909347A1012

1 CHECK IGNITION SWITCH SIGNAL. Is the voltage more than 10 Ignition switch Check the har-
1) Disconnect the security control module har- V? circuit is OK. ness for open cir-
2) Turn the ignition switch ON. between the secu-
3) Measure the voltage between the harness rity control module
connector terminal and chassis ground. and ignition relay.
SL-33
墌 00.5.31/68j/9sl 墍
FRONT INNER REMOTE
Security and Locks
5. Front Inner Remote S909344
1) Remove the door trim. <Ref. to EI-32

2) Remove the sealing cover. <Ref. to EB-13
3) Remove the two rod joints.
4) Remove the front inner remote.
B5M0725

CAUTION:
Make sure the lock operates properly after
installation.
1) Make sure the rod is not deformed.

2) Make sure the lever and rod work smoothly.
SL-34
FRONT OUTER HANDLE
Security and Locks
6. Front Outer Handle S909349

3) Remove the front door latch assembly. <Ref. to
5) Remove the two bolts. Remove the front outer
handle (A).
B5M0996A
CAUTION:
Do not use excessive force to remove the door
panel. This will deform it.

SL-35
FRONT DOOR LATCH ASSEMBLY
Security and Locks
7. Front Door Latch Assembly

S909334
1) Remove the front door trim. <Ref. to EI-32

3) Remove the front inner remote. <Ref. to SL-34
REMOVAL, Front Inner Remote.>
4) Remove the three screws and bolt.
B5M0997
5) Disconnect the connector. Remove the front

door latch assembly.

CAUTION:
installation.

SL-36
FRONT DOOR LOCK ACTUATOR
Security and Locks
8. Front Door Lock Actuator S909319
1) Remove the front door latch assembly. <Ref. to

2) Remove the bolt. Remove the front door lock
actuator.
B5M0998
1) Disconnect the door lock actuator harness con-

nector.
2) Connect the battery to the door lock actuator
terminals.
B6M0135
Battery connection Actuator operation

No. 2 (+) — No. 4 (–) Unlocked → Locked
No. 4 (+) — No. 2 (–) Locked → Unlocked
If NG, replace the door lock actuator.
SL-37
REAR INNER REMOTE
Security and Locks
9. Rear Inner Remote S909321
1) Remove the rear door trim. <Ref. to EI-33

REMOVAL, Rear Sealing Cover.>
4) Remove the inner remote.
B5M0725

CAUTION:
installation.

SL-38
REAR OUTER HANDLE
Security and Locks
10. Rear Outer Handle S909322

3) Remove the rear door latch assembly. <Ref. to
SL-40 REMOVAL, Rear Door Latch Assembly.>
4) Remove the two bolts and nut. Remove the rear
outer handle.
B5M1000
CAUTION:
Do not use excessive force to remove the door
panel. This will deform it.

SL-39
墌 00.5.31/68j/9sl 墍
REAR DOOR LATCH ASSEMBLY
Security and Locks
11. Rear Door Latch Assembly

S909320

3) Remove the rear inner remote. <Ref. to SL-38
REMOVAL, Rear Inner Remote.>
4) Remove the three screws and bolt.
B5M1001
5) Disconnect the connector. Remove the rear

door latch assembly.

CAUTION:
installation.

3) Make sure the child safety lock on the rear
doors works properly.
SL-40
墌 00.5.31/68j/9sl 墍
REAR DOOR LOCK ACTUATOR
Security and Locks
12. Rear Door Lock Actuator S909323
1) Remove the rear door latch assembly. <Ref. to

SL-40 REMOVAL, Rear Door Latch Assembly.>
2) Remove the bolt. Remove the rear door lock
actuator.
B5M1002

CAUTION:
installation.

nector.
terminals.
B6M0135

If NG, replace the door lock actuator.
SL-41
REAR GATE OUTER HANDLE
Security and Locks
13. Rear Gate Outer Handle S909626
1) Remove the rear gate lower trim. <Ref. to 49

2) Remove the rear gate latch rod.
3) Remove the nut holding the rear gate outer
handle, and then remove the rear gate outer
handle.
B5M1116
1) Inspect the rod for deformation.

2) Make sure the lever and rod move smoothly.
SL-42
REAR GATE LATCH ASSEMBLY
Security and Locks
14. Rear Gate Latch Assembly

S909316
1) Remove the rear gate lower trim. <Ref. to EI-49

2) Remove the rear gate key cylinder rod.
3) Remove the nut holding the rear gate outer
handle. Remove the stay.
4) Remove the three bolts.
B5M1003
5) Remove the two connectors and pull out the

latch.

CAUTION:
installation.

SL-43
REAR GATE LATCH LOCK ACTUATOR
Security and Locks
15. Rear Gate Latch Lock

Actuator S909313
1) Remove the rear gate latch assembly. <Ref. to

SL-43 REMOVAL, Rear Gate Latch Assembly.>
2) Remove the rear gate lock actuator.
B5M1004

nector.
terminals.
B6M0135

If NG, replace the rear gate latch lock actuator.
SL-44
TRUNK LID LOCK ASSEMBLY
Security and Locks
16. Trunk Lid Lock Assembly

S909314
1) Remove the trunk lid key cylinder rod.

2) Remove the lock assembly cover (A).
3) Remove the nut while holding the lock assem-
bly. Remove the lock assembly (B).
B5M0795A

CAUTION:
쐌 Apply grease to parts that rub.
쐌 Make sure the lock operates properly after
installation.
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 for-
mation and unsmooth movement.
SL-45
墌 00.5.31/68j/9sl 墍
FRONT HOOD LOCK ASSEMBLY
Security and Locks
17. Front Hood Lock Assembly

S909595
1) Open the hood.

2) Remove the bolt. Remove the hood lock
assembly.
3) Remove the release cable from the lock assem-
bly.
B5M0748

CAUTION:
쐌 Apply grease to parts that rub.
쐌 Make sure the release cable works properly
after installation.
Loosen the bolt. Adjust the lock assembly while

moving it up and down.
B5M0752
D: INSPECTION S909595A10
1) Check the striker for bending or abnormal wear.

2) Check the safety lever for improper movement.
3) Check other levers and the spring for rust for-
mation and unsmooth movement.
SL-46
REMOTE OPENERS
Security and Locks
18. Remote Openers S909317

3. FUEL FLAP OPENER S909317A1803
1) Remove the rear seat. <Ref. to SE-16

1. HOOD OPENER S909317A1801 2) Remove the center pillar lower trim and side sill
cover on the passenger side. Remove the rear pil-
1) Remove the release cable from the hood lock.
lar lower trim. Pull back the floor mat. Remove the
2) Remove the bolt. Remove the opener lever.
clip holding the cable.
3) Remove the bolt. Remove the opener pull
handle.
B5M0751
2. TRUNK LID OPENER S909317A1802 G5M0151
1) Remove the rear seat. <Ref. to SE-16 4) Remove the cable from the opener pull handle.
REMOVAL, Rear Seat.> 5) Remove the right rear quarter trim. <Ref. to
2) Remove the center pillar lower trim and side sill EI-44 REMOVAL, Rear Quarter Trim.>
cover on the passenger side. Remove the rear pil- 6) Rotate the fuel lock inside the quarter panel to
lar lower trim. Pull back the floor mat. Remove the left and remove.
clip holding the cable.
3) Remove the bolt. Remove the opener pull
handle.
B5M1067
G5M0151 B: INSTALLATION S909317A11
4) Remove the cable from the opener pull handle. 1. HOOD OPENER S909317A1101
5) Remove the striker from the trunk lid. Install in the reverse order of removal.
6) Remove the cable from the striker.
2. TRUNK LID OPENER S909317A1102

3. FUEL FLAP OPENER S909317A1103
Make sure the fuel flap opens and closes smoothly.
G5M0147
SL-47
墌 00.5.31/68j/9sl 墍
IGNITION KEY LOCK
Security and Locks
19. Ignition Key Lock S909318
1) Remove the battery ground cable.

2) Remove the steering column. <Ref. to DS-20
REMOVAL, Steering Column.>
3) Secure the steering column in a vise. Remove
the bolt with a drill.
B5M1061
4) Remove the ignition key lock.

5) Use a new torn bolt. Tighten the torn bolt to the
end of the thread.
S6M0162A
1) Remove the instrument panel lower cover.

2) Remove the lower column cover.
3) Unfasten the holddown clip which secures the
harness and disconnect the connector of the igni-
tion switch from the body harness.
4) Turn the ignition key plate to each position and
check the continuity between the terminals of the
ignition connector.
Switch position Tester connection Specified condi-
tion
LOCK
ACC No. 1 — No. 2 Continuity
ON No. 1 — No. 2 — Continuity
No. 4
ST No. 1 — No. 3 — Continuity
No. 4
If NG, replace the ignition switch.
SL-48
KEY LOCK CYLINDERS
Security and Locks
20. Key Lock Cylinders S909326
1. FRONT DOOR S909326A2001

2) Pull back the sealing cover.
3) Remove the rod clamp. Remove the bolt.
Replace the key cylinder.
B5M1006
B5M0999
1) Remove the trunk trim. <Ref. to EI-51

REMOVAL, Trunk Trim.>
2) Remove the rod clamp. Remove the nut.
B5M1085
3. REAR GATE S909326A2003
1) Remove the rear gate lower trim. <Ref. to EI-49

2) Remove the rod clamp. Remove the nut.
SL-49
墌 00.5.31/68j/9sl 墍
SECURITY CONTROL MODULE
Security and Locks
21. Security Control Module S909330
1) Disconnect battery ground cable.

3) Remove screws (B) and then detach center
panel (C) while disconnecting connector.
B6M1424A
If NG, adjust the impact sensitivity. <Ref. to SL-50

ADJUSTMENT, Security Control Module.>
D: ADJUSTMENT S909330A01
1. IMPACT SENSITIVITY S909330A0101
NOTE:
B6M1209A
Before adjustment, make sure the security control
4) Remove two screws. module has been securely installed on the bracket.
NOTE: 1) Remove security control module. <Ref. to
Before removing the screw, apply a few turns of SL-50 REMOVAL, Security Control Module.>
2) Adjust the sensitivity adjust screw in security
butyl tape to the tip of the service tool. This pre-
control module.
vents the screw from falling during removal.
NOTE:
After adjusting, be sure to plug the adjust screw
hole.
B6M1339
5) Remove radio and security control module

B6M1389A
together while disconnecting connector. <Ref. to
ET-10 REMOVAL, Radio Body.> 3) Install security control module.
4) Perform impact sensitivity test.
1. IMPACT SENSITIVITY TEST S909330A1001

2) Close all windows.
3) Close all doors and the rear gate or trunk lid.
4) Cover the hood with a blanket.
5) Press the LOCK/ARM button of the transmitter.
6) Confirm that the security indicator light blinks
every 2 seconds.
7) Hit the center of the windshield with your palm
and make sure the alarm operates.
SL-50
墌 00.5.31/68j/9sl 墍
SECURITY HORN
Security and Locks
22. Security Horn S909333

2) Remove bolt and then detach security horn
while disconnecting connector.
B6M1340
Connect the battery to the security horn terminal

and case ground and make sure the horn sounds
properly.
B6M1397
If NG, replace the security horn.
SL-51
SECURITY HORN RELAY
Security and Locks
23. Security Horn Relay S909596
Remove the mounting nuts and detach the secu-

rity horn relay (near the fuse box).
B6M1376
Check continuity between the security horn relay

terminals (indicated in the table below) when con-
necting the battery to terminal No. 1 and No. 4.
When current Between terminals Continuity exists.
flows No. 2 and No. 3
When current Between terminals Continuity does
does not flow No. 2 and No. 3 not exist.
B6M1391
If NG, replace the security horn relay.
SL-52
INTERRUPT RELAY
Security and Locks
24. Interrupt Relay S909597
Remove the mounting nuts and detach the inter-

rupt relay (near the fuse box).
B6M1376
Check continuity between the security horn relay

terminals (indicated in the table below) when con-
necting the battery to terminals No. 1 and No. 4.
When current Between terminals Continuity does
flows No. 2 and No. 6 not exist.
When current Between terminals Continuity exists.
does not flow No. 2 and No. 6
B6M0994
If NG, replace the interrupt relay.
SL-53
KEYLESS ENTRY CONTROL MODULE
Security and Locks
25. Keyless Entry Control

Module S909324

Glove Box.>
3) Remove nut, then remove keyless entry control
module (B) and the other electrical control module
(A) while disconnecting connector.
B6M1338A
4) Disconnect keyless entry control module and

the other electrical control module.
SL-54
KEYLESS TRANSMITTER
Security and Locks
26. Keyless Transmitter S909325

If NG, replace the battery. (Use CR2032 or equiva-
lent.)
D: REPLACEMENT S909325A20
1. TRANSMITTER BATTERY S909325A1801
1. TRANSMITTER PROGRAMMING S909325A2001

Remove battery from transmitter.
NOTE:
NOTE: Perform programming when the transmitter is
To prevent static electricity damage to transmitter replaced and when an additional transmitter is
printed circuit board, touch steel area of building required.
with hand to discharge static electricity carried on
body or clothes before disassembling transmitter. NOTE:
Finish operation from step 1) through 4) within 45
seconds.
1) Sit on the driver’s seat and close all doors, rear
gate and trunk lid.
2) Open the driver’s door.
3) Close the driver’s door.
4) Turn the ignition switch from ON to LOCK ten
times within 15 seconds.
NOTE:
Do not start the engine at this time.
B6M0950
5) The horn chirps one time to indicate that the
system has entered in the programming mode.
6) Open the driver’s door.
7) Close the driver’s door.
1. TRANSMITTER BATTERY S909325A1101 8) Press any button on the transmitter that you
Install in the reverse order of removal. wish to program into the system.
9) Horn will chirp two times to indicate that the
transmitter has been programmed.
NOTE:
1. TRANSMITTER BATTERY S909325A1001
Any additional transmitter can also be pro-
Measure voltage between battery (+) terminal and grammed at this time. Repeat steps 6) through 9)
(–) terminal. for an additional transmitter.
NOTE: 10) Remove the ignition key from the ignition
쐌 Battery discharge occurs during measurement. switch.
Complete measurement within 5 seconds. 11) The horn will chirp three times to indicate that
쐌 During battery voltage measurement, voltage the system has exited the programming mode.
falls more than 1.8 volts in 3 seconds period. 12) Check the keyless entry system properly oper-
ates by operating each transmitter.
S6M0291A
Tester connection
Voltage (V)
(+) (–)
Battery (+) termi- Battery (–) termi-
More than 2
nal nal
SL-55
KEYLESS TRANSMITTER
Security and Locks
MEMO:
SL-56
GENERAL DESCRIPTION
Sunroof/T-top/Convertible Top (Sunroof)
1. SEDAN S910001A0501
B5M0890A
(1) Glass lid (6) Sunroof bracket (Front) Tightening torque: N·m (kgf-m, ft-lb)
(2) Guide rail cover (7) Motor cover
T: 7.4 (0.75, 5.4)
(3) Sunshade (8) Motor ASSY
(4) Drain tube (9) Frame ASSY
(5) Sunroof bracket (Rear) (10) Deflector
SR-2
墌 00.5.31/68j/9sr 墍
GENERAL DESCRIPTION
2. WAGON S910001A0502
B5M0749A
(1) Glass lid (Front) (5) Frame ASSY (Front) Tightening torque: N·m (kgf-m, ft-lb)
(2) Glass lid (Rear) (6) Drain tube
T: 7.4 (0.75, 5.4)
(3) Sunshade (7) Cover
(4) Frame ASSY (Rear) (8) Frame bracket
SR-3
墌 00.5.31/68j/9sr 墍
GENERAL DESCRIPTION
B: CAUTION S910001A03

contents before disconnecting the battery ground
cable. Otherwise, the memory will be erased.
unless otherwise indicated.
reassembly.
operate smoothly.
TOOL NAME REMARKS

Circuit Tester Used for measuring resistance and
voltage.
SR-4
墌 00.5.31/68j/9sr 墍
SUNROOF CONTROL SYSTEM
2. Sunroof Control System S910328

1. SUNROOF S910328A2101
SR-5
BU75-21
墌 00.5.31/68j/9sr 墍
SUNROOF CONTROL SYSTEM
Symptom Checking order

Water leaks. (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.
Booming noise (1) Check sunroof lid and roof panel for improper clearance.
(2) Check sunshade and roof trim for improper clearance.
Abnormal motor noise (1) Check motor for looseness.
(2) Check gears and bearings for wear.
(3) Check cables for wear.
(4) Check cable pipe for deformities.
Failure of sunroof (1) Check guide rail for foreign particles.
(Motor operates properly.) (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.
Motor does not rotate or rotates improperly. (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-6
墌 00.5.31/68j/9sr 墍
SUNROOF LID
3. Sunroof Lid S910536 B: INSTALLATION S910536A11
CAUTION:
1. WAGON (FRONT) S910536A1801
When installing sunroof lid, be careful not to
1) Tilt-up the front sunroof (most upper position). pinch the lip of lid.
2) disconnect ground cable from battery.
3) Remove sunroof switch. <Ref. to SR-15
REMOVAL, Sunroof Switch.>
4) Remove two mounting bolts.
5) Detach covers (A) then remove two nuts from
tilt-up assembly.
B5M0483A
1. ALIGNMENT OF HEIGHT BETWEEN

SUNROOF LID AND ROOF PANEL S910536A0101
B5M0482B
Loosen sunroof lid installation nuts and then adjust
6) Remove the sunroof lid carefully. height by adding (max: two pieces) or extracting
(max: one piece) shims (standard: one piece)
2. SEDAN AND WAGON (REAR) S910536A1802 between sunroof lid and body.
1) Completely close rear sunroof lid and open Difference in height between sunroof lid and
sunshade. roof panel: L
2) Disconnect ground cable from battery. L: 2.0±0.5 mm (0.079±0.020 in)
3) Remove covers (A) then remove nuts (B).
B5M0743B
B5M1029A
4) Remove the sunroof lid carefully.
SR-7
墌 00.5.31/68j/9sr 墍
SUNROOF ASSEMBLY
4. Sunroof Assembly S910329
1. SEDAN S910329A1801
1) Remove roof trim. <Ref. to EI-47 REMOVAL,

Roof Trim.>
2) Remove sunroof lid. <Ref. to SR-7 SEDAN
AND WAGON (REAR), REMOVAL, Sunroof Lid.>
3) Disconnect drain tubes from sunroof frame.
B5M0902
4) Remove room lamp harness clip.
2. WAGON (FRONT) S910329A1802
1) Remove roof trim. <Ref. to EI-47 REMOVAL,

Roof Trim.>
2) Remove front sunroof lid. <Ref. to SR-7
WAGON (FRONT), REMOVAL, Sunroof Lid.>
3) Remove room lamp harness clip.
4) Remove bolts (A), nuts (B) and clips (C) then
detach the sunroof frame.
B5M0310A
5) Disconnect sunroof harness connector.

6) Remove motor cover.
B5M1030A
B5M0900
7) Remove sunroof brackets front (a) and rear (b).
B5M0901A
8) Remove nuts then detach the sunroof frame.
SR-8
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SUNROOF ASSEMBLY
3. WAGON (REAR) S910329A1803
1) Remove roof trim. <Ref. to EI-47 REMOVAL, Roof Trim.>

2) Remove rear sunroof lid. <Ref. to SR-7 SEDAN AND WAGON (REAR), REMOVAL, Sunroof Lid.>
3) Disconnect drain tubes (A) from rear sunroof frame.
4) Disconnect sunroof harness connector (B).
5) Remove sunroof brackets (C).
6) Remove bolts (D) and nuts (E) then detach the sunroof frame.
B5M1031A
SR-9
墌 00.5.31/68j/9sr 墍
SUNROOF ASSEMBLY
B: INSTALLATION S910329A11 2. WAGON (REAR) S910329A0602
Install in the reverse order of removal. 1) Remove rear sunroof frame.

2) Remove sunroof motor bracket mounting
CAUTION: screws (A).
Be careful not to snag the harness. 3) Remove rail stoppers (B) then pull the motor
NOTE: assembly (C) in the direction shown in the figure.
쐌 Make sure to connect harness connector.
쐌 When installing drain tube, insert it securely onto
drain pipe.
Length A:
15 mm (0.59 in) or more
B5M1034A
4) Pull out the sunshade (A) from sunroof frame.
G5M0205
C: DISASSEMBLY S910329A06
1. SEDAN AND WAGON (FRONT) S910329A0601
1) Remove sunroof frame.

2) Remove rail stoppers (A).
B5M1035A
Assemble in the reverse order of disassembly.
B5M1032A
3) Pull out the sunshade (A) from sunroof frame.
B5M1033A
SR-10
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SUNROOF ASSEMBLY
E: INSPECTION S910329A10
1. CHECK FOR MOVEMENT OF

SUNSHADE S910329A1001
1) Place a cloth on sunshade, and attach a spring
scale to sunshade edge using a cloth.
B5M0317
B5M0766
2) Pull spring scale to measure force required to

move the sunshade.
Force required to move rear sunshade:
Less than 24.5±4.9 N (2.5±0.5 kgf, 55±1.1
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
SR-11
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SUNROOF MOTOR
5. Sunroof Motor S910537

3) Confirm the matching mark (A) of rear sunroof
bracket link and the guide from sunroof opening. (If
A: REMOVAL S910537A18 the mark does not match, adjust to match the
CAUTION: mark.)
When removing clip, use great care to not dam-
age the roof trim.
1. SEDAN S910537A1801
1) Completely close the sunroof.

2) Remove sunroof lid. <Ref. to SR-7 SEDAN
3) Confirm the matching mark of sunroof bracket
link and the guide from sunroof opening. (If the
mark does not match, adjust to match the mark.)
B5M1036A
4) Remove luggage room light. <Ref. to LI-42

REMOVAL, Luggage Room Light.>
5) Remove rear assist grips.
6) Remove rear window mole of both sides (A).
7) Remove screws (B) and clips (C) of rear quar-
ter lower trim shown in the figure.
8) Remove rear quarter upper trim (D) of both
sides.
B5M1036A
4) Remove roof trim. <Ref. to ROOF TRIM.>

5) Remove motor cover.
B5M0900

sunroof motor mounting screw.
2. WAGON S910537A1802
1) Completely close the front and rear sunroof,

then tilt-up the front sunroof to the most upper posi-
tion. B5M1037A
2) Remove rear sunroof lid. <Ref. to SR-7 SEDAN
SR-12
墌 00.5.31/68j/9sr 墍
SUNROOF MOTOR
10) Remove cover (B) while detaching snap lock B: INSTALLATION S910537A11
carefully. Put the rear center seat belt tongue (A)
out to the other side of the trim through the hole. CAUTION:
쐌 Never rotate the sunroof motor while
removed.
쐌 Be careful not to move the sunroof cable
when installing sunroof motor.
1) Check the matching mark (A) of sunroof motor.
B5M0675A
11) Remove clips and hang down rear end of roof

trim.
12) Disconnect harness connector (A) and
remove sunroof motor mounting screw (B).
B5M1039A
2) Confirm the matching mark (A) of sunroof

bracket link.
B5M1038A
B5M1036A
3) Install sunroof motor.

4) After installing the motor, reconfirm the match-
ing marks of motor side and sunroof bracket link
side.
5) Connect sunroof motor harness connector and
then connect battery ground cable.
6) Operate the sunroof switch, and check the sun-
roof stop position.
7) Move sunroof to completely closed position and
install sunroof lid.
SR-13
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SUNROOF MOTOR
8) Check the sunroof operation with the procedure as shown in the figure.
B5M1040A
9) Install trims in the reverse order of removal.
SR-14
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SUNROOF SWITCH
6. Sunroof Switch S910538 Switch position Tester connection Specified condition

Open S1: 3 — 4 Continuity
Close S1: 1 — 3 Continuity
1) Disconnect ground cable from battery. Tilt-up S2: 3 — 4 Continuity
2) Remove spot light lens (A) and sunroof switch Tilt-down S2: 1 — 3 Continuity
mounting screw (B).
2. WAGON S910538A1002
B5M1058A

ing the switch.
Open 3—4 Continuity
Close 1—3 Continuity
B5M1041A

sunroof switch.
1. SEDAN S910538A1001
B5M1042A

ing the switch.
SR-15
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SUNROOF SWITCH
MEMO:
SR-16
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GENERAL DESCRIPTION
Wiper and Washer Systems
Front wiper motor Input 12 V — 72 W or less

Rear wiper motor Input 12 V — 42 W or less
Pump type Centrifugal
Front washer motor
Input 12 V — 36 W or less
Pump type Centrifugal
Rear washer motor
Input 12 V — 36 W or less
1. FRONT WIPER S902001A0501
B6M1462A
(1) Wiper rubber (5) Wiper motor Tightening torque: N·m (kgf-m, ft-lb)
(2) Wiper blade ASSY
T1: 5.9 (0.6, 4.3)
(3) Wiper arm
T2: 20 (2.0, 14.5)
(4) Wiper link
WW-2
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GENERAL DESCRIPTION
2. REAR WIPER S902001A0502
B6M1463A
(1) Wiper rubber (7) Spacer B Tightening torque: N·m (kgf-m, ft-lb)
(2) Wiper blade ASSY (8) Nut
T1: 5.9 (0.6, 4.3)
(3) Wiper arm (9) Cap
T2: 7.4 (0.75, 5.4)
(4) Wiper motor (10) Wiper arm cover
T3: 7.8 (0.8, 5.8)
(5) Spacer A
(6) Cushion
WW-3
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GENERAL DESCRIPTION
3. WASHER TANK S902001A0503
B6M1464A
(1) Washer nozzle (5) Front washer motor Tightening torque: N·m (kgf-m, ft-lb)
(2) Washer hose (6) Rear washer motor
T: 5.9 (0.6, 4.3)
(3) Washer tank (7) Grommet
(4) Washer tank cap
쐌 Reconnect connectors and hoses securely.

After reconnecting, confirm that each function operates normally.
쐌 Be careful that wire harnesses of airbag system pass near electrical parts and switches.
쐌 Wire harnesses and connectors of all airbag system are yellow color. Do not use a tester on these cir-
cuits.
쐌 Care must be taken when installing the piping hose so that no bending, jamming, etc. are caused.
쐌 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
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WIPER AND WASHER SYSTEM
2. Wiper and Washer System

S902394
1. WIPER AND WASHER (FRONT) S902394A2101
WW-5
BU50-21
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2. WIPER AND WASHER (REAR) S902394A2102
BU51-21
WW-6
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Wiper and washers do not operate. (1) Wiper fuse (F/B No. 14, 15)
(2) Combination switch
(3) Wiper motor
(4) Wire harness
Wipers do not operate in LO or HI. (1) Combination switch
(2) Wiper motor
(3) Wire harness
Wipers do not operate in INT. (1) Combination switch
(2) Wiper motor
(3) Wire harness
Washer motor does not operate. (1) Washer switch
(2) Washer motor
(3) Wire harness
Wipers do not operate when washer switch is ON. (1) Washer motor
(2) Wire harness
Washer fluid spray does not operate. (1) Washer hose and nozzle
WW-7
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COMBINATION SWITCH (WIPER)
3. Combination Switch (Wiper) C: INSPECTION S902395A10
S902395
쐌 Inspect the continuity between each connector
terminal.
1) Loosen screw to remove a steering column

cover.
B6M1184
2) Disconnect connectors from combination

switches.
3) Loosen screw to remove combination switch.
S6M0137
Test Specified
Switch position
connection condition
OFF 7 — 16 Continuity
INT 7 — 16 Continuity
B6M1499
FRONT LO 7 — 17 Continuity
HI 8 — 17 Continuity
B: INSTALLATION S902395A11 Washer ON 2 — 11 Continuity
Washer ON 2 — 10 — 12 Continuity
REAR
ON 2 — 10 Continuity
Washer ON 2 — 10 — 12 Continuity
If continuity is not as specified, replace the switch.
WW-8
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COMBINATION SWITCH (WIPER)
쐌 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 17 and 2, and inspect the voltage of terminals 7 and 2. (Mea-
sure the voltage from after the second time the wiper stops.)
B6M1465A
If operation is not as specified, replace the switch.
WW-9
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WIPER BLADE
4. Wiper Blade S902392 D: ASSEMBLY S902392A02
1) Insert the wiper rubber onto the blade so that
the stopper is in the position shown (at the bottom
While pushing locking clip up, pull out blade from of the wiper arm).
arm to arrow direction.
B6M1497
B6M1536A
2) Make sure the wiper rubber is securely fas-
tened to the pull stopper (A).

2) Confirm that clip was locked securely.
Pull on side (A) of the wiper rubber stopper and

remove the rubber from the blade assembly.
B6M1498A
1) When the wiper does not perform well, inspect

the following:
쐌 Make sure the movable part of the blade assem-
bly moves smoothly.
B6M1496A 쐌 Make sure the wiper rubber is not deformed or
damaged.
2) Replace with a new part if damage is found.
WW-10
WASHER TANK AND MOTOR
5. Washer Tank and Motor S902405 D: ASSEMBLY S902405A02
2) Confirm that water does not leak from installa-
1) Open hood. tion area of motor.
2) Remove the 2 bolts, hose and connector and
then remove the tank. E: INSPECTION S902405A10
Apply battery voltage to the connector terminal of

the washer motor and make sure the motor oper-
ates.
B5M1464
B6M0111
Remove washer motor from tank.
B5M1465
WW-11
FRONT WIPER ARM
6. Front Wiper Arm S902404
1) Open hood.
2) Remove cap.
3) Loosen nut to remove arm.
S6M0050

2) Operate wiper once.
3) Align wiper blade to ceramic print point mark
(A) of front window pane.
B6M1193A
Operate wiper once. Align wiper blade to ceramic

print point mark (A) of front window pane.
B6M1193A
WW-12
FRONT WIPER MOTOR AND LINK
7. Front Wiper Motor and Link 2) When battery is connected to terminal of

connectors, confirm that motor operates at high
S902406
speed.
1) Remove cowl panel. <Ref. to EI-27 REMOVAL,

Cowl Panel.>
2) Disconnect wiper motor connector.
3) Loosen bolts and nuts to remove wiper link.
B6M1196
3) Connect battery to terminals of connector, and

remove terminal connection with motor rotated at
low speed, and stop wiper motor through opera-
tion.
B5M1466
4) Loosen bolts and nut to remove motor.
B6M1197
4) Connect battery and confirm that motor stops at

B5M1467
automatic stop position after motor operates at low
speed again.
1) When battery is connected to terminal of

connectors, confirm that motor operates at low
speed.
B6M1198
B6M1195
WW-13
FRONT WASHER
8. Front Washer S902401
B6M1466
B: REMOVAL S902401A18 C: INSTALLATION S902401A11
1. NOZZLE S902401A1801 1. NOZZLE S902401A1101
1) Remove the washer hose from the washer 1) Install in the reverse order of removal.
nozzle. 2) Adjust the position of the washer liquid sprayer.
2) Open the clips on the underside of the hood <Ref. to WW-15 ADJUSTMENT, Front Washer.>
with a thin screwdriver or other tool, and remove
the washer nozzle. D: INSPECTION S902401A10
쐌 Make sure the nozzle and hose are not clogged.

쐌 Make sure the hose is not bent.
B6M1505
WW-14
FRONT WASHER
E: ADJUSTMENT S902401A01
1) Turn wiper switch to OFF position.

2) When vehicle stops, adjust washer injection
position as shown in the figure.
Injection position:
A: 350 mm (13.78 in)
B: 100 mm (3.94 in)
C: 200 mm (7.87 in)
B6M1315A
WW-15
REAR WIPER ARM
9. Rear Wiper Arm S902402
1) Raise wiper arm cover (A).

2) Loosen nut to remove wiper arm.
B6M1201A

2) Operate rear wiper once.
3) Align blade to rear defogger heat wire (A).
B6M1199A
1) Operate rear wiper once.

2) Align blade to rear defogger heat wire (A).
B6M1199A
WW-16
REAR WIPER MOTOR
10. Rear Wiper Motor S902532 C: INSPECTION S902532A10
1) Connect battery to wiper motor connector and
confirm that wiper motor operates.
1) Remove rear wiper arm.
2) Remove cap (A), nut (B), and spacer (C) from
rear wiper shaft.
S6M0072
2) Connect battery to terminal of connector and

B6M1202A remove terminal connections with motor rotated,
and stop wiper motor through operation.
3) Remove rear gate lower trim. <Ref. to EI-49
4) Unclip clip of harness and disconnect connec-
tor of wiper motor.
5) Loosen bolts to remove wiper motor assembly
(A).
S6M0073
3) Connect battery and confirm that motor stops at

automatic stop position after motor operates at low
speed again.
B6M1203A

2) Install rear wiper cushion with the arrow mark
facing up, as shown in the figure.
S6M0074
B5M1463
WW-17
REAR WASHER
11. Rear Washer S902400
B6M1467
B: REMOVAL S902400A18 C: INSTALLATION S902400A11
1. NOZZLE S902400A1801 1. NOZZLE S902400A1101
1) Remove the high-mount stop light. <Ref. to 1) Install in the reverse order of removal.
LI-39 REMOVAL, High-mounted Stop Light.> 2) Adjust the position of the washer liquid sprayer.
2) Remove the washer hose from the washer <Ref. to WW-19 ADJUSTMENT, Rear Washer.>
nozzle.
3) Open the clips on the underside of the hood D: INSPECTION S902400A10
with a thin screwdriver or other tool, and remove

쐌 Make sure the nozzle and hose are not clogged.
the washer nozzle.
쐌 Make sure the hose is not bent.
B6M1505
WW-18
REAR WASHER
1) Turn wiper switch to OFF position.

2) When vehicle stops, adjust washer injection
position as shown in the figure.
Injection position:
A: 60 mm (2.36 in)
B: 42°
B6M1200C
WW-19
WIPER CONTROL RELAY
12. Wiper Control Relay S902403 C: INSPECTION S902403A10
1. WAGON S902403A1001
1. WAGON S902403A1801
Apply battery voltage to the rear terminals 8 and 2,
and then inspect the voltage of 6 and 2. (Measure
1) Remove right quarter lower trim. <Ref. to EI-44 the voltage from after the second time the wiper
REMOVAL, Rear Quarter Trim.> stops.)
2) Remove quarter pocket.
3) Loosen nut to remove control unit.
B6M1544A
B5M1462
1. WAGON S902403A1101
B6M1523A
If operation is not as specified, replace the switch.
WW-20
GENERAL DESCRIPTION
Instrumentation/Driver Info
Speedometer Electric pulse type

Temperature gauge Thermistor cross coil type
Fuel gauge Resistance cross coil type
Tachometer Electric impulse type
Turn signal indicator light 12 V — 1.4 W
Charge indicator light 12 V — 1.4 W
Oil pressure indicator light 12 V — 1.4 W
ABS warning light 12 V — 1.4 W
Check engine warning light (Malfunction indicator light) 12 V — 1.4 W
HI-beam indicator light 12 V — 1.4 W
Combination meter Door open warning light LED
Seat belt warning light LED
Brake fluid and parking brake warning light 12 V — 1.4 W
FWD indicator light 12 V — 1.4 W
AIRBAG warning light 12 V — 1.4 W
Meter illumination light 12 V — 3.4 W
AT OIL TEMP. warning light 12 V — 1.4 W
Security indicator light LED
Low fuel warning light 12 V — 1.4 W
AT select lever position indicator light 12 V — 100 mA
LCD back light 12 V — 1.4 W
IDI-2
GENERAL DESCRIPTION
쐌 Be careful not to damage meters and instrument panel.

쐌 Be careful not to damage meter glasses.
쐌 Make sure that electrical connector is connected securely.
쐌 After installation, make sure that each meter operates normally.
쐌 Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces.
쐌 Do not apply excessive force to circuit plate.
쐌 Do not drop or otherwise apply impact.
TOOL NAME REMARKS

Circuit Tester Used for measuring resistance and voltage.
IDI-3
COMBINATION METER SYSTEM
2. Combination Meter System S907607
1. COMBINATION METER S907607A2101
BU64-21A
IDI-4
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BU64-21B
IDI-5
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BU64-21C
IDI-6
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BU64-21D
IDI-7
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BU64-21E
IDI-8
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2. OUTSIDE TEMPERATURE INDICATOR S907607A2102
BU96-20
IDI-9
墌 00.5.31/68j/9idi 墍
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 5 mm (0.20 in).

Combination meter assembly does not (1) Power supply <Ref. to IDI-11 CHECK POWER
operate. (2) Ground circuit SUPPLY AND GROUND CIRCUIT,
INSPECTION, Combination Meter
System.>
Speedometer does not operate. (1) (MT) Vehicle speed sensor <Ref. to IDI-12 CHECK VEHICLE
(A/T) Transmission control module SPEED SENSOR, INSPECTION,
(2) Harness Combination Meter System.>
(3) Speedometer <Ref. to IDI-13 CHECK TRANSMIS-
SION CONTROL MODULE,
INSPECTION, Combination Meter
System.>
Tachometer does not operate. (1) Engine control module <Ref. to IDI-14 CHECK ENGINE
(2) Harness CONTROL MODULE, INSPECTION,
(3) Tachometer Combination Meter System.>
Fuel gauge does not operate. (1) Fuel level sensor <Ref. to IDI-15 CHECK FUEL
(2) Harness LEVEL SENSOR, INSPECTION,
(3) Fuel gauge Combination Meter System.>
Water temperature gauge does not oper- (1) Engine coolant temperature sensor <Ref. to IDI-16 CHECK ENGINE
ate. (2) Harness COOLANT TEMPERATURE
(3) Water temperature gauge SENSOR, INSPECTION, Combina-
tion Meter System.>
Outside temperature indicator does not (1) Ambient sensor <Ref. to IDI-16 CHECK OUTSIDE
operate. (2) Harness TEMPERATURE INDICATOR,
(3) Combination meter INSPECTION, Combination Meter
System.>
IDI-10
墌 00.5.31/68j/9idi 墍

1 CHECK POWER SUPPLY FOR COMBINA- Is the voltage more than 10 Go to step 2. Check harness for
TION METER. V? open or short
1) Remove combination meter. <Ref. to IDI-17 between ignition
REMOVAL, Combination Meter Assembly.> relay and combi-
2) Disconnect combination meter harness nation meter.
connector.
4) Measure voltage between combination
meter connector (i12) and chassis ground.
(i12) No. 3 (+) — Chassis ground (−):
2 CHECK POWER SUPPLY FOR COMBINA- Is the voltage more than 10 Go to step 3. Check harness for
TION METER. V? open or short
Measure voltage between combination meter between ignition
connector (i12) and chassis ground. relay and combi-
Connector & terminal nation meter.
3 CHECK GROUND CIRCUIT OF COMBINA- Is the resistance less than Go to step 4. Repair wiring har-
TION METER. 10 Ω? ness.
1) Turn ignition switch to OFF.
2) Measure resistance of harness between
combination meter connector (i10) and chas-
sis ground.
4 CHECK GROUND CIRCUIT OF COMBINA- Is the resistance less than Replace combina- Repair wiring har-
TION METER. 10 Ω? tion meter. ness.
Measure resistance of harness between com-
bination meter connector (i11) and chassis
ground.
IDI-11
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3. CHECK VEHICLE SPEED SENSOR

S907607A1002

1 CHECK VEHICLE SPEED SENSOR. Is the voltage more than 5 Check speedom- Go to step 2.
1) Set the vehicle on a free roller, or lift-up the V? eter. <Ref. to
vehicle and support it with safety stands. IDI-19 REMOVAL,
2) Remove the combination meter with har- Speedometer.>
ness connector.
WARNING:
Be careful not to get caught in the running
wheels.
3) Drive the vehicle at a speed greater than
20 km/h/ (12 MPH).
4) Measure voltage between combination
meter connector (i10) and chassis ground.
2 CHECK VEHICLE SPEED SENSOR POWER Is the voltage more than 10 Go to step 3. Check harness for
SUPPLY. V? open or short
1) Turn ignition switch to OFF. between ignition
2) Disconnect vehicle speed sensor harness relay and vehicle
connector. speed sensor.
4) Measure voltage between vehicle speed
sensor connector (B17) and engine ground.
3 CHECK HARNESS BETWEEN VEHICLE Is the resistance less than Go to step 4. Repair wiring har-
SPEED SENSOR AND ENGINE GROUND. 10 Ω? ness.
sensor connector (B17) and engine ground.
4 CHECK HARNESS BETWEEN VEHICLE Is the resistance less than Replace vehicle Repair wiring har-
SPEED SENSOR AND COMBINATION 10 Ω? speed sensor. ness.
METER.
1) Disconnect connector from combination
meter.
sensor harness connector and combination
meter harness connector.
(B17) No. 1 — (i10) No. 13:
IDI-12
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4. CHECK TRANSMISSION CONTROL

MODULE S907607A1008
1 CHECK AUTOMATIC TRANSMISSION CON- Is the voltage less than 5 V Go to step 2. Check automatic
TROL MODULE SIGNAL. ←→ more than 4 V? transmission con-
1) Set the vehicle on a free roller, or lift-up the trol module. <Ref.
vehicle and support it with safety stands. to AT-2 Basic
WARNING: Diagnostic Proce-
Be careful not to get caught in the running dure.>
wheels.
2) Drive the vehicle faster than 10 km/h (6
MPH).
3) Measure voltage between automatic trans-
mission control module connector (B55) and
chassis ground.
2 CHECK HARNESS BETWEEN AUTOMATIC Is the resistance less than Check speed Repair wiring har-
TRANSMISSION CONTROL MODULE AND 10 Ω? meter. <Ref. to ness.
COMBINATION METER. IDI-19 REMOVAL,
1) Turn ignition switch to OFF. Speedometer.>
2) Disconnect connector from automatic trans-
mission control module and combination
meter.
3) Measure resistance between automatic
transmission control module harness connec-
tor (B55) and combination meter harness con-
nector (i10).
(B55) No. 13 — (i10) No. 13:
IDI-13
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5. CHECK ENGINE CONTROL MODULE

S907607A1004

1 CHECK ENGINE CONTROL MODULE SIG- Is the voltage 0 ←→ 13 V Go to step 2. Check engine
NAL. or more? control module.
1) Start the engine. <Ref. to EN(H4)-2
2) Measure voltage between engine control Basic Diagnostic
module connector (B134) and engine ground. Procedure.>
2 CHECK HARNESS BETWEEN COMBINA- Is the resistance less than Check tachom- Repair wiring har-
TION METER AND ENGINE CONTROL 10 Ω? eter. <Ref. to ness.
MODULE. IDI-20 REMOVAL,
1) Turn ignition switch to OFF. Tachometer.>
2) Disconnect connector from engine control
module and combination meter.
3) Measure resistance between engine control
module harness connector (B134) and combi-
nation meter harness connector (i11).
(B134) No. 30 — (i11) No. 7:
IDI-14
墌 00.5.31/68j/9idi 墍
6. CHECK FUEL LEVEL SENSOR S907607A1005

1 CHECK FUEL LEVEL SENSOR. Is fuel level sensor OK? Go to step 2. Replace fuel level
Check fuel level sensor. <Ref. to EC(H4)-9 sensor.
REMOVAL, Main Fuel Level Sensor.>
2 CHECK HARNESS BETWEEN FUEL LEVEL Is the resistance less than Check fuel gauge. Repair wiring har-
SENSOR AND COMBINATION METER. 10 Ω? <Ref. to IDI-21 ness.
1) Turn ignition switch to OFF. REMOVAL, Fuel
2) Disconnect connector from fuel tank cord Gauge.>
and combination meter.
3) Measure resistance between rear wiring
harness connector (R15) and combination
meter harness connector (i10).
(R15) No. 6 — (i10) No. 3:
IDI-15
墌 00.5.31/68j/9idi 墍
7. CHECK ENGINE COOLANT

TEMPERATURE SENSOR S907607A1006
1 CHECK ENGINE COOLANT TEMPERA- Is engine coolant tempera- Go to step 2. Check engine
TURE SENSOR. ture sensor OK? coolant tempera-
Check engine coolant temperature sensor. ture sensor.
<Ref. to FU(H4)-40 REMOVAL, Engine Cool-
ant Temperature Sensor.>
2 CHECK HARNESS BETWEEN ENGINE Is the resistance less than Check water tem- Repair wiring har-
COOLANT TEMPERATURE SENSOR AND 10 Ω? perature meter. ness.
COMBINATION METER. <Ref. to IDI-22
1) Turn ignition switch to OFF. REMOVAL, Water
2) Disconnect connector from engine coolant Temperature
temperature sensor and combination meter. Gauge.>
3) Measure resistance between engine cool-
ant temperature sensor harness connector
(E8) and combination meter harness connec-
tor (i12).
(E8) No. 3 — (i12) No. 8:
8. CHECK OUTSIDE TEMPERATURE

INDICATOR S907607A1009
1 CHECK POWER SUPPLY FOR AMBIENT Is the voltage more than 10 Go to step 2. Check harness for
SENSOR. V? open or short
1) Turn ignition switch OFF. between ambient
2) Disconnect connector from ambient sensor. sensor and com-
3) Turn ignition switch ON. bination meter.
4) Measure voltage between ambient sensor
harness connector terminal and chassis
ground.
(F78) No. 1 (+) — Chassis ground (−):
2 CHECK AMBIENT SENSOR. Is the ambient sensor OK? Go to step 3. Replace the ambi-
1) Turn ignition switch OFF. ent sensor.
2) Remove ambient sensor.
3) Check ambient sensor. <Ref. to IDI-23
INSPECTION, Ambient Sensor.>
3 CHECK HARNESS BETWEEN AMBIENT Is the resistance less than Go to step 4. Repair wiring har-
SENSOR AND COMBINATION METER. 10 Ω? ness.
1) Disconnect connector from combination
meter.
2) Measure resistance between ambient sen-
sor harness connector terminal and combina-
tion meter harness connector terminal.
(F78) No. 2 — (i10) No. 9:
4 CHECK OUTSIDE TEMPERATURE INDICA- Is the outside temperature Outside tempera- Replace combina-
TOR. indicator indicating 25°C ture indicator is tion meter printed
1) Connect combination meter harness con- (77°F)? OK. circuit.
nector.
2) Connect a resistor (2.2 kΩ) between termi-
nals of ambient sensor harness connector.
3) Turn ignition switch ON and check the out-
side temperature indicator display.
IDI-16
墌 00.5.31/68j/9idi 墍
COMBINATION METER ASSEMBLY
3. Combination Meter B: INSTALLATION S907335A11
Assembly S907335 Install in the reverse order of removal.

CAUTION:
쐌 Make sure that electrical connector is con-
1) Disconnect ground cable from battery. nected securely.
2) Set tilt steering at the lowest position. 쐌 Make sure that each meter operates nor-
3) Disconnect each electrical connector to remove mally.
front cover (A) and switch panel (B).
4) Loosen screws (C) to remove center panel (D). C: DISASSEMBLY S907335A06
5) Remove meter visor (E).

CAUTION:
Use gloves to avoid damage and getting finger-
prints on the glass surface and meter surfaces.
1) Disengage claw (F) to remove case (B) from
back cover (A).
2) Disengage claw (G) to remove meter glass (E),
reflector (D), and window plate (C) from inner case.
B6M1207A
3) Pull up claw (A) in portion (B) of circuit plate (C)

with combination pliers. Push out speedometer
B6M1204A
assembly (D) and tachometer assembly (E) using
hole (F).
6) Remove screws of combination meter to pull 4) Pull up claw in the center of circuit plate (C),
out the meter toward you. and remove circuit plate from case (G).
7) Remove connector in the upper area of combi-
nation meter to remove meter.
B6M1422A
B6M1205
CAUTION:
쐌 Be careful not to damage meter or instru-
ment panel.
쐌 Pay particular attention to avoid damaging
the meter glass.
IDI-17
墌 00.5.31/68j/9idi 墍
COMBINATION METER ASSEMBLY
1. BULB REPLACEMENT S907335A0601
B6M1547A
(1) FWD
(2) AT OIL TEMP.
(3) Oil pressure
(4) Check engine
(5) Charge
(6) HI-beam
(7) Turn RH
(8) Tachometer
(9) Turn LH
(10) Brake
(11) Speedometer
(12) Airbag
(13) ABS
(14) Speedometer and fuel gauge
(15) Low fuel
(16) Tachometer and temperature gauge
(17) LCD (Clock or clock and outside temperature indi-
cator)
(18) LCD (Odometer and trip meter)
IDI-18
墌 00.5.31/68j/9idi 墍
SPEEDOMETER
4. Speedometer S907608
Disassemble combination meter, and then remove

speedometer and fuel gauge assembly. <Ref. to
IDI-17 DISASSEMBLY, Combination Meter
Assembly.>
Measure resistance between speedometer termi-

nals.
B6M1232A

Terminals SIN+ —SIN— 200±8 Ω
Terminals COS+ —COS— 200±8 Ω
If NG, replace speedometer and fuel gauge

assembly.
If OK, replace combination meter printed circuit.
IDI-19
TACHOMETER
5. Tachometer S907609

tachometer and water temperature gauge
assembly.<Ref. to IDI-17 DISASSEMBLY, Combi-
nation Meter Assembly.>
Measure resistance between tachometer termi-

nals.
B6M1232A

Terminals SIN+ —SIN— 200±8 Ω
Terminals COS+ —COS— 200±8 Ω
If NG, replace tachometer and water temperature

gauge assembly.
IDI-20
FUEL GAUGE
6. Fuel Gauge S907610

speedometer and fuel gauge assembly. <Ref. to
IDI-17 DISASSEMBLY, Combination Meter
Assembly.>
Measure resistance between fuel gauge terminals.
B6M1233A

Terminals IGN — GND 170±10 Ω
Terminals IGN — UNIT 35±10 Ω
Terminals UNIT — GND 136±10 Ω
If NG, replace speedometer and fuel gauge

assembly.
IDI-21
WATER TEMPERATURE GAUGE
7. Water Temperature Gauge S907611

tachometer and water temperature gauge assem-
bly. <Ref. to IDI-17 DISASSEMBLY, Combination
Meter Assembly.>
Measure resistance between fuel gauge terminals.
B6M1233A

Terminals IGN — GND 208±10 Ω
Terminals IGN — UNIT 56±10 Ω
Terminals UNIT — GND 264±10 Ω
If NG, replace tachometer and water temperature

gauge assembly.
IDI-22
AMBIENT SENSOR
8. Ambient Sensor S907644
1) Open front hood.

2) Disconnect ground cable from battery.
3) Disconnect ambient sensor connector.
4) Remove ambient sensor from radiator lower
panel.
B4M2338
Measure resistance between ambient sensor ter-

minals.
B6M1537

1—2 2.2 kΩ/25°C (77°F)
If NG, replace the ambient sensor.
IDI-23
AMBIENT SENSOR
MEMO:
IDI-24
ABS (DIAGNOSTICS)
1. WITHOUT SUBARU SELECT MONITOR S006501E4501
CAUTION:
Remove foreign matter (dust, water, etc.) from the ABSCM&H/U connector during removal and
installation.
NOTE:
쐌 To check harness for broken wires or short circuits, shake it while holding it or the connector.
쐌 When ABS warning light illuminates, read and record trouble code indicated by ABS warning light.
1 CHECK PRE-INSPECTION. Is unit that might influence Go to step 2. Repair or replace
1) Ask the customer when and how the the ABS problem normal? each unit.
trouble occurred using interview checklist.
<Ref. to ABS-5 Check List for Interview.>
2) Before performing diagnosis, inspect unit
which might influence the ABS problem. <Ref.
to ABS-8 INSPECTION, General Description.>
2 CHECK INDICATION OF TROUBLE CODE. Is trouble code readable? Go to step 3. Inspect using
Calling up trouble code. <Ref. to ABS-18 diagnostic chart
Read Diagnostic Trouble Code.> for ABS warning
light failure. <Ref.
to ABS-26 Diag-
nostics Chart with
Diagnosis Con-
nector.>
NOTE:
Call up trouble
code again after
inspecting ABS
warning light.
<Ref. to ABS-18
Read Diagnostic
Trouble Code.>
3 CHECK TROUBLE CODE. Is only the start code Go to step 4. Go to step 5.
NOTE: issued?
Record all trouble codes.
4 PERFORM THE GENERAL DIAGNOSTICS. Is only the start code Complete the Go to step 5.
1) Inspect using “General Diagnostics Table”. issued? diagnosis.
<Ref. to ABS-163 General Diagnostics
Table.>
2) Perform the clear memory mode. <Ref. to
ABS-20 WITHOUT SUBARU SELECT
MONITOR, OPERATION, Clear Memory
Mode.>
3) Perform the inspection mode. <Ref. to
ABS-19 Inspection Mode.>
Calling up the trouble code. <Ref. to ABS-18
Read Diagnostic Trouble Code.>
ABS-2
ABS (DIAGNOSTICS)

5 PERFORM THE DIAGNOSIS. Is only the start code Complete the Inspect using
1) Inspect using “Diagnostics Chart with Diag- issued? diagnosis. “Diagnostics Chart
nostic Connector”. <Ref. to ABS-26 Diagnos- with Diagnostic
tics Chart with Diagnosis Connector.> Connector”. <Ref.
NOTE: to ABS-26 Diag-
For trouble code list, refer to “List of Diagnos- nostics Chart with
tics Trouble Code”. <Ref. to ABS-22 WITH- Diagnosis Con-
OUT SUBARU SELECT MONITOR, LIST, List nector.>
of Diagnostics Trouble Code.>
2) Repair trouble cause.
ABS-20 WITHOUT SUBARU SELECT
Mode.>
5) Calling up the trouble code. <Ref. to
ABS-18 Read Diagnostic Trouble Code.>
ABS-3
ABS (DIAGNOSTICS)
2. WITH SUBARU SELECT MONITOR S006501E4502
CAUTION:
Remove foreign matter (dust, water, etc.) from the ABSCM&H/U connector during removal and
installation.
NOTE:
쐌 Check list for interview. <Ref. to ABS-24 WITH SUBARU SELECT MONITOR, LIST, List of Diagnostics
Trouble Code.>
1) Ask the customer when and how the the ABS problem normal? each unit.
<Ref. to ABS-5 Check List for Interview.>
which might influence the ABS problem. <Ref.
to ABS-8 INSPECTION, General Description.>
2 CHECK INDICATION OF TROUBLE CODE Is the corresponding Go to step 3. Go to step 4.
DISPLAY. trouble encoding?
2) Connect the SUBARU SELECT MONITOR
to data link connector.
3) Turn ignition switch to ON and SUBARU
SELECT MONITOR to ON.
4) Read diagnostic trouble code. <Ref. to
ABS-17 READ CURRENT DATA,
OPERATION, Subaru Select Monitor.>
5) Record all trouble codes and frame data.
3 PERFORM THE GENERAL DIAGNOSTICS. Is no trouble code desig- Complete the Go to step 4.
1) Inspect using “General Diagnostics Table”. nated and ABS warning diagnosis.
<Ref. to ABS-163 General Diagnostics light goes out after turning
Table.> on?
ABS-17 CLEAR MEMORY MODE,
OPERATION, Subaru Select Monitor.>
ABS-16 READ DIAGNOSTIC TROUBLE
CODE, OPERATION, Subaru Select Monitor.>
4 PERFORM THE DIAGNOSIS. Is no trouble code desig- Complete the Inspect using
1) Inspect using “Diagnostics Chart with nated and does ABS warn- diagnosis. “Diagnostics Chart
Subaru Select Monitor”. <Ref. to ABS-88 ing light go out after turning with Subaru
Diagnostics Chart with Subaru Select Moni- on? Select Monitor”.
tor.> <Ref. to ABS-88
NOTE: Diagnostics Chart
For trouble code list, refer to “List of Diagnos- with Subaru
tics Trouble Code”. <Ref. to ABS-22 WITH- Select Monitor.>
OUT SUBARU SELECT MONITOR, LIST, List
ABS-17 CLEAR MEMORY MODE,
OPERATION, Subaru Select Monitor>
ABS-4
CHECK LIST FOR INTERVIEW
ABS (DIAGNOSTICS)
2. Check List for Interview S006502
A: CHECK S006502A04
Check the following items about the vehicle’s state.

1. STATE OF ABS WARNING LIGHT
ABS warning light 쏔 Always

comes on. 쏔 Sometimes
쏔 Only once
쏔 Does not come on
쐌 When / how long does it come on?:
Ignition key position 쏔 LOCK
쏔 ACC
쏔 ON (before starting engine)
쏔 START
쏔 On after starting (Engine is running)
쏔 On after starting (Engine is stop)
Timing 쏔 Immediately after ignition is ON.
쏔 Immediately after ignition starts.
쏔 When advancing km/h to km/h
MPH to MPH
쏔 While traveling at a constant speed km/h MPH
쏔 When decelerating km/h to km/h
MPH to MPH
쏔When turning to right Steering angle : deg
Steering time : sec
쏔 When turning to left Steering angle : deg
Steering time : sec
쏔 When moving other electrical parts
쐌 Parts name :
쐌 Operating condition :
2. SYMPTOMS
ABS operating condi- 쏔 Performs no work.

tion 쏔 Operates only when abruptly applying brakes. Vehicle speed : km/h
MPH
쐌 How to step on brake pedal :
a) Operating time : sec
b) Operating noise : 쏔 Produce / 쏔 Does not produce
쐌 What kind of noise? 쏔 Knock
쏔 Gong gong
쏔 Bong
쏔 Buzz
쏔 Gong gong buzz
쏔 Others :
c) Reaction force of brake pedal
쏔 Stick
쏔 Press down once with a clunk
쏔 Press and released
쏔 Others :
ABS-5
ABS (DIAGNOSTICS)
Behavior of vehicle a) Directional stability cannot be obtained or steering arm refuses to work when applying brakes :
쏔 Yes / 쏔 No
쐌 When : 쏔 Vehicle turns to right
쏔 Vehicle turns to left
쏔 Spins
쏔 Others :
b) Directional stability cannot be obtained or steering arm refuses to work when accelerating :
쏔 Yes / 쏔 No
쐌 When : 쏔 Vehicle turns to right
쏔 Vehicle turns to left
쏔 Spins
쏔 Others :
c) Brakes are out of order : 쏔 Yes / 쏔 No
쐌 What : 쏔 Braking distance is long
쏔 Brakes lock or drag
쏔 Pedal stroke is long
쏔 Pedal sticks
쏔 Others :
d) Poor acceleration : 쏔 Yes / 쏔 No
쐌 What : 쏔 Fails to accelerate
쏔 Engine stalls
쏔 Others :
e) Occurrence of vibration : 쏔 Yes / 쏔 No
쐌 Where
쐌 What kind :
f) Occurrence of abnormal noise : 쏔 Yes / 쏔 No
쐌 Where
쐌 What kind :
g) Occurrence of other phenomena : 쏔 Yes / 쏔 No
쐌 What kind :
3. CONDITIONS UNDER WHICH TROUBLE OCCURS
Environment a) Weather 쏔 Fine

쏔 Cloudy
쏔 Rainy
쏔 Snowy
쏔 Various/Others :
b) Ambient temperature °F (°C)
c) Road 쏔 Urban area
쏔 Suburbs
쏔 Highway
쏔 General road
쏔 Ascending slope
쏔 Descending slope
쏔 Paved road
쏔 Gravel road
쏔 Muddy road
쏔 Sandy place
쏔 Others :
d) Road surface 쏔 Dry
쏔 Wet
쏔 New-fallen snow
쏔 Compressed snow
쏔 Frozen slope
쏔 Others :
ABS-6
ABS (DIAGNOSTICS)
Condition a) Brakes Deceleration : g

쏔 Continuous / 쏔 Intermittent
b) Accelerator Acceleration : g
c) Vehicle speed km/h MPH
쏔 Advancing
쏔 Accelerating
쏔 Reducing speed
쏔 Low speed
쏔 Turning
쏔 Others :
d) Tire inflation pressure Front RH tire : kPa
Front LH tire : kPa
Rear RH tire : kPa
Rear LH tire : kPa
e) Degree of wear Front RH tire :
Front LH tire :
Rear RH tire :
Rear LH tire :
f) Genuine parts are used. : 쏔 Yes / 쏔 No
g) Chain is passed around tires. : 쏔 Yes / 쏔 No
h) T tire is used. : 쏔 Yes / 쏔 No
i) Condition of suspension alignment :
j) Loading state :
k) Repair parts are used. : 쏔 Yes / 쏔 No
쐌 What :
l) Others :
ABS-7
GENERAL DESCRIPTION
ABS (DIAGNOSTICS)
3. General Description S006001 B: INSPECTION S006001A10
Before performing diagnostics, check the following
items which might affect ABS problems:
1. SUPPLEMENTAL RESTRAINT SYSTEM
“AIRBAG” S006001A0301 1. BATTERY S006001A1001
Airbag system wiring harness is routed near the Measure battery voltage and specific gravity of
ABS sensor, ABS control module and hydraulic electrolyte.
control unit. Standard voltage: 12 V, or more
CAUTION: Specific gravity: Above 1.260
nectors are colored yellow. Do not use electri- 2. BRAKE FLUID S006001A1002
cal test equipment on these circuit. 1) Check brake fluid level.

쐌 Be careful not to damage Airbag system wir- 2) Check brake fluid leakage.
ing harness when servicing the ABS sensor,
ABS control module and hydraulic control unit. 3. HYDRAULIC UNIT S006001A1006
Check the hydraulic unit.

쐌 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).>
쐌 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 S006001A1003
Check brake drag.

5. BRAKE PAD AND ROTOR S006001A1004
Check brake pad and rotor.

쐌 Front <Ref. to BR-17 INSPECTION, Front Brake
Pad.> and <Ref. to BR-19 INSPECTION, Front
Disc Rotor.>
쐌 Rear <Ref. to BR-26 INSPECTION, Rear Brake
Pad.> and <Ref. to BR-29 INSPECTION, Rear
Disc Brake Assembly.>
6. TIRE S006001A1005
Check tire specifications, tire wear and air pres-

sure. <Ref. to WT-2 SPECIFICATIONS, General
Description.>
ABS-8
GENERAL DESCRIPTION
ABS (DIAGNOSTICS)

24082AA150 CARTRIDGE Troubleshooting for electrical systems.
B2M3876
KIT 쐌 English: 22771AA030 (Without printer)
쐌 German: 22771AA070 (Without printer)
쐌 French: 22771AA080 (Without printer)
쐌 Spanish: 22771AA090 (Without printer)
B2M3877
2. GENERAL PURPOSE TOOLS S006001A1702
TOOL NAME REMARKS

Circuit tester Used for measuring resistance, voltage and ampere.
Oscilloscope Used for measuring sensor.
ABS-9
ABS (DIAGNOSTICS)
B4M2200A
(1) ABS control module and hydrau- (5) Data link connector (for Subaru (8) ABS sensor
lic control unit (ABSCM&H/U) select monitor) (9) Wheel cylinder
(2) Proportioning valve (6) Transmission control module (10) G sensor
(3) Diagnosis connector (only AT vehicle) (11) Stop light switch
(4) ABS warning light (7) Tone wheel (12) Master cylinder
ABS-10
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
B4M1646A B4M2225A
B4M1734A
B4M2262A
B4M1767A B2M2960D
ABS-11
墌 00.5.31/68j/0abs 墍
CONTROL MODULE I/O SIGNAL
ABS (DIAGNOSTICS)
5. Control Module I/O Signal S006524
A: ELECTRICAL SPECIFICATION
S006524A08
B4M1228A
NOTE:
쐌 The terminal numbers in the ABS control module and hydraulic control unit connector are as shown in
the figure.
쐌 When the connector is removed from the ABSCM&H/U, the connector switch closes the circuit between
terminal No. 21 and No. 23. The ABS warning light illuminates.
ABS-12
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
Terminal No. Input/Output signal

Contents
(+)—(−) Measured value and measuring conditions
Front left wheel 9—10
ABS sensor*2 Front right wheel 11—12 0.12 — 1 V
(Wheel speed sensor) Rear left wheel 7—8 (When it is 20 Hz.)
Rear right wheel 14—15
Valve relay power supply 24—23 10 — 15 V
Motor relay power supply 25—23 10 — 15 V
power supply 30—28 4.75 — 5.25 V
G sensor*2
ground 28 —
(AWD model only)
output 6—28 2.3±0.2 V when vehicle is in horizontal position.
Less than 1.5 V when the stop light is OFF and, 10 — 15 V
Stop light switch*1 2—23
when the stop light is ON.
Less than 1.5 V during 1.5 seconds when ignition switch is
ABS warning light*2 21—23
ON, and 10 — 15 V after 1.5 seconds.
AT ABS signal*2 Less than 1.5 V when the ABS control still operates and
31—23
(AT model only) more than 5.5 V when ABS does not operate.
Less than 1.5 V when the ABS control still operates and
ABS operation signal monitor*2 3—23
more than 5.5 V when ABS does not operate.
Data is received. 20—23 Less than 1.5 V when no data is received.
Select monitor*2
Data is sent. 5—23 4.75 — 5.25 V when no data is sent.
ABS diagnosis connec- Terminal No. 3 29—23 10 — 15 V when ignition switch is ON.
tor*2 Terminal No. 6 4—23 10 — 15 V when ignition switch is ON.
Power supply*1 1—23 10 — 15 V when ignition switch is ON.
Grounding line 23 —
Grounding line 26 —
*1: Measure the I/O signal voltage after removing the connector from the ABSCM&H/U terminal.
*2: Measure the I/O signal voltage at connector (B62) or (F55).
ABS-13
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
B4M2226
(1) ABS control module and hydrau- (9) Front right outlet solenoid valve (17) ABS warning light
lic control unit (ABSCM&H/U) (10) Rear left inlet solenoid valve (18) Stop light switch
(2) ABS control module area (11) Rear left outlet solenoid valve (19) Stop light
(3) Valve relay (12) Rear right inlet solenoid valve (20) G sensor
(4) Motor relay (13) Rear right outlet solenoid valve (21) Front left ABS sensor
(5) Motor (14) Transmission control module (22) Front right ABS sensor
(6) Front left inlet solenoid valve (only AT model) (23) Rear left ABS sensor
(7) Front left outlet solenoid valve (15) Diagnosis connector (24) Rear right ABS sensor
(8) Front right inlet solenoid valve (16) Data link connector
ABS-14
墌 00.5.31/68j/0abs 墍
DATA LINK CONNECTOR
ABS (DIAGNOSTICS)
6. Data Link Connector S006505
A: NOTE S006505A15
Refer to “EN(H4)” section for information about the

differential connector. <Ref. to EN(H4)-49 Data
Link Connector.>
ABS-15
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

5) Turn ignition switch to ON (engine OFF) and
Subaru Select Monitor switch to ON.
1. READ DIAGNOSTIC TROUBLE CODE

S006503A1601
S2M0288D
(1) Power switch

S2M0285 7) On the ⰆSystem Selection MenuⰇ display
screen, select the {Brake Control System} and
2) Connect diagnosis cable to Subaru Select press the [YES] key.
Monitor. 8) Press the [YES] key after displayed the infor-
3) Insert cartridge into Subaru Select Monitor. mation of engine type.
<Ref. to ABS-9 SPECIAL TOOLS, PREPARATION 9) On the ⰆABS DiagnosisⰇ display screen,
TOOL, General Description.> select the {Diagnostic Code(s) Display} and press
the [YES] key.
10) On the ⰆDiagnostic Code(s) DisplayⰇ display
screen, select the {Current Diagnostic Code(s)} or
{History Diagnostic Code(s)} and press the [YES]
key.
NOTE:
쐌 For detailed operation procedure, refer to the
SUBARU SELECT MONITOR OPERATION
MANUAL.
쐌 For detailed concerning diagnostic trouble
S2M0286 codes, refer to the LIST OF DIAGNOSTICS
TROUBLE CODE. <Ref. to ABS-22 List of Diag-
4) Connect Subaru Select Monitor to data link nostics Trouble Code.>
connector.
(1) Data link connector located in the lower por-
tion of the instrument panel (on the driver’s
side).
B2M2960G
(1) Data link connector

nector.
ABS-16
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
2. READ CURRENT DATA S006503A1602
1) On the ⰆMain MenuⰇ display screen, select the {Each System Check} and press the ⰆYESⰇ key.
2) On the ⰆSystem Selection MenuⰇ display screen, select the {Brake Control System} and press the
ⰆYESⰇ key.
3) Press the ⰆYESⰇ key after displayed the information of ABS type.
4) On the ⰆBrake Control DiagnosisⰇ display screen, select the {Current Data Display & Save} and press
the ⰆYESⰇ key.
5) On the ⰆData Display MenuⰇ display screen, select the {Data Display} and press the ⰆYESⰇ key.
6) Using the scroll key, move the display screen up or down until the desired data is shown.
쐌 A list of the support data is shown in the following table.
Display screen Contents to be monitored Unit of measure
Wheel speed detected by the Front Right ABS sensor is dis-
FR Wheel Speed km/h or MPH
played
Wheel speed detected by the Front Left ABS sensor is dis-
FL Wheel Speed km/h or MPH
played
Wheel speed detected by the Rear Right ABS sensor is dis-
RR Wheel Speed km/h or MPH
played
Wheel speed detected by the Rear Left ABS sensor is dis-
RL Wheel Speed km/h or MPH
played
Stop Light Switch Stop light switch signal ON or OFF
Stop Light Switch Stop light switch monitor voltage is displayed. V
Refers to vehicle acceleration detecting by the analog G sensor.
G sensor output Signal V
It appears on the select monitor display in volts.
Valve Relay Signal Valve Relay Signal ON or OFF
Motor Relay Signal Motor Relay Signal ON or OFF
ABS Signal to TCM ABS operation signal from ABS control module to TCM ON or OFF
ABS Warning Lamp ON operation of the ABS warning light is displayed. ON or OFF
Motor Relay Monitor Operating condition of the motor relay is displayed. High or Low
Valve Relay Monitor Operating condition of the valve relay is displayed. ON or OFF
CCM Signal ABS operation signal from ABS control module to TCM ON or OFF
NOTE:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
3. CLEAR MEMORY MODE S006503A1603
1) On the ⰆMain MenuⰇ display screen, select the {2. Each System Check} and press the ⰆYESⰇ key.
2) On the ⰆSystem Select MenuⰇ display screen, select {Brake System} and press the ⰆYESⰇ key.
3) Press the ⰆYESⰇ key after displayed the information of engine type.
4) On the ⰆBrake Control DiagnosisⰇ display screen, select the {Clear Memory} and press the ⰆYESⰇ
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:
ABS-17
墌 00.5.31/68j/0abs 墍
READ DIAGNOSTIC TROUBLE CODE
ABS (DIAGNOSTICS)
8. Read Diagnostic Trouble 2) Turn ignition switch OFF.

3) Connect diagnosis connector terminal 8 to
Code S006508
diagnosis terminal.
4) Turn ignition switch ON.
5) ABS warning light is set in the diagnostic mode
1. WITHOUT SUBARU SELECT MONITOR and blinks to identify trouble code.
S006508A1602
1) Take out diagnosis connector from side of driv-

er’s seat heater unit.
B4M1767F
(1) Diagnosis connector

(2) Diagnosis terminal
(3) 8 terminal
(4) 5 terminal
6) After the start code (11) is shown, the trouble codes will be shown in order of the last information first.
These repeat for a maximum of 3 minutes.
NOTE:
쐌 When there are no trouble codes in memory, only the start code (11) is shown.
쐌 When on-board diagnosis of the ABS control module detects a problem, the information (up to a maxi-
mum of three) will be stored in the EEP ROM as a trouble code. When there are more than three, the most
recent three will be stored. (Stored codes will stay in memory until they are cleared.)
B4M0232A
2. WITH SUBARU SELECT MONITOR S006508A1601
Refer to SUBARU SELECT MONITOR for information about how to obtain and understand trouble codes.
<Ref. to ABS-16 Subaru Select Monitor.>
ABS-18
INSPECTION MODE
ABS (DIAGNOSTICS)
9. Inspection Mode S006510
Reproduce the condition under which the problem

has occurred as much as possible.
Drive the vehicle at a speed more than 40 km/h (25
MPH) for at least one minute.
ABS-19
墌 00.5.31/68j/0abs 墍
CLEAR MEMORY MODE
ABS (DIAGNOSTICS)
10. Clear Memory Mode S006513
1. WITHOUT SUBARU SELECT MONITOR

S006513A1602
1) After calling up a trouble code, disconnect diag-

nosis connector terminal 8 from diagnosis terminal.
B4M1767F

(3) 8 terminal
(4) 5 terminal
2) Repeat 3 times within approx. 12 seconds; connecting and disconnecting terminal 8 and diagnosis ter-
minal for at least 0.2 seconds each time.
B4M0233G
NOTE:
After diagnostics is completed, make sure to clear memory. Make sure only start code (11) is shown after
memory is cleared.
Refer to SUBARU SELECT MONITOR for information about how to clear trouble codes. <Ref. to ABS-16
Subaru Select Monitor.>
ABS-20
ABS WARNING LIGHT ILLUMINATION PATTERN
ABS (DIAGNOSTICS)
11. ABS Warning Light Illumination Pattern S006581
B4M0781A
1) When the ABS warning light does not illuminate in accordance with this illumination pattern, there must
be an electrical malfunction.
2) When the ABS warning light remains constantly OFF, repair the ABS warning light circuit or diagnosis
circuit. <Ref. to ABS-26 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 oper-
ates normally when the warning light goes out while driving at approximately 12 km/h (7 MPH). However,
the Anti-lock brakes do not work while the ABS warning light is illuminated.
ABS-21
LIST OF DIAGNOSTICS TROUBLE CODE
ABS (DIAGNOSTICS)
12. List of Diagnostics Trouble Code S006511
A: LIST S006511A12
1. WITHOUT SUBARU SELECT MONITOR S006511A1201
Trouble
Contents of diagnosis Index No.
code
Start code
11 쐌 Trouble code is shown after start code. —
쐌 Only start code is shown in normal condition.
<Ref. to ABS-36 TROUBLE CODE 21 — ABNORMAL ABS SEN-
21 Front right ABS sensor SOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH)
(FRONT RH) —, Diagnostics Chart with Diagnosis Connector.>
23 Front left ABS sensor SOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH)
Abnormal ABS sensor
(FRONT LH) —, Diagnostics Chart with Diagnosis Connector.>
(Open circuit or input
voltage too high) <Ref. to ABS-36 TROUBLE CODE 25 — ABNORMAL ABS SEN-
25 Rear right ABS sensor SOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR
RH) —, Diagnostics Chart with Diagnosis Connector.>
27 Rear left ABS sensor SOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR
LH) —, Diagnostics Chart with Diagnosis Connector.>
22 Front right ABS sensor SOR (FRONT RH) —, Diagnostics Chart with Diagnosis Connec-
tor.>
24 Front left ABS sensor SOR (FRONT LH) —, Diagnostics Chart with Diagnosis Connec-
tor.>
Abnormal ABS sensor <Ref. to ABS-42 TROUBLE CODE 26 — ABNORMAL ABS SEN-
26 (Abnormal ABS sensor Rear right ABS sensor SOR (REAR RH) —, Diagnostics Chart with Diagnosis Connec-
signal) tor.>
28 Rear left ABS sensor SOR (REAR LH) —, Diagnostics Chart with Diagnosis Connec-
tor.>
29 Any one of four SOR SIGNAL (ANY ONE OF FOUR) —, Diagnostics Chart with
Diagnosis Connector.>
ABS-22
ABS (DIAGNOSTICS)
Trouble
code
<Ref. to ABS-52 TROUBLE CODE 31 — ABNORMAL INLET
31 Front right inlet valve SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT RH)
—, Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-56 TROUBLE CODE 32 — ABNORMAL OUTLET
32 Front right outlet valve SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT RH)
—, Diagnostics Chart with Diagnosis Connector.>
33 Front left inlet valve SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT LH) —,
Diagnostics Chart with Diagnosis Connector.>
34 Abnormal solenoid Front left outlet valve SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT LH) —,
valve circuit(s) in ABS Diagnostics Chart with Diagnosis Connector.>
control module and <Ref. to ABS-52 TROUBLE CODE 35 — ABNORMAL INLET
35 hydraulic unit Rear right inlet valve SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR RH) —,
36 Rear right outlet valve SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR RH) —,
37 Rear left inlet valve SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH) —,
38 Rear left outlet valve SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH) —,
<Ref. to ABS-60 TROUBLE CODE 41 — ABNORMAL ABS CON-
41 Abnormal ABS control module TROL MODULE —, Diagnostics Chart with Diagnosis Connec-
tor.>
<Ref. to ABS-62 TROUBLE CODE 42 — SOURCE VOLTAGE IS
42 Source voltage is abnormal.
ABNORMAL. —, Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-66 TROUBLE CODE 44 — A COMBINATION OF
44 A combination of AT control abnormal AT CONTROL ABNORMAL —, Diagnostics Chart with Diagnosis
Connector.>
<Ref. to ABS-70 TROUBLE CODE 51 — ABNORMAL VALVE
51 Abnormal valve relay
RELAY —, Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-74 TROUBLE CODE 52 — ABNORMAL MOTOR
52 Abnormal motor and/or motor relay AND/OR MOTOR RELAY —, Diagnostics Chart with Diagnosis
Connector.>
<Ref. to ABS-78 TROUBLE CODE 54 — ABNORMAL STOP
54 Abnormal stop light switch LIGHT SWITCH —, Diagnostics Chart with Diagnosis Connec-
tor.>
<Ref. to ABS-82 TROUBLE CODE 56 — ABNORMAL G SEN-
56 Abnormal G sensor output voltage SOR OUTPUT VOLTAGE —, Diagnostics Chart with Diagnosis
Connector.>
ABS-23
ABS (DIAGNOSTICS)
Code Display screen Contents of diagnosis Index No.

Communication for Select monitor communi- <Ref. to ABS-88 COMMUNICATION FOR INITIALIZING
—
initializing impossible cation failure IMPOSSIBLE, Diagnostics Chart with Subaru Select Monitor.>
Although no trouble
code appears on the
<Ref. to ABS-92 NO TROUBLE CODE, Diagnostics Chart with
— No trouble code select monitor display,
the ABS warning light
remains on.
Open or short circuit Open or short circuit in <Ref. to ABS-96 TROUBLE CODE 21 — OPEN OR SHORT CIR-
21 in front right ABS sen- front right ABS sensor CUIT IN FRONT RIGHT ABS SENSOR CIRCUIT —, Diagnostics
sor circuit circuit Chart with Subaru Select Monitor.>
<Ref. to ABS-102 TROUBLE CODE 22 — FRONT RIGHT
Front right ABS sen- Front right ABS sensor
22 ABNORMAL ABS SENSOR SIGNAL —, Diagnostics Chart with
sor abnormal signal abnormal signal
23 in front left ABS sen- front left ABS sensor CUIT IN FRONT LEFT ABS SENSOR CIRCUIT —, Diagnostics
<Ref. to ABS-102 TROUBLE CODE 24 — FRONT LEFT ABNOR-
Front left ABS sensor Front left ABS sensor
24 MAL ABS SENSOR SIGNAL —, Diagnostics Chart with Subaru
abnormal signal abnormal signal
Select Monitor.>
25 in rear right ABS sen- rear right ABS sensor CUIT IN REAR RIGHT ABS SENSOR CIRCUIT —, Diagnostics
<Ref. to ABS-102 TROUBLE CODE 26 — REAR RIGHT ABNOR-
Rear right ABS sensor Rear right ABS sensor
Select Monitor.>
27 in rear left ABS sen- rear left ABS sensor cir- CUIT IN REAR LEFT ABS SENSOR CIRCUIT —, Diagnostics
sor circuit cuit Chart with Subaru Select Monitor.>
<Ref. to ABS-102 TROUBLE CODE 28 — REAR LEFT ABNOR-
Rear left ABS sensor Rear left ABS sensor
Select Monitor.>
Abnormal ABS sensor Abnormal ABS sensor <Ref. to ABS-108 TROUBLE CODE 29 — ABNORMAL ABS SEN-
29 signal on any one of signal on any one of SOR SIGNAL ON ANY ONE OF FOUR SENSOR —, Diagnostics
four sensor four Chart with Subaru Select Monitor.>
<Ref. to ABS-112 TROUBLE CODE 31 — FRONT RIGHT INLET
Front right inlet valve Front right inlet valve
31 VALVE MALFUNCTION —, Diagnostics Chart with Subaru Select
malfunction malfunction
Monitor.>
<Ref. to ABS-116 TROUBLE CODE 32 — FRONT RIGHT OUT-
Front right outlet valve Front right outlet valve
32 LET VALVE MALFUNCTION —, Diagnostics Chart with Subaru
Select Monitor.>
<Ref. to ABS-112 TROUBLE CODE 33 — FRONT LEFT INLET
Front left inlet valve Front left inlet valve mal-
malfunction function
Monitor.>
<Ref. to ABS-116 TROUBLE CODE 34 — FRONT LEFT OUTLET
Front left outlet valve Front left outlet valve
Monitor.>
<Ref. to ABS-112 TROUBLE CODE 35 — REAR RIGHT INLET
Rear right inlet valve Rear right inlet valve
Monitor.>
<Ref. to ABS-116 TROUBLE CODE 36 — REAR RIGHT OUTLET
Rear right outlet valve Rear right outlet valve
Monitor.>
<Ref. to ABS-112 TROUBLE CODE 37 — REAR LEFT INLET
Rear left inlet valve Rear left inlet valve mal-
malfunction function
Monitor.>
ABS-24
ABS (DIAGNOSTICS)

<Ref. to ABS-116 TROUBLE CODE 38 — REAR LEFT OUTLET
Rear left outlet valve Rear left outlet valve
Monitor.>
ABS control module and <Ref. to ABS-120 TROUBLE CODE 41 — ABS CONTROL MOD-
ABS control module
41 hydraulic control unit ULE MALFUNCTION —, Diagnostics Chart with Subaru Select
malfunction
malfunction Monitor.>
<Ref. to ABS-122 TROUBLE CODE 42 — POWER SUPPLY
Power supply voltage Power supply voltage
42 VOLTAGE TOO LOW —, Diagnostics Chart with Subaru Select
too low too low
Monitor.>
<Ref. to ABS-124 TROUBLE CODE 42 — POWER SUPPLY
Power supply voltage Power supply voltage
42 VOLTAGE TOO HIGH —, Diagnostics Chart with Subaru Select
too high too high
Monitor.>
<Ref. to ABS-126 TROUBLE CODE 44 — ABS-AT CONTROL
ABS-AT control (Non ABS-AT control (Non
44 (NON CONTROLLED) —, Diagnostics Chart with Subaru Select
Controlled) Controlled)
Monitor.>
<Ref. to ABS-128 TROUBLE CODE 44 — ABS-AT CONTROL
ABS-AT control (Con- ABS-AT control (Con-
44 (CONTROLLED) —, Diagnostics Chart with Subaru Select Moni-
trolled) trolled)
tor.>
Valve relay malfunc- <Ref. to ABS-130 TROUBLE CODE 51 — VALVE RELAY MAL-
51 Valve relay malfunction
tion FUNCTION —, Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-132 TROUBLE CODE 51 — VALVE RELAY ON
51 Valve relay ON failure Valve relay ON failure
FAILURE —, Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-134 TROUBLE CODE 52 — OPEN CIRCUIT IN
Open circuit in motor Open circuit in motor
52 MOTOR RELAY CIRCUIT —, Diagnostics Chart with Subaru
relay circuit relay circuit
Select Monitor.>
<Ref. to ABS-138 TROUBLE CODE 52 — MOTOR RELAY ON
52 Motor relay ON failure Motor relay ON failure
FAILURE —, Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-142 TROUBLE CODE 52 — MOTOR MALFUNC-
52 Motor malfunction Motor malfunction
TION —, Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-146 TROUBLE CODE 54 — STOP LIGHT SWITCH
Stop light switch sig- Stop light switch signal
54 SIGNAL CIRCUIT MALFUNCTION —, Diagnostics Chart with
nal circuit malfunction circuit malfunction
<Ref. to ABS-148 TROUBLE CODE 56 — OPEN OR SHORT CIR-
Open or short circuit Open or short circuit in
56 CUIT IN G SENSOR CIRCUIT —, Diagnostics Chart with Subaru
in G sensor circuit G sensor circuit
Select Monitor.>
<Ref. to ABS-152 TROUBLE CODE 56 — BATTERY SHORT IN G
Battery short in G Battery short in G sen-
56 SENSOR CIRCUIT —, Diagnostics Chart with Subaru Select Moni-
sensor circuit sor circuit
tor.>
<Ref. to ABS-156 TROUBLE CODE 56 — ABNORMAL G SEN-
Abnormal G sensor Abnormal G sensor high
56 SOR HIGH µ OUTPUT —, Diagnostics Chart with Subaru Select
high µ output µ output
Monitor.>
<Ref. to ABS-160 TROUBLE CODE 56 — DETECTION OF G
Detection of G sensor Detection of G sensor
56 SENSOR STICK —, Diagnostics Chart with Subaru Select Moni-
stick stick
tor.>
NOTE:
High µ means high friction coefficient against road surface.
ABS-25
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)
13. Diagnostics Chart with Diagnosis Connector S006522
A: ABS WARNING LIGHT DOES NOT COME ON. S006522E24
DIAGNOSIS:
쐌 ABS warning light circuit is open or shorted.
TROUBLE SYMPTOM:
쐌 When ignition switch is turned ON (engine OFF), ABS warning light does not come on
ABS-26
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M1454
ABS-27
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK IF OTHER WARNING LIGHTS Do other warning lights turn Go to step 2. Repair combina-
TURN ON. on? tion meter. <Ref.
Turn ignition switch to ON (engine OFF). to IDI-17 Combi-
nation Meter
Assembly.>
2 CHECK ABS WARNING LIGHT BULB. Is ABS warning light bulb Go to step 3. Replace ABS
1) Turn ignition switch to OFF. OK? warning light bulb.
2) Remove combination meter. <Ref. to IDI-17
3) Remove ABS warning light bulb from com- Combination
bination meter. Meter Assembly.>
3 CHECK BATTERY SHORT OF ABS WARN- Is the voltage less than 3 Go to step 4. Repair warning
ING LIGHT HARNESS. V? light harness.
1) Disconnect connector (B62) from connector
(F45).
2) Measure voltage between connector (B62)
and chassis ground.
(B62) No. G6 (+) — Chassis ground (−):
4 CHECK BATTERY SHORT OF ABS WARN- Is the voltage less than 3 Go to step 5. Repair warning
ING LIGHT HARNESS. V? light harness.
and chassis ground.
5 CHECK WIRING HARNESS. Is the voltage between 10 Go to step 6. Repair wiring har-
1) Turn ignition switch to OFF. and 15 V? ness.
2) Install ABS warning light bulb from combi-
nation meter.
3) Install combination meter.
and chassis ground.
6 CHECK BATTERY SHORT OF ABS WARN- Is the voltage less than 3 Go to step 7. Repair wiring har-
ING LIGHT HARNESS. V? ness.
2) Measure voltage between connector (F45)
and chassis ground.
(F45) No. G6 (+) — Chassis ground (−):
7 CHECK BATTERY SHORT OF ABS WARN- Is the voltage less than 3 Go to step 8. Repair wiring har-
ING LIGHT HARNESS. V? ness.
2) Measure voltage between connector (F45)
and chassis ground.
(F45) No. G6 (+) — Chassis ground (−):
8 CHECK GROUND CIRCUIT OF Is the resistance less than Go to step 9. Repair
ABSCM&H/U. 0.5 Ω? ABSCM&H/U
Measure resistance between ABSCM&H/U ground harness.
and chassis ground.
(F49) No. 23 — GND:
ABS-28
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

9 CHECK WIRING HARNESS. Is the resistance less than Go to step 10. Repair harness/
Measure resistance between connector (F45) 0.5 Ω? connector.
and chassis ground.
(F45) No. G6 — Chassis ground:
10 CHECK POOR CONTACT IN CONNEC- Is there poor contact in Repair connector. Replace
TORS. connectors between combi- ABSCM&H/U.
Turn ignition switch to OFF. nation meter and <Ref. to ABS-7
ABSCM&H/U? ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-29
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
B: ABS WARNING LIGHT DOES NOT GO OFF. S006522E25
DIAGNOSIS:
TROUBLE SYMPTOM:
쐌 When starting the engine and while ABS warning light is kept ON.
WIRING DIAGRAM:
B4M1454
ABS-30
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK INSTALLATION OF ABSCM&H/U Is ABSCM&H/U connector Go to step 2. Insert
CONNECTOR. inserted into ABSCM until ABSCM&H/U con-
Turn ignition switch to OFF. the clamp locks onto it? nector into
ABSCM&H/U until
the clamp locks
onto it.
2 CHECK DIAGNOSIS TERMINAL. Is the resistance less than Go to step 3. Repair diagnosis
Measure resistance between diagnosis termi- 0.5 Ω? terminal harness.
nals (B81) and chassis ground.
Terminals
Diagnosis terminal (A) — Chassis
ground:
Diagnosis terminal (B) — Chassis
ground:
3 CHECK DIAGNOSIS LINE. Is the resistance less than Go to step 4. Repair harness
1) Turn ignition switch to OFF. 0.5 Ω? connector
2) Connect diagnosis terminal (B81) to diag- between
nosis connector (B82) No. 8. ABSCM&H/U and
3) Disconnect connector from ABSCM&H/U. diagnosis connec-
4) Measure resistance between ABSCM&H/U tor.
connector and chassis ground.
(F49) No. 4 — Chassis ground:
4 CHECK GENERATOR. Is the voltage between 10 Go to step 5. Repair generator.
1) Start the engine. and 15 V? <Ref. to
2) Idle the engine. SC(H4)-15 Gen-
3) Measure voltage between generator and erator.>
chassis ground.
Terminal
Generator B terminal (+) — Chassis
ground (−):
5 CHECK BATTERY TERMINAL. Is there poor contact at Repair battery Go to step 6.
Turn ignition switch to OFF. battery terminal? terminal.
6 CHECK POWER SUPPLY OF ABSCM. Is the voltage between 10 Go to step 7. Repair
1) Disconnect connector from ABSCM&H/U. and 15 V? ABSCM&H/U
2) Start engine. power supply cir-
3) Idle the engine. cuit.
4) Measure voltage between ABSCM&H/U
7 CHECK WIRING HARNESS. Does the ABS warning light Go to step 8. Repair front wiring
1) Disconnect connector (F45) from connector remain off? harness.
(B62).
8 CHECK PROJECTION AT ABSCM&H/U. Are the projection broken? Go to step 9. Replace
1) Turn ignition switch to OFF. ABSCM&H/U.
2) Check for broken projection at the <Ref. to ABS-7
ABSCM&H/U terminal. ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
9 CHECK ABSCM&H/U. Is the resistance more than Go to step 10. Replace
Measure resistance between ABSCM&H/U 1 MΩ? ABSCM&H/U.
terminals. <Ref. to ABS-7
Terminal ABS Control Mod-
No. 21 — No. 23: ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-31
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

10 CHECK WIRING HARNESS. Is the resistance less than Go to step 11. Repair harness.
Measure resistance between connector (F45) 0.5 Ω?
and chassis ground.
11 CHECK WIRING HARNESS. Is the resistance more than Go to step 12. Repair harness.
1) Connect connector to ABSCM&H/U. 1 MΩ?
2) Measure resistance between connector
(F45) and chassis ground.
12 CHECK POOR CONTACT IN ABSCM&H/U Is there poor contact in Repair connector. Replace
CONNECTOR. ABSCM&H/U connector? ABSCM&H/U.
<Ref. to ABS-7
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-32
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-33
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
C: TROUBLE CODE DOES NOT APPEAR. S006522E50
DIAGNOSIS:
쐌 Diagnosis circuit is open.
TROUBLE SYMPTOM:
쐌 The ABS warning light turns on or off normally but the start code cannot be read out in the diagnostic
mode.
WIRING DIAGRAM:
B4M1454
ABS-34
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1) Turn ignition switch to OFF. 0.5 Ω? terminal harness.
2) Measure resistance between diagnosis ter-
minals (B81) and chassis ground.
Terminals
ground:
ground:
2) Connect diagnosis terminal (B81) to diag- between
nosis connector (B82) No. 8. ABSCM&H/U and
3) Disconnect connector from ABSCM&H/U. diagnosis connec-
4) Measure resistance between ABSCM&H/U tor.
<Ref. to ABS-7
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-35
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
D: TROUBLE CODE 21
— ABNORMAL ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO
HIGH) (FRONT RH) — S006522E60
NOTE:
For the diagnostic procedure, refer to TROUBLE CODE 27. <Ref. to ABS-36 TROUBLE CODE 27 —
ABNORMAL ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR LH) —, Diagnos-
tics Chart with Diagnosis Connector.>
E: TROUBLE CODE 23
HIGH) (FRONT LH) — S006522E61
NOTE:
F: TROUBLE CODE 25
HIGH) (REAR RH) — S006522E62
NOTE:
G: TROUBLE CODE 27
HIGH) (REAR LH) — S006522E63
DIAGNOSIS:
쐌 Faulty ABS sensor (Broken wire, input voltage too high)
쐌 Faulty harness connector
TROUBLE SYMPTOM:
쐌 ABS does not operate.
ABS-36
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M1455
ABS-37
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK ABS SENSOR. Is the resistance between 1 Go to step 2. Replace ABS sen-
1) Turn ignition switch to OFF. and 1.5 kΩ? sor. Front: <Ref.
2) Disconnect connector from ABS sensor. to ABS-14 Front
3) Measure resistance of ABS sensor connec- ABS Sensor.>
tor terminals. Rear: <Ref. to
Terminal ABS-17 Rear ABS
Front RH No. 1 — No. 2: Sensor.>
2 CHECK BATTERY SHORT OF ABS SEN- Is the voltage less than 1 Go to step 3. Replace ABS sen-
SOR. V? sor. Front: <Ref.
1) Disconnect connector from ABSCM&H/U. to ABS-14 Front
2) Measure voltage between ABS sensor and ABS Sensor.>
chassis ground. Rear: <Ref. to
Front RH No. 1 (+) — Chassis ground Sensor.>
(−):
Front LH No. 1 (+) — Chassis ground
(−):
Rear RH No. 1 (+) — Chassis ground
(−):
Rear LH No. 1 (+) — Chassis ground
(−):
1) Turn ignition switch to ON. to ABS-14 Front
(−):
(−):
(−):
(−):
4 CHECK HARNESS/CONNECTOR Is the resistance between 1 Go to step 5. Repair harness/
BETWEEN ABSCM&H/U AND ABS SEN- and 1.5 kΩ? connector
SOR. between
1) Turn ignition switch to OFF. ABSCM&H/U and
2) Connect connector to ABS sensor. ABS sensor.
3) Measure resistance between ABSCM&H/U
connector terminals.
Trouble code 21 / (F49) No. 11 — No.
12:
10:
15:
Trouble code 27 / (F49) No. 7 — No. 8:
ABS-38
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

5 CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 Go to step 6. Repair harness
Measure voltage between ABSCM&H/U con- V? between
nector and chassis ground. ABSCM&H/U and
Connector & terminal ABS sensor.
Trouble code 21 / (F49) No. 11 (+) —
Chassis ground (−):
Trouble code 23 / (F49) No. 9 (+) —
Trouble code 25 / (F49) No. 14 (+) —
1) Turn ignition switch to ON. V? between
2) Measure voltage between ABSCM&H/U ABSCM&H/U and
connector and chassis ground. ABS sensor.
Trouble code 21 / (F49) No. 11 (+) —
Trouble code 25 / (F49) No. 14 (+) —
7 CHECK INSTALLATION OF ABS SENSOR. Are the ABS sensor instal- Go to step 8. Tighten ABS sen-
Turn ignition switch to OFF. lation bolts tightened sor installation
Tightening torque: securely? bolts securely.
32 N·m (3.3 kgf-m, 24 ft-lb)
8 CHECK ABS SENSOR GAP. Is the gap within the speci- Go to step 9. Adjust the gap.
Measure tone wheel to ABS sensor piece gap fications? NOTE:
over entire perimeter of the wheel. Adjust the gap
Front wheel using spacers
0.3 — 0.8 mm (0.012 — 0.031 in) (Part No.
Rear wheel 26755AA000). If
0.44 — 0.94 mm (0.0173 — 0.0370 in) spacers cannot
correct the gap,
replace worn sen-
sor or worn tone
wheel.
9 CHECK TONE WHEEL RUNOUT. Is the runout less than 0.05 Go to step 10. Replace tone
Measure tone wheel runout. mm (0.0020 in)? wheel. Front:
<Ref. to ABS-22
Front Tone
Wheel.> Rear:
<Ref. to ABS-23
Rear Tone
Wheel.>
ABS-39
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

10 CHECK GROUND SHORT OF ABS SEN- Is the resistance more than Go to step 11. Replace ABS sen-
SOR. 1 MΩ? sor and
1) Turn ignition switch to ON. ABSCM&H/U.
2) Measure resistance between ABS sensor Front: <Ref. to
and chassis ground. ABS-14 Front
Terminal ABS Sensor.>
Front RH No. 1 — Chassis ground: Rear: <Ref. to
Front LH No. 1 — Chassis ground: ABS-17 Rear ABS
Rear RH No. 1 — Chassis ground: Sensor.> and
Rear LH No. 1 — Chassis ground: <Ref. to ABS-7
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
11 CHECK GROUND SHORT OF HARNESS. Is the resistance more than Go to step 12. Repair harness
1) Turn ignition switch to OFF. 1 MΩ? between
2) Connect connector to ABS sensor. ABSCM&H/U and
3) Measure resistance between ABSCM&H/U ABS sensor.
connector terminal and chassis ground. Replace
Connector & terminal ABSCM&H/U.
Trouble code 21 / (F49) No. 11 — Chas- <Ref. to ABS-7
sis ground: ABS Control Mod-
Trouble code 23 / (F49) No. 9 — Chas- ule and Hydraulic
sis ground: Control Unit
Trouble code 25 / (F49) No. 14 — Chas- (ABSCM&H/U).>
sis ground:
Trouble code 27 / (F49) No. 7 — Chas-
sis ground:
12 CHECK POOR CONTACT IN CONNEC- Is there poor contact in Repair connector. Go to step 13.
TORS. connectors between
ABSCM&H/U and ABS
sensor?
13 CHECK ABSCM&H/U. Is the same trouble code Replace Go to step 14.
1) Connect all connectors. as in the current diagnosis ABSCM&H/U.
2) Erase the memory. still being output? <Ref. to ABS-7
3) Perform inspection mode. ABS Control Mod-
4) Read out the trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
14 CHECK ANY OTHER TROUBLE CODES Are other trouble codes Proceed with the A temporary poor
APPEARANCE. being output? diagnosis corre- contact.
sponding to the NOTE:
trouble code. Check harness
and connectors
between
ABSCM&H/U and
ABS sensor.
ABS-40
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-41
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
H: TROUBLE CODE 22
— ABNORMAL ABS SENSOR (FRONT RH) — S006522E64
NOTE:
ABNORMAL ABS SENSOR (REAR LH) —, Diagnostics Chart with Diagnosis Connector.>
I: TROUBLE CODE 24
— ABNORMAL ABS SENSOR (FRONT LH) — S006522E65
NOTE:
J: TROUBLE CODE 26
— ABNORMAL ABS SENSOR (REAR RH) — S006522E66
NOTE:
K: TROUBLE CODE 28
— ABNORMAL ABS SENSOR (REAR LH) — S006522E67
DIAGNOSIS:
쐌 Faulty ABS sensor signal (noise, irregular signal, etc.)
쐌 Faulty harness/connector
TROUBLE SYMPTOM:
ABS-42
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M1455
ABS-43
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

Turn ignition switch to OFF. lation bolts tightened sor installation
Tightening torque: securely? bolts securely.
32±10 N·m (3.3±1.0 kgf-m, 24±7 ft-lb)
Front wheel using spacer (Part
0.3 — 0.8 mm (0.012 — 0.031 in) No. 26755AA000).
Rear wheel If spacers cannot
0.44 — 0.94 mm (0.0173 — 0.0370 in) correct the gap,
replace worn sen-
sor or worn tone
wheel.
3 PREPARE OSCILLOSCOPE. Is an oscilloscope avail- Go to step 4. Go to step 5.
able?
4 CHECK ABS SENSOR SIGNAL. Is oscilloscope pattern Go to step 8. Go to step 7.
1) Raise all four wheels of ground. smooth, as shown in fig-
2) Turn ignition switch OFF. ure?
3) Connect the oscilloscope to the connector.
5) Rotate wheels and measure voltage at
specified frequency.
NOTE:
When this inspection is completed, the ABS
control module sometimes stores the trouble
code 29.
Trouble code 22 / (B62) No. C5 (+) —
No. B5 (−):
No. B6 (−):
Trouble code 26 / (F55) No. 1 (+) — No.
2 (−):
5 (−):
5 CHECK CONTAMINATION OF ABS SEN- Is the ABS sensor piece or Thoroughly Go to step 6.
SOR OR TONE WHEEL. the tone wheel contami- remove dirt or
Remove disc rotor or drum from hub in accor- nated by dirt or other for- other foreign mat-
dance with trouble code. eign matter? ter.
6 CHECK DAMAGE OF ABS SENSOR OR Are there broken or dam- Replace ABS sen- Go to step 7.
TONE WHEEL. aged in the ABS sensor sor or tone wheel.
piece or the tone wheel? Front: <Ref. to
ABS-14 Front
ABS Sensor.>
Rear: <Ref. to
ABS-17 Rear ABS
Sensor.> and
Front: <Ref. to
ABS-22 Front
Tone Wheel.>
Rear: <Ref. to
ABS-23 Rear
Tone Wheel.>
ABS-44
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

<Ref. to ABS-22
Front Tone
Wheel.> Rear:
<Ref. to ABS-23
Rear Tone
Wheel.>
8 CHECK RESISTANCE OF ABS SENSOR. Is the resistance between 1 Go to step 9. Replace ABS sen-
1) Turn ignition switch OFF. and 1.5 kΩ? sor. Front: <Ref.
3) Measure resistance between ABS sensor ABS Sensor.>
connector terminals. Rear: <Ref. to
SOR. 1 MΩ? sor. Front: <Ref.
Measure resistance between ABS sensor and to ABS-14 Front
chassis ground. ABS Sensor.>
Terminal Rear: <Ref. to
Front RH No. 1 — Chassis ground: ABS-17 Rear ABS
Front LH No. 1 — Chassis ground: Sensor.>
Rear RH No. 1 — Chassis ground:
Rear LH No. 1 — Chassis ground:
SOR. between
2) Disconnect connector from ABSCM&H/U. ABS sensor.
3) Measure resistance at ABSCM&H/U con-
nector terminals.
12:
10:
15:
11 CHECK GROUND SHORT OF HARNESS. Is the resistance more than Go to step 12. Repair harness/
Measure resistance between ABSCM&H/U 1 MΩ? connector
connector and chassis ground. between
Connector & terminal ABSCM&H/U and
Trouble code 22 / (F49) No. 11 — Chas- ABS sensor.
sis ground:
sis ground:
sis ground:
sis ground:
and chassis ground.
(F49) No. 23 — GND:
ABS-45
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

ABSCM&H/U and ABS
sensor?
14 CHECK SOURCES OF SIGNAL NOISE. Is the car telephone or the Go to step 15. Properly install
wireless transmitter prop- the car telephone
erly installed? or the wireless
transmitter.
15 CHECK SOURCES OF SIGNAL NOISE. Are noise sources (such as Install the noise Go to step 16.
an antenna) installed near sources apart
the sensor harness? from the sensor
harness.
16 CHECK SHIELD CIRCUIT. Is the resistance less than Go to step 17. Repair shield har-
1) Connect all connectors. 0.5 Ω? ness.
2) Measure resistance between shield con-
nector and chassis ground.
Trouble code 22 / (B62) No. A5 —
Chassis ground:
Chassis ground:
NOTE:
For the Trouble code 26 and 28:
Go to step 17.
Control Unit
(ABSCM&H/U).>
18 CHECK ANY OTHER TROUBLE CODES Are other trouble codes Proceed with the A temporary noise
APPEARANCE. being output? diagnosis corre- interference.
sponding to the
trouble code.
ABS-46
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-47
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
L: TROUBLE CODE 29
— ABNORMAL ABS SENSOR SIGNAL (ANY ONE OF FOUR) — S006522E68
DIAGNOSIS:
쐌 Faulty tone wheel
쐌 Wheels turning freely for a long time
TROUBLE SYMPTOM:
ABS-48
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M1455
ABS-49
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK IF THE WHEELS HAVE TURNED Check if the wheels have The ABS is nor- Go to step 2.
FREELY FOR A LONG TIME. been turned freely for more mal. Erase the
than one minute, such as trouble code.
when the vehicle is jacked- NOTE:
up, under full-lock corner- When the wheels
ing or when tire is not in turn freely for a
contact with road surface. long time, such as
when the vehicle
is towed or
jacked-up, or
when steering
wheel is continu-
ously turned all
the way, this
trouble code may
sometimes occur.
2 CHECK TIRE SPECIFICATIONS. Are the tire specifications Go to step 3. Replace tire.
Turn ignition switch to OFF. correct?
3 CHECK WEAR OF TIRE. Is the tire worn exces- Replace tire. Go to step 4.
sively?
4 CHECK TIRE PRESSURE. Is the tire pressure correct? Go to step 5. Adjust tire pres-
sure.
Tightening torque: lation bolts tightened sor installation
32±10 N·m (3.3±1.0 kgf-m, 24±7 ft-lb) securely? bolts securely.
Specifications using spacer (Part
Front wheel No. 26755AA000).
0.3 — 0.8 mm (0.012 — 0.031 in) If spacers cannot
Rear wheel correct the gap,
0.44 — 0.94 mm (0.0173 — 0.0370 in) replace worn sen-
sor or worn tone
wheel.
able?
NOTE:
When this inspection is completed, the
ABSCM&H/U sometimes stores the trouble
code 29.
(B62) No. C5 (+) — No. B5 (−) (Front
RH):
(B62) No. C6 (+) — No. B6 (−) (Front
LH):
(F55) No. 1 (+) — No. 2 (−) (Rear RH):
(F55) No. 4 (+) — No. 5 (−) (Rear LH):
Remove disc rotor from hub. nated by dirt or other for- other foreign mat-
eign matter? ter.
ABS-50
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

TONE WHEEL. aged teeth in the ABS sensor or tone wheel.
sor piece or the tone Front: <Ref. to
wheel? ABS-14 Front
ABS Sensor.>
Rear: <Ref. to
ABS-17 Rear ABS
Sensor.> and
Front: <Ref. to
ABS-17Front Tone
Wheel.> Rear:
<Ref. to ABS-23
Rear Tone
Wheel.>
<Ref. to ABS-22
Front Tone
Wheel.> Rear:
<Ref. to ABS-23
Rear Tone
Wheel.>
1) Turn ignition switch to OFF. as in the current diagnosis ABSCM&H/U.
2) Connect all connectors. still being output? <Ref. to ABS-7
3) Erase the memory. ABS Control Mod-
4) Perform inspection mode. ule and Hydraulic
5) Read out the trouble code. Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-51
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
M: TROUBLE CODE 31
— ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT
RH) — S006522E69
NOTE:
ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH) —, Diagnostics Chart with
N: TROUBLE CODE 33
— ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT
LH) — S006522E70
NOTE:
O: TROUBLE CODE 35
— ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR
RH) — S006522E71
NOTE:
P: TROUBLE CODE 37
— ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR
LH) — S006522E72
DIAGNOSIS:
쐌 Faulty inlet solenoid valve in ABSCM&H/U
TROUBLE SYMPTOM:
ABS-52
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2334
ABS-53
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage between 10 Go to step 2. Repair harness
1) Disconnect connector from ABSCM&H/U. and 15 V? connector
2) Run the engine at idle. between battery,
3) Measure voltage between ABSCM&H/U ignition switch and
connector and chassis ground. ABSCM&H/U.
1) Turn ignition switch to OFF. ground harness.
generator, battery and
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-54
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-55
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
Q: TROUBLE CODE 32
— ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U
(FRONT RH) — S006522E73
NOTE:
ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH) —, Diagnostics Chart
with Diagnosis Connector.>
R: TROUBLE CODE 34
(FRONT LH) — S006522E74
NOTE:
S: TROUBLE CODE 36
(REAR RH) — S006522E75
NOTE:
T: TROUBLE CODE 38
(REAR LH) — S006522E76
DIAGNOSIS:
쐌 Faulty outlet solenoid valve in ABSCM&H/U
TROUBLE SYMPTOM:
ABS-56
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2334
ABS-57
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-58
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-59
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
U: TROUBLE CODE 41
— ABNORMAL ABS CONTROL MODULE — S006522D29
DIAGNOSIS:
쐌 Faulty ABSCM&H/U.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M1457
ABS-60
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

2) Disconnect connector from ABSCM&H/U.
and chassis ground.
battery, ignition switch and
ABSCM&H/U?
transmitter.
harness.
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-61
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
V: TROUBLE CODE 42
— SOURCE VOLTAGE IS ABNORMAL. — S006522D37
DIAGNOSIS:
쐌 Power source voltage of the ABSCM&H/U is low or high.
TROUBLE SYMPTOM:
ABS-62
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2334
ABS-63
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1) Start engine. and 17 V? <Ref. to
2) Idling after warm-up. SC(H4)-15 Gen-
3) Measure voltage between generator B ter- erator.>
minal and chassis ground.
Terminal
Generator B terminal — Chassis
ground:
2 CHECK BATTERY TERMINAL. Are the positive and nega- Go to step 3. Tighten the clamp
Turn ignition switch to OFF. tive battery terminals tightly of terminal.
clamped?
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-64
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-65
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
W: TROUBLE CODE 44
— A COMBINATION OF AT CONTROL ABNORMAL — S006522D42
DIAGNOSIS:
쐌 Combination of AT control faults
TROUBLE SYMPTOM:
ABS-66
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M1458
ABS-67
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK SPECIFICATIONS OF THE Is an ABSCM&H/U for AT Replace Go to step 2.
ABSCM&H/U. model installed on a MT ABSCM&H/U.
Check specifications of the mark to the model? <Ref. to ABS-7
ABSCM&H/U. ABS Control Mod-
C5: AT (Except OUTBACK) ule and Hydraulic
C6: MT (Except OUTBACK) Control Unit
CE: AT (OUTBACK) (ABSCM&H/U).>
CF: MT (OUTBACK)
1) Turn ignition switch to OFF. 1 MΩ? between TCM and
2) Disconnect two connectors from TCM. ABSCM&H/U.
Measure voltage between ABSCM&H/U con- V? between TCM and
nector and chassis ground. ABSCM&H/U.
1) Turn ignition switch to ON. V? between TCM and
2) Measure voltage between ABSCM&H/U ABSCM&H/U.
5 CHECK TCM. Is the voltage between 10 Go to step 7. Go to step 6.
1) Turn ignition switch to OFF. and 15 V?
2) Connect all connectors to TCM.
4) Measure voltage between TCM connector
terminal and chassis ground.
6 CHECK AT. Is the AT functioning nor- Replace TCM. Repair AT.
mally?
7 CHECK OPEN CIRCUIT OF HARNESS. Is the voltage between 10 Go to step 8. Repair harness/
Measure voltage between ABSCM&H/U con- and 15 V? connector
nector and chassis ground. between TCM and
TORS. connectors between TCM
and ABSCM&H/U?
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-68
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-69
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
X: TROUBLE CODE 51
— ABNORMAL VALVE RELAY — S006522D61
DIAGNOSIS:
쐌 Faulty valve relay
TROUBLE SYMPTOM:
ABS-70
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M1459
ABS-71
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1) Turn ignition switch to OFF. and 15 V? connector
2) Disconnect connector from ABSCM&H/U. between battery
3) Run the engine at idle. and ABSCM&H/U.
3 CHECK VALVE RELAY IN ABSCM&H/U. Is the resistance more than Go to step 4. Replace
and terminals. <Ref. to ABS-7
Terminals ABS Control Mod-
No. 23 (+) — No. 24 (−): ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-72
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-73
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
Y: TROUBLE CODE 52
— ABNORMAL MOTOR AND/OR MOTOR RELAY — S006522D65
DIAGNOSIS:
쐌 Faulty motor
쐌 Faulty motor relay
TROUBLE SYMPTOM:
ABS-74
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M1460
ABS-75
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage between 10 Go to step 2. Repair harness/
3) Turn ignition switch to ON. and ABSCM&H/U
4) Measure voltage between ABSCM&H/U and check fuse
connector and chassis ground. SBF-holder.
2 CHECK GROUND CIRCUIT OF MOTOR. Is the resistance less than Go to step 3. Repair
1) Turn ignition switch to OFF. 0.5 Ω? ABSCM&H/U
2) Measure resistance between ABSCM&H/U ground harness.
1) Run the engine at idle. and 15 V? connector
2) Measure voltage between ABSCM&H/U between battery,
connector and chassis ground. ignition switch and
5 CHECK MOTOR OPERATION. Can motor revolution noise Go to step 6. Replace
Operate the sequence control. <Ref. to (buzz) be heard when car- ABSCM&H/U.
ABS-11 ABS Sequence Control.> rying out the sequence <Ref. to ABS-7
NOTE: control? ABS Control Mod-
Use the diagnosis connector to operate the ule and Hydraulic
sequence control. Control Unit
(ABSCM&H/U).>
TORS. connector between
Turn ignition switch to OFF. generator, battery and
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-76
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-77
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
Z: TROUBLE CODE 54
— ABNORMAL STOP LIGHT SWITCH — S006522D72
DIAGNOSIS:
쐌 Faulty stop light switch
TROUBLE SYMPTOM:
ABS-78
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M1461
ABS-79
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK STOP LIGHTS COME ON. Do stop lights come on? Go to step 2. Repair stop lights
Depress the brake pedal. circuit.
2 CHECK OPEN CIRCUIT IN HARNESS. Is the voltage between 10 Go to step 3. Repair harness
1) Turn ignition switch to OFF. and 15 V? between stop light
2) Disconnect connector from ABSCM&H/U. switch and
3) Depress brake pedal. ABSCM&H/U.
TORS. connector between stop
light switch and
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-80
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-81
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
AA: TROUBLE CODE 56

— ABNORMAL G SENSOR OUTPUT VOLTAGE — S006522E77
DIAGNOSIS:
쐌 Faulty G sensor output voltage
TROUBLE SYMPTOM:
ABS-82
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M1462
ABS-83
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK ALL FOUR WHEELS FOR FREE Have the wheels been The ABS is nor- Go to step 2.
TURNING. turned freely such as when mal. Erase the
the vehicle is lifted up, or trouble code.
operated on a rolling road?
2 CHECK SPECIFICATIONS OF ABSCM&H/U. Does the vehicle specifica- Replace Go to step 3.
Check specifications of the mark to the tion and the ABSCM&H/U ABSCM&H/U.
ABSCM&H/U. specification match? <Ref. to ABS-7
C5: AT (Except OUTBACK) ABS Control Mod-
C6: MT (Except OUTBACK) ule and Hydraulic
CE: AT (OUTBACK) Control Unit
CF: MT (OUTBACK) (ABSCM&H/U).>
CAUTION:
Be sure to turn
ignition switch
to OFF when
removing
ABSCM&H/U.
3 CHECK INPUT VOLTAGE OF G SENSOR. Is the voltage between 4.75 Go to step 4. Repair harness/
1) Turn ignition switch to OFF. and 5.25 V? connector
2) Remove console box. between G sensor
3) Disconnect G sensor from body. (Do not and ABSCM&H/U.
disconnect connector.)
5) Measure voltage between G sensor con-
nector terminals.
(R70) No. 1 (+) — No. 3 (−):
4 CHECK OPEN CIRCUIT IN G SENSOR OUT- Is the resistance between Go to step 5. Repair harness/
PUT HARNESS AND GROUND HARNESS. 4.3 and 4.9 kΩ? connector
1) Turn ignition switch to OFF. between G sensor
2) Disconnect connector from ABSCM&H/U. and ABSCM&H/U.
(F49) No. 6 — No. 28:
5 CHECK GROUND SHORT IN G SENSOR Is the resistance more than Go to step 6. Repair harness
OUTPUT HARNESS. 1 MΩ? between G sensor
1) Disconnect connector from G sensor. and ABSCM&H/U.
Measure voltage between ABSCM&H/U con- V? between G sensor
nector and chassis ground. and ABSCM&H/U.
1) Turn ignition switch to ON. V? between G sensor
2) Measure voltage between ABSCM&H/U and ABSCM&H/U.
ABS-84
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

Measure resistance between ABSCM&H/U 1 MΩ? between G sensor
connector and chassis ground. and ABSCM&H/U.
Connector & terminal Replace
(F49) No. 28 — Chassis ground: ABSCM&H/U.
<Ref. to ABS-7
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
9 CHECK G SENSOR. Is the voltage between 2.1 Go to step 10. Replace G sen-
1) Turn ignition switch to OFF. and 2.4 V when G sensor sor. <Ref. to
2) Remove G sensor from vehicle. is horizontal? ABS-24 G Sen-
3) Connect connector to G sensor. sor.>
4) Connect connector to ABSCM&H/U.
nector terminals.
(R70) No. 2 (+) — No. 3 (−):
Measure voltage between G sensor connector and 4.1 V when G sensor sor. <Ref. to
terminals. is inclined forwards to 90°? ABS-24 G Sen-
Connector & terminal sor.>
(R70) No. 2 (+) — No. 3 (−):
terminals. is inclined backwards to ABS-24 G Sen-
Connector & terminal 90°? sor.>
(R70) No. 2 (+) — No. 3 (−):
ABSCM&H/U and G sen-
sor?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-85
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
AB: SELECT MONITOR S006522E48 AE: ANALOG DATA ARE

Applicable cartridge of select monitor: <Ref. to DISPLAYED. S006522E29
ABS-9 SPECIAL TOOLS, PREPARATION TOOL,

Display screen Contents to be monitored
General Description.>
Wheel speed detected by the Front
NOTE: FR wheel speed Right ABS sensor is displayed in km/h
For basic handling of the select monitor, refer to its or mile/h.
Operation Manual. Wheel speed detected by the Front
FL wheel speed Left ABS sensor is displayed in km/h
AC: TROUBLE CODES ARE or mile/h.
DISPLAYED. S006522E51
Wheel speed detected by the Rear
A maximum of 3 trouble codes are displayed in RR wheel speed Right ABS sensor is displayed in km/h
or mile/h.
order of occurrence.
쐌 If a particular trouble code is not properly stored Wheel speed detected by the Rear Left
RL wheel speed ABS sensor is displayed in km/h or
in memory (due to a drop in ABSCM&H/U power
mile/h.
supply, etc.) when a problem occurs, the trouble
Stop light switch monitor voltage is dis-
code, followed by a question mark “?”, appears on Stop light switch
played.
the select monitor display. This shows it may be an
Refers to vehicle acceleration detecting
unreliable reading. G sensor output
by the analog G sensor. It appears on
voltage
the select monitor display in volts.
AF: ON/OFF DATA ARE

DISPLAYED. S006522E43

Stop light switch Stop light switch signal
Valve relay signal Valve relay signal
Motor relay signal Motor relay signal
ABS operation signal from ABS con-
S4M0076A ABS signal to TCM
trol module to TCM
쐌 *a* refers to the troubles in order of occurrence ABS warning light ABS warning light
(Latest, Old, Older and Reference). Valve relay monitor Valve relay operation monitor signal
Motor relay monitor Motor relay operation monitor signal
Display screen Contents to be monitored ABS operation signal from ABS con-
CCM signal
The most recent trouble code appears trol module to TCM
Latest
on the select monitor display.
The second most recent trouble code AG: ABS SEQUENCE CONTROL
Old
appears on the select monitor display. S006522E23
The third most recent trouble code

Older Display
appears on the select monitor display. Contents to be monitored Index No.
A specified period of time proceeding screen
Reference trouble code appears on the select Perform ABS sequence
ABS <Ref. to ABS-11
monitor display. control by operating valve
sequence ABS Sequence
and pump motor sequen-
control Control.>
AD: CLEAR MEMORY S006522E33 tially.

Function of clearing trouble code and
Clear memory?
freeze frame data.
ABS-86
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
AH: FREEZE FRAME DATA S006522E39
NOTE:
쐌 Data stored at the time of trouble occurrence is
shown on display.
쐌 Each time trouble occurs, the latest information
is stored in the freeze frame data in memory.
쐌 If freeze frame data is not properly stored in
memory (due to a drop in ABSCM power supply,
etc.), a trouble code, preceded by a question mark
“?”, appears on the select monitor display. This
shows it may be an unreliable reading.
FR wheel speed Right ABS sensor is displayed in km/h
or mile/h.
FL wheel speed Left ABS sensor is displayed in km/h
or mile/h.
Wheel speed detected by the Rear
RR wheel speed Right ABS sensor is displayed in km/h
or mile/h.
Wheel speed detected by the Rear Left
RL wheel speed ABS sensor is displayed in km/h or
mile/h.
Power (in volts) supplied to
ABSCM power
ABSCM&H/U appears on the select
voltage
monitor display.
Refers to vehicle acceleration detected
G sensor output
by the analog G sensor. It appears on
voltage
the select monitor display in volts.
Motor relay moni-
Motor relay operation monitor signal
tor
Stop light switch Stop light switch signal
ABS signal to ABS operation signal from ABS control
TCM module to TCM
ABS operation signal from ABS control
ABS-AT control
module to TCM
ABS operation
ABS operation signal
signal
ABS-87
墌 00.5.31/68j/0abs 墍
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)
14. Diagnostics Chart with Subaru Select Monitor S006583
A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE S006583E34
DIAGNOSIS:
TROUBLE SYMPTOM:
쐌 ABS warning light remains on.
ABS-88
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M1463
ABS-89
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK IGNITION SWITCH. Is ignition switch ON? Go to step 2. Turn ignition
switch ON, and
select ABS/TCS
mode using the
select monitor.
1) Start the engine. and 15 V? <Ref. to
2) Idle the engine. SC(H4)-15 Gen-
3) Measure voltage between generator and erator.>
chassis ground.
Terminal
ground (−):
4 CHECK COMMUNICATION OF SELECT Are the name and year of Go to step 5. Repair select
MONITOR. the system displayed on monitor communi-
Using the select monitor, check whether com- the select monitor? cation cable and
munication to other system (such as engine, connector.
AT, etc.) can be executed normally.
5 CHECK INSTALLATION OF ABSCM&H/U Is ABSCM&H/U connector Go to step 6. Insert
CONNECTOR. inserted into ABSCM&H/U ABSCM&H/U con-
Turn ignition switch to OFF. until the clamp locks onto nector into
it? ABSCM&H/U until
the clamp locks
onto it.
6 CHECK POWER SUPPLY OF ABSCM&H/U. Is the voltage between 10 Go to step 7. Repair
1) Disconnect connector from ABSCM&H/U. and 15 V? ABSCM&H/U
2) Start engine. power supply cir-
3) Idle the engine. cuit.
7 CHECK GROUND CIRCUIT OF Is the resistance less than Repair harness/ Go to step 8.
ABSCM&H/U. 0.5 Ω? connector
1) Turn ignition switch to OFF. between
2) Measure resistance between ABSCM&H/U ABSCM&H/U and
connector and chassis ground. select monitor.
8 CHECK HARNESS/CONNECTOR Is the resistance less than Repair harness Go to step 9.
BETWEEN ABSCM&H/U AND DATA LINK 0.5 Ω? and connector
CONNECTOR. between
1) Turn ignition switch OFF. ABSCM&H/U and
2) Measure resistance between ABSCM&H/U data link connec-
connector and data link connector. tor.
(F49) No. 20 — (B40) No. 5:
(F49) No. 5 — (B40) No. 4:
9 CHECK POOR CONTACT IN CONNEC- Is there poor contact in Repair connector. Replace
TORS. connectors between ABSCM&H/U.
ABSCM&H/U and data link <Ref. to ABS-7
connector? ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-90
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-91
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
B: NO TROUBLE CODE S006583E41
DIAGNOSIS:
쐌 ABS warning light circuit is shorted.
TROUBLE SYMPTOM:
쐌 NO TROUBLE CODE displayed on the select monitor.
NOTE:
When the ABS warning light is OFF and “NO TROUBLE CODE” is displayed on the select monitor, the
system is in normal condition.
ABS-92
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M1454
ABS-93
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK WIRING HARNESS. Does the ABS warning light Go to step 2. Repair front wiring
1) Turn ignition switch to OFF. remain off? harness.
2) Disconnect connector (F45) from connector
(B62).
2 CHECK PROJECTION AT ABSCM&H/U. Are the projection broken? Go to step 3. Replace
1) Turn ignition switch to OFF. ABSCM&H/U.
2) Disconnect connector from ABSCM&H/U. <Ref. to ABS-7
3) Check for broken projection at the ABS Control Mod-
ABSCM&H/U terminal. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
3 CHECK ABSCM&H/U. Is the resistance more than Go to step 4. Replace
Control Unit
(ABSCM&H/U).>
4 CHECK WIRING HARNESS. Is the resistance less than Go to step 5. Repair harness.
Measure resistance between connector (F45) 0.5 Ω?
and chassis ground.
5 CHECK WIRING HARNESS. Is the resistance more than Go to step 6. Repair harness.
1) Connect connector to ABSCM&H/U. 1 MΩ?
(F45) and chassis ground.
<Ref. to ABS-7
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-94
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-95
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
C: TROUBLE CODE 21
— OPEN OR SHORT CIRCUIT IN FRONT RIGHT ABS SENSOR CIRCUIT — S006583C50
NOTE:
For the diagnostic procedure, refer to TROUBLE CODE 27. <Ref. to ABS-96 TROUBLE CODE 27 — OPEN
OR SHORT CIRCUIT IN REAR LEFT ABS SENSOR CIRCUIT —, Diagnostics Chart with Subaru Select
Monitor.>
D: TROUBLE CODE 23
— OPEN OR SHORT CIRCUIT IN FRONT LEFT ABS SENSOR CIRCUIT — S006583C60
NOTE:
Monitor.>
E: TROUBLE CODE 25
— OPEN OR SHORT CIRCUIT IN REAR RIGHT ABS SENSOR CIRCUIT — S006583C69
NOTE:
Monitor.>
F: TROUBLE CODE 27
— OPEN OR SHORT CIRCUIT IN REAR LEFT ABS SENSOR CIRCUIT — S006583C78
DIAGNOSIS:
TROUBLE SYMPTOM:
ABS-96
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M1455
ABS-97
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK OUTPUT OF ABS SENSOR USING Does the speed indicated Go to step 2. Go to step 8.
SELECT MONITOR. on the display change in
1) Select “Current data display & Save” on response to the speedom-
the select monitor. eter reading during
2) Read the ABS sensor output correspondingacceleration/deceleration
when the steering wheel is
to the faulty system in the select monitor data
display mode. in the straight-ahead posi-
tion?
0.3 — 0.8 mm (0.012 — 0.031 in) (Part No.
correct the gap,
replace worn sen-
sor or worn tone
wheel.
<Ref. to ABS-22
Front Tone
Wheel.> Rear:
<Ref. to ABS-23
Rear Tone
Wheel.>
Turn ignition switch to OFF. ABSCM&H/U and ABS
sensor?
Control Unit
(ABSCM&H/U).>
and connectors
between
ABSCM&H/U and
ABS sensor.
8 CHECK ABS SENSOR. Is the resistance between 1 Go to step 9. Replace ABS sen-
1) Turn ignition switch to OFF. and 1.5 kΩ? sor. Front: <Ref.
tor terminals. Rear: <Ref. to
ABS-98
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1) Disconnect connector from ABSCM&H/U. to ABS-14 Front
(−):
(−):
(−):
(−):
1) Turn ignition switch to ON. to ABS-14 Front
(−):
(−):
(−):
(−):
SOR. between
1) Turn ignition switch to OFF. ABSCM&H/U and
2) Connect connector to ABS sensor. ABS sensor.
12:
10:
15:
Measure voltage between ABSCM&H/U con- V? between
nector and chassis ground. ABSCM&H/U and
Connector & terminal ABS sensor.
Trouble code 21 / (F49) No. 11 (+) —
Trouble code 25 / (F49) No. 14 (+) —
ABS-99
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1) Turn ignition switch to ON. V? between
2) Measure voltage between ABSCM&H/U ABSCM&H/U and
connector and chassis ground. ABS sensor.
Trouble code 21 / (F49) No. 11 (+) —
Trouble code 25 / (F49) No. 14 (+) —
0.3 — 0.8 mm (0.012 — 0.031 in) (Part No.
correct the gap,
replace worn sen-
sor or worn tone
wheel.
<Ref. to ABS-22
Front Tone
Wheel.> Rear:
<Ref. to ABS-23
Rear Tone
Wheel.>
SOR. 1 MΩ? sor and
2) Measure resistance between ABS sensor Front: <Ref. to
and chassis ground. ABS-14 Front
Terminal ABS Sensor.>
Front RH No. 1 — Chassis ground: Rear: <Ref. to
Front LH No. 1 — Chassis ground: ABS-17 Rear ABS
Rear RH No. 1 — Chassis ground: Sensor.> and
Rear LH No. 1 — Chassis ground: <Ref. to ABS-7
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-100
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1) Turn ignition switch to OFF. 1 MΩ? between
3) Measure resistance between ABSCM&H/U ABS sensor.
connector terminal and chassis ground. And replace
Trouble code 21 / (F49) No. 11 — Chas- <Ref. to ABS-7
sis ground: ABS Control Mod-
Trouble code 23 / (F49) No. 9 — Chas- ule and Hydraulic
sis ground: Control Unit
Trouble code 25 / (F49) No. 14 — Chas- (ABSCM&H/U).>
sis ground:
sis ground:
ABSCM&H/U and ABS
sensor?
2) Erase the memory. still being output?
3) Perform inspection mode.
4) Read out the trouble code.
and connectors
between
ABSCM&H/U and
ABS sensor.
ABS-101
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
G: TROUBLE CODE 22
— FRONT RIGHT ABNORMAL ABS SENSOR SIGNAL — S006583C54
NOTE:
REAR LEFT ABNORMAL ABS SENSOR SIGNAL —, Diagnostics Chart with Subaru Select Monitor.>
H: TROUBLE CODE 24
— FRONT LEFT ABNORMAL ABS SENSOR SIGNAL — S006583C64
NOTE:
I: TROUBLE CODE 26
— REAR RIGHT ABNORMAL ABS SENSOR SIGNAL — S006583C73
NOTE:
J: TROUBLE CODE 28
— REAR LEFT ABNORMAL ABS SENSOR SIGNAL — S006583C82
DIAGNOSIS:
TROUBLE SYMPTOM:
ABS-102
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M1455
ABS-103
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

2) Read the ABS sensor output corresponding acceleration/deceleration
to the faulty system in the select monitor data when the steering wheel is
tion?
Turn ignition switch to OFF. ABSCM&H/U and ABS
sensor?
transmitter.
harness.
1) Turn ignition switch to OFF. 0.5 Ω? ness.
2) Connect all connectors.
Chassis ground:
Chassis ground:
NOTE:
Go to step 6.
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
0.3 — 0.8 mm (0.012 — 0.031 in) No. 26755AA000).
replace worn sen-
sor or worn tone
wheel.
able?
ABS-104
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

NOTE:
code 29.
No. B5 (−):
No. B6 (−):
2 (−):
5 (−):
Remove disc rotor or drum from hub in accor- nated by dirt or other for- other foreign mat-
dance with trouble code. eign matter? ter.
piece or the tone wheel? Front: <Ref. to
ABS-14 Front
ABS Sensor.>
Rear: <Ref. to
ABS-17 Rear ABS
Sensor.> and
Front: <Ref. to
ABS-22 Front
Tone Wheel.>
Rear: <Ref. to
ABS-23 Rear
Tone Wheel.>
<Ref. to ABS-22
Front Tone
Wheel.> Rear:
<Ref. to ABS-23
Rear Tone
Wheel.>
15 CHECK RESISTANCE OF ABS SENSOR. Is the resistance between 1 Go to step 16. Replace ABS sen-
1) Turn ignition switch OFF. and 1.5 kΩ? sor. Front: <Ref.
connector terminals. Rear: <Ref. to
ABS-105
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

SOR. 1 MΩ? sor. Front: <Ref.
Measure resistance between ABS sensor and to ABS-14 Front
Terminal Rear: <Ref. to
Front RH No. 1 — Chassis ground: ABS-17 Rear ABS
Front LH No. 1 — Chassis ground: Sensor.>
SOR. between
2) Disconnect connector from ABSCM&H/U. ABS sensor.
3) Measure resistance at ABSCM&H/U con-
nector terminals.
12:
10:
15:
Measure resistance between ABSCM&H/U 1 MΩ? connector
connector and chassis ground. between
Connector & terminal ABSCM&H/U and
Trouble code 22 / (F49) No. 11 — Chas- ABS sensor.
sis ground:
sis ground:
sis ground:
sis ground:
and chassis ground.
(F49) No. 23 — GND:
ABSCM&H/U and ABS
sensor?
transmitter.
harness.
ABS-106
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

Chassis ground:
Chassis ground:
NOTE:
Go to step 24.
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-107
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
K: TROUBLE CODE 29
— ABNORMAL ABS SENSOR SIGNAL ON ANY ONE OF FOUR SENSOR — S006583E78
DIAGNOSIS:
TROUBLE SYMPTOM:
ABS-108
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M1455
ABS-109
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK IF THE WHEELS HAVE TURNED Check if the wheels have The ABS is nor- Go to step 2.
when the vehicle
is towed or
jacked-up, or
when steering
wheel is continu-
ously turned all
the way, this
trouble code may
sometimes occur.
Turn ignition switch to OFF. correct?
sively?
sure.
0.3 — 0.8 mm (0.012 — 0.031 in) No. 26755AA000).
replace worn sen-
sor or worn tone
wheel.
able?
3) Connect the oscilloscope to the connector
(B62) in accordance with trouble code.
NOTE:
code 29.
(B62) No. C5 (+) — No. B5 (−) (Front
RH):
(B62) No. C6 (+) — No. B6 (−) (Front
LH):
(F55) No. 1 (+) — No. 2 (−) (Rear RH):
(F55) No. 4 (+) — No. 5 (−) (Rear LH):
ABS-110
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

Remove disc rotor from hub. nated by dirt or other for- other foreign mat-
eign matter? ter.
sor piece or the tone Front: <Ref. to
wheel? ABS-14 Front
ABS Sensor.>
Rear: <Ref. to
ABS-17 Rear ABS
Sensor.> and
Front: <Ref. to
ABS-22 Front
Tone Wheel.>
Rear: <Ref. to
ABS-23 Rear
Tone Wheel.>
<Ref. to ABS-22
Front Tone
Wheel.> Rear:
<Ref. to ABS-23
Rear Tone
Wheel.>
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-111
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
L: TROUBLE CODE 31
— FRONT RIGHT INLET VALVE MALFUNCTION — S006583C93
NOTE:
REAR LEFT INLET VALVE MALFUNCTION —, Diagnostics Chart with Subaru Select Monitor.>
M: TROUBLE CODE 33
— FRONT LEFT INLET VALVE MALFUNCTION — S006583D03
NOTE:
N: TROUBLE CODE 35
— REAR RIGHT INLET VALVE MALFUNCTION — S006583D11
NOTE:
O: TROUBLE CODE 37
— REAR LEFT INLET VALVE MALFUNCTION — S006583D20
DIAGNOSIS:
쐌 Faulty inlet solenoid valve
TROUBLE SYMPTOM:
ABS-112
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2334
ABS-113
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

2) Disconnect connector from ABSCM&H/U. between battery,
3) Run the engine at idle. ignition switch and
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-114
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-115
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
P: TROUBLE CODE 32
— FRONT RIGHT OUTLET VALVE MALFUNCTION — S006583C99
NOTE:
REAR LEFT OUTLET VALVE MALFUNCTION —, Diagnostics Chart with Subaru Select Monitor.>
Q: TROUBLE CODE 34
— FRONT LEFT OUTLET VALVE MALFUNCTION — S006583D08
NOTE:
R: TROUBLE CODE 36
— REAR RIGHT OUTLET VALVE MALFUNCTION — S006583D15
NOTE:
S: TROUBLE CODE 38
— REAR LEFT OUTLET VALVE MALFUNCTION — S006583D24
DIAGNOSIS:
쐌 Faulty outlet solenoid valve
TROUBLE SYMPTOM:
ABS-116
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2334
ABS-117
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

2) Disconnect connector from ABSCM&H/U. between battery,
3) Run the engine at idle. ignition switch and
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-118
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-119
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
T: TROUBLE CODE 41
— ABS CONTROL MODULE MALFUNCTION — S006583D31
DIAGNOSIS:
쐌 Faulty ABSCM&H/U
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M1457
ABS-120
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

and chassis ground.
ABSCM&H/U?
transmitter.
harness.
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-121
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
U: TROUBLE CODE 42
— POWER SUPPLY VOLTAGE TOO LOW — S006583D36
DIAGNOSIS:
쐌 Power source voltage of the ABSCM&H/U is low.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2334
ABS-122
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

Terminal
ground:
clamped?
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-123
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
V: TROUBLE CODE 42
— POWER SUPPLY VOLTAGE TOO HIGH — S006583D35
DIAGNOSIS:
쐌 Power source voltage of the ABSCM&H/U is high.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2334
ABS-124
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

Terminal
ground:
clamped?
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-125
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
W: TROUBLE CODE 44
— ABS-AT CONTROL (NON CONTROLLED) — S006583E79
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M1458
ABS-126
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK SPECIFICATIONS OF THE Is an ABSCM&H/U for AT Replace Go to step 2.
ABSCM&H/U. model installed on a MT ABSCM&H/U.
Check specifications of the mark to the model? <Ref. to ABS-7
ABSCM&H/U. ABS Control Mod-
C5: AT (Except OUTBACK) ule and Hydraulic
C6: MT (Except OUTBACK) Control Unit
CE: AT (OUTBACK) (ABSCM&H/U).>
CF: MT (OUTBACK)
1) Turn ignition switch to OFF. 1 MΩ? between TCM and
3 CHECK TCM. Is the voltage between 10 Go to step 5. Go to step 4.
1) Connect all connectors to TCM. and 15 V?
3) Measure voltage between TCM connector
4 CHECK AT. Is the AT functioning nor- Replace TCM. Repair AT.
mally?
5 CHECK OPEN CIRCUIT OF HARNESS. Is the voltage more than 10 Go to step 6. Repair harness/
Measure voltage between ABSCM&H/U con- V? connector
nector and chassis ground. between TCM and
and ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-127
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
X: TROUBLE CODE 44
— ABS-AT CONTROL (CONTROLLED) — S006583E80
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M1458
ABS-128
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1) Turn ignition switch to OFF. V? between TCM and
1) Turn ignition switch to ON. V? between TCM and
3 CHECK OPEN CIRCUIT OF HARNESS. Is the voltage between 10 Go to step 4. Repair harness/
2) Connect all connectors to TCM. between TCM and
Turn ignition switch to OFF. and ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-129
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
Y: TROUBLE CODE 51
— VALVE RELAY MALFUNCTION — S006583E81
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M1459
ABS-130
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

3) Run the engine at idle. and ABSCM&H/U.
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-131
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
Z: TROUBLE CODE 51
— VALVE RELAY ON FAILURE — S006583D63
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M1459
ABS-132
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK VALVE RELAY IN ABSCM&H/U. Is the resistance more than Go to step 2. Replace
No. 23 (+) — No. 24 (−): ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-133
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
AA: TROUBLE CODE 52

— OPEN CIRCUIT IN MOTOR RELAY CIRCUIT — S006583E82
DIAGNOSIS:
쐌 Faulty motor
TROUBLE SYMPTOM:
ABS-134
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M1460
ABS-135
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

connector and chassis ground. SBF6.
ABS-11 ABS Sequence Control.> rying out the check <Ref. to ABS-7
NOTE: sequence? ABS Control Mod-
(ABSCM&H/U).>
TORS. connector between hydra-
Turn ignition switch to OFF. clic unit, relay box and
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-136
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-137
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
AB: TROUBLE CODE 52

— MOTOR RELAY ON FAILURE — S006583E83
DIAGNOSIS:
쐌 Faulty motor
TROUBLE SYMPTOM:
ABS-138
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M1460
ABS-139
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK MOTOR RELAY IN ABSCM&H/U. Is the resistance more than Go to step 2. Replace
Control Unit
(ABSCM&H/U).>
(ABSCM&H/U).>
TORS. connector between hydrau-
Turn ignition switch to OFF. lic unit, relay box and
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-140
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-141
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
AC: TROUBLE CODE 52

— MOTOR MALFUNCTION — S006583D68
DIAGNOSIS:
쐌 Faulty motor
TROUBLE SYMPTOM:
ABS-142
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
B4M1460
ABS-143
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

connector and chassis ground. SBF6.
1) Run the engine at idle. and 15 V? connector
2) Measure voltage between ABSCM&H/U between battery,
connector and chassis ground. ignition switch and
(ABSCM&H/U).>
Turn ignition switch to OFF. generator, battery and
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-144
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-145
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
AD: TROUBLE CODE 54

— STOP LIGHT SWITCH SIGNAL CIRCUIT MALFUNCTION — S006583E84
DIAGNOSIS:
쐌 Faulty stop light switch
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M1461
ABS-146
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK OUTPUT OF STOP LIGHT SWITCH Is the reading indicated on Go to step 2. Go to step 3.
USING SELECT MONITOR. monitor display less than
1) Select “Current data display & Save” on 1.5 V?
the select monitor.
2) Release the brake pedal.
3) Read the stop light switch output in the
select monitor data display.
2 CHECK OUTPUT OF STOP LIGHT SWITCH Is the reading indicated on Go to step 5. Go to step 3.
USING SELECT MONITOR. monitor display between 10
1) Depress the brake pedal. and 15 V?
2) Read the stop light switch output in the
select monitor data display.
3 CHECK IF STOP LIGHTS COME ON. Do stop lights turn on? Go to step 4. Repair stop lights
Depress the brake pedal. circuit.
4 CHECK OPEN CIRCUIT IN HARNESS. Is the voltage between 10 Go to step 5. Repair harness
1) Turn ignition switch to OFF. and 15 V? between stop light
2) Disconnect connector from ABSCM&H/U. switch and
3) Depress brake pedal. ABSCM&H/U con-
4) Measure voltage between ABSCM&H/U nector.
TORS. connector between stop
light switch and
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-147
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
AE: TROUBLE CODE 56

— OPEN OR SHORT CIRCUIT IN G SENSOR CIRCUIT — S006583E85
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M1462
ABS-148
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK OUTPUT OF G SENSOR USING Is the G sensor output on Go to step 2. Go to step 5.
SELECT MONITOR. the monitor display
1) Select “Current data display & Save” on between 2.1 and 2.5 V
the select monitor. when the G sensor is in
2) Read the G sensor output in select monitor horizontal position?
data display.
sor?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
nector terminals.
(R70) No. 1 (+) — No. 3 (−):
(F49) No. 6 — No. 28:
7 CHECK GROUND SHORT IN G SENSOR Is the resistance more than Go to step 8. Repair harness
OUTPUT HARNESS. 1 MΩ? between G sensor
1) Disconnect connector from G sensor. and ABSCM&H/U.
1) Connect connector to G sensor. and 2.5 V when G sensor sor. <Ref. to
2) Connect connector to ABSCM&H/U. is horizontal? ABS-24 G Sen-
3) Turn ignition switch to ON. sor.>
nector terminals.
(R70) No. 2 (+) — No. 3 (−):
(R70) No. 2 (+) — No. 3 (−):
ABS-149
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

(R70) No. 2 (+) — No. 3 (−):
Turn ignition switch to OFF. ABSCM&H/U and G sen-
sor?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-150
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-151
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
AF: TROUBLE CODE 56

— BATTERY SHORT IN G SENSOR CIRCUIT — S006583E86
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M1462
ABS-152
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

the select monitor. when the G sensor is in
2) Read the G sensor output in select monitor horizontal position?
data display.
sor?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
5 CHECK FREEZE FRAME DATA. Is the front right wheel Go to step 6. Go to step 16.
1) Select “Freeze frame data” on the select speed on monitor display 0
monitor. km?
2) Read front right wheel speed on the select
monitor display.
6 CHECK FREEZE FRAME DATA. Is the front left wheel Go to step 7. Go to step 16.
Read front left wheel speed on the select speed on monitor display 0
monitor display. km?
7 CHECK FREEZE FRAME DATA. Is the rear right wheel Go to step 8. Go to step 16.
Read rear right wheel speed on the select speed on monitor display 0
monitor display. km?
8 CHECK FREEZE FRAME DATA. Is the rear left wheel speed Go to step 9. Go to step 16.
Read rear left wheel speed on the select on monitor display 0 km?
monitor display.
9 CHECK FREEZE FRAME DATA. Is the G sensor output on Go to step 10. Go to step 16.
Read G sensor output on the select monitor monitor display more than
display. 3.65 V?
(F49) No. 6 — No. 28:
1) Turn ignition switch to OFF. V? between G sensor
2) Remove console box. and ABSCM&H/U.
3) Disconnect connector from G sensor.
ABS-153
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1) Turn ignition switch to ON. V? between G sensor
2) Measure voltage between ABSCM&H/U and ABSCM&H/U.
sor?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
nector terminals.
(R70) No. 1 (+) — No. 3 (−):
(F49) No. 6 — No. 28:
1) Connect connector to G sensor. and 2.5 V when G sensor sor. <Ref. to
2) Connect connector to ABSCM&H/U. is horizontal? ABS-24 G Sen-
3) Turn ignition switch to ON. sor.>
nector terminals.
(R70) No. 2 (+) — No. 3 (−):
(R70) No. 2 (+) — No. 3 (−):
(R70) No. 2 (+) — No. 3 (−):
ABS-154
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

sor?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-155
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
AG: TROUBLE CODE 56

— ABNORMAL G SENSOR HIGH µ OUTPUT — S006583E87
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M1462
ABS-156
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

SELECT MONITOR. monitor display 2.3±0.2 V
1) Select “Current data display & Save” on when the G sensor is in
the select monitor. horizontal position?
2) Read G sensor output on the select moni-
tor display.
sor?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
(F49) No. 6 — No. 28:
Measure resistance between ABSCM&H/U 1 MΩ? between G sensor
connector and chassis ground. and ABSCM&H/U.
Connector & terminal Replace
(F49) No. 28 — Chassis ground: ABSCM&H/U.
<Ref. to ABS-7
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
1) Remove console box. and 2.5 V when G sensor sor. <Ref. to
nector terminals.
(R70) No. 2 (+) — No. 3 (−):
(R70) No. 2 (+) — No. 3 (−):
(R70) No. 2 (+) — No. 3 (−):
ABS-157
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

(ABSCM&H/U).>
sponding to the
trouble code.
ABS-158
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
MEMO:
ABS-159
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
AH: TROUBLE CODE 56

— DETECTION OF G SENSOR STICK — S006583E88
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M1462
ABS-160
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

1 CHECK ALL FOUR WHEELS FOR FREE Have the wheels been The ABS is nor- Go to step 2.
TURNING. turned freely such as when mal. Erase the
the vehicle is lifted up, or trouble code.
operated on a rolling road?
the select monitor. when the vehicle is in hori-
2) Read the select monitor display. zontal position?
3 CHECK OUTPUT OF G SENSOR USING Is the G sensor output on Go to step 4. Replace G sen-
SELECT MONITOR. the monitor display sor. <Ref. to
1) Turn ignition switch to OFF. between 3.7 and 4.1 V ABS-24 G Sen-
2) Remove console box. when G sensor is inclined sor.>
3) Remove G sensor from vehicle. (Do not forwards to 90°?
5) Select “Current data display & Save” on
the select monitor.
6) Read the select monitor display.
4 CHECK OUTPUT OF G SENSOR USING Is the G sensor output on Go to step 5. Replace G sen-
SELECT MONITOR. the monitor display sor. <Ref. to
Read the select monitor display. between 0.5 and 0.9 V ABS-24 G Sen-
when G sensor is inclined sor.>
backwards to 90°?
sor?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
(F49) No. 6 — No. 28:
1) Remove console box. and 2.5 V when G sensor sor. <Ref. to
nector terminals.
(R70) No. 2 (+) — No. 3 (−):
ABS-161
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)

(R70) No. 2 (+) — No. 3 (−):
(R70) No. 2 (+) — No. 3 (−):
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-162
墌 00.5.31/68j/0abs 墍
GENERAL DIAGNOSTICS TABLE
ABS (DIAGNOSTICS)
15. General Diagnostics Table S006121
Symptom Probable faulty units/parts

쐌 ABSCM&H/U (solenoid valve)
쐌 ABS sensor
쐌 Brake (caliper & piston, pads)
Vehicle pulls to either side. 쐌 Wheel alignment
쐌 Tire specifications, tire wear and air pressures
쐌 Incorrect wiring or piping connections
Vehicle instability during braking 쐌 Road surface (uneven, camber)
쐌 ABS sensor
Vehicle spins. 쐌 Brake (pads)
쐌 Brake (pads)
Long braking/stopping distance 쐌 Air in brake line
쐌 ABSCM&H/U (solenoid valve, motor)
Wheel locks. 쐌 ABS sensor
쐌 ABS sensor
쐌 Master cylinder
Brake dragging 쐌 Brake (caliper & piston)
쐌 Parking brake
Poor braking 쐌 Axle & wheels
쐌 Brake pedal play
쐌 Air in brake line
Long brake pedal stroke
쐌 Brake pedal play
쐌 Suspension play or fatigue (reduced damping)
Vehicle pitching 쐌 Incorrect wiring or piping connections
쐌 Road surface (uneven)
쐌 ABS sensor
쐌 Brake (caliper & piston, pads)
Unstable or uneven braking
Excessive pedal vibration
쐌 ABSCM&H/U (mount bushing)
Noise from ABSCM&H/U 쐌 ABS sensor
쐌 Brake piping
쐌 ABSCM&H/U (mount bushing)
쐌 ABS sensor
쐌 Master cylinder
Vibration and/or noise
Noise from front of vehicle 쐌 Brake (caliper & piston, pads, rotor)
(while driving on slippery roads)
쐌 Brake piping
쐌 Brake booster & check valve
쐌 Suspension play or fatigue
쐌 ABS sensor
쐌 Brake (caliper & piston, pads, rotor)
Noise from rear of vehicle 쐌 Parking brake
쐌 Brake piping
쐌 Suspension play or fatigue
ABS-163
ABS (DIAGNOSTICS)
MEMO:
ABS-164
ABS (DIAGNOSTICS)
MEMO:
ABS-165
墌 00.5.31/68j/0abs 墍
ABS (DIAGNOSTICS)
ABS-166
墌 00.5.31/68j/0abs 墍
GENERAL DESCRIPTION
ABS
Item Standard or remarks

Front 0.3 — 0.8 mm (0.012 — 0.031 in)
ABS sensor gap
Rear 0.44 — 0.94 mm (0.0173 — 0.0370 in)
ABS sensor resistance 1.25±0.25 kΩ
Except OUTBACK Yellow
Front LH
ABS sensor OUTBACK Brown
Marks of the Except OUTBACK Light blue
Front RH
harness OUTBACK White
Rear LH White
Rear RH Yellow
G sensor G sensor voltage 2.3±0.2 V
AT (Except OUTBACK) C5
ABS control module and MT (Except OUTBACK) C6
hydraulic control unit
AT (OUTBACK) CE
(ABSCM&H/U) marks
MT (OUTBACK) CF
ABS-2
墌 00.5.31/68j/4abs 墍
GENERAL DESCRIPTION
ABS
1. SENSOR S401001A0501
B4M2208A
(1) G sensor (6) Housing Tightening torque: N·m (kgf-m, ft-lb)

(2) Clip (7) Front ABS sensor LH
T1: 7.4 (0.75, 5.4)
(3) Rear ABS sensor LH (8) Tone wheel (Front)
T2: 32 (3.3, 24)
(4) ABS spacer
(5) Tone wheel (Rear)
ABS-3
墌 00.5.31/68j/4abs 墍
GENERAL DESCRIPTION
ABS
2. ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT

(ABSCM&H/U) S401001A0502
B4M2462A
(1) Stud bolt (6) Front-RH outlet Tightening torque: N·m (kgf-m, ft-lb)
(2) Damper (7) Primary inlet
T1: 18 (1.8, 13.06)
(3) ABS control module and hydrau- (8) Rear-LH outlet
T2: 32 (3.3, 24)
lic control unit (9) Rear-RH outlet
T3: 38 (3.8, 28)
(4) Front-LH outlet (10) Bracket
(5) Secondary inlet
ABS-4
墌 00.5.31/68j/4abs 墍
GENERAL DESCRIPTION
ABS
쐌 Wear working clothing, including a cap, protec-

tive goggles, and protective shoes during opera-
tion.
쐌 Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
쐌 Keep the disassembled parts in order and pro-
tect them from dust or dirt.
쐌 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary
removal, installation, disassembly, and replace-
ment.
쐌 Be careful not to burn your hands, because each
part in the vehicle is hot after running.
쐌 Be sure to tighten fasteners including bolts and
nuts to the specified torque.
쐌 Place shop jacks or safety stands at the speci-
fied points.
쐌 Before disconnecting electrical connectors of
sensors or units, be sure to disconnect negative
terminal from battery.
ABS-5
墌 00.5.31/68j/4abs 墍
GENERAL DESCRIPTION
ABS

B2M3876
B2M3877
TOOL NAME REMARKS

Pressure gauge Used for measuring oil pressure.
ABS-6
墌 00.5.31/68j/4abs 墍
ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
ABS
2. ABS Control Module and

Hydraulic Control Unit
(ABSCM&H/U) S401543

2) Remove air intake duct from engine compart-
ment to facilitate removal of ABSCM&H/U.
3) Use an air gun to get rid of water around the B4M1222
ABSCM&H/U.
CAUTION:
The contact will be insufficient if the terminal
gets wet.
4) Pull off the lock of the ABSCM&H/U connector
to remove it.
B4M1224

CAUTION:
Be careful not to let water or other foreign mat-
ter contact the ABSCM&H/U terminal.
6) Unlock cable clip.
7) Disconnect brake pipes from ABSCM&H/U.
CAUTION:
Wrap brake pipes with vinyl bag to avoid spill-
ing brake fluid on vehicle body.
8) Remove ABSCM&H/U ground terminal from
bracket.
9) Remove ABSCM&H/U from engine compart-
ment.
CAUTION:
쐌 ABSCM&H/U cannot be disassembled. Do
not attempt to loosen bolts and nuts.
쐌 Do not drop or bump ABSCM&H/U.
쐌 Do not turn the ABSCM&H/U upside down or
place it on its side.
쐌 Be careful to prevent foreign particles from
getting into ABSCM&H/U.
쐌 Apply a coat of rust-preventive wax (Nippeco
LT or GB) to bracket attaching bolt after tight-
ening.
쐌 Do not pull harness when disconnecting
connector.
ABS-7
墌 00.5.31/68j/4abs 墍
ABS
B: INSTALLATION S401543A11 C: INSPECTION S401543A10
1) Install ABSCM&H/U. 1) Check connected and fixed condition of con-

CAUTION: nector.
Confirm that the specifications of the 2) Check specifications of the mark with
ABSCM&H/U conforms to the vehicle specifica- ABSCM&H/U.
tions. Mark Model
Tightening torque: C5 AT (Except OUTBACK)
18 N·m (1.8 kgf-m, 13.0 ft-lb) C6 MT (Except OUTBACK)
2) Install ABSCM&H/U ground terminal to bracket. CE AT (OUTBACK)
CF MT (OUTBACK)
Tightening torque:
32 N·m (3.3 kgf-m, 24 ft-lb)
3) Connect brake pipes to their correct
ABSCM&H/U connections.
Tightening torque:
15 N·m (1.5 kgf-m, 10.8 ft-lb)
S4M0289C
(1) Mark
1. CHECKING THE HYDRAULIC UNIT ABS

OPERATION BY PRESSURE GAUGE
S401543A1001
B4M1222
1) Lift-up vehicle and remove wheels.
4) Using cable clip, secure ABSCM&H/U harness 2) Disconnect the air bleeder screws from the FL
to bracket. and FR caliper bodies.
5) Connect connector to ABSCM&H/U. 3) Connect two pressure gauges to the FL and FR
CAUTION: caliper bodies.
쐌 Be sure to remove all foreign matter from CAUTION:
inside the connector before connecting. 쐌 Pressure gauges used exclusively for brake
쐌 Ensure that the ABSCM&H/U connetor is fluid must be used.
securely locked. 쐌 Do not employ pressure gauge previously
6) Install air intake duct. used for transmission since the piston seal is
7) Connect ground cable to battery. expanded which may lead to malfunction of the
8) Bleed air from the brake system. brake.
NOTE:
Wrap sealing tape around the pressure gauge.
B4M1732
ABS-8
墌 00.5.31/68j/4abs 墍
ABS
4) Bleed air from the pressure gauges. 2. CHECKING THE HYDRAULIC UNIT ABS
5) Perform ABS sequence control. OPERATION WITH BRAKE TESTER S401543A1002
<Ref. to ABS-11 ABS Sequence Control.>
6) When the hydraulic unit begins to work, and 1) In the case of AWD AT vehicles, install a spare
first the FL side performs decompression, holding, fuse with the FWD connector in the main fuse box
and compression, and then the FR side performs to simulate FWD vehicles.
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 stan-
dard values. Also check if any irregular brake pedal
tightness is felt.
Front wheel Rear wheel
3,432 kPa 3,432 kPa
Initial value (35 kg/cm2, 498 (35 kg/cm2, 498
psi) psi)
B4M1731C
490 kPa 490 kPa
When
(5 kg/cm2, 71 psi) (5 kg/cm2, 71 psi) (1) FWD connector
decompressed
or less or less
3,432 kPa 3,432 kPa 2) Prepare for operating ABS sequence control.
When (35 kg/cm2, 498 (35 kg/cm2, 498 <Ref. to ABS-11 ABS Sequence Control.>
compressed psi) psi) 3) Set the front wheels or rear wheels on the brake
or more or more tester and set the select lever’s position at “neu-
tral”.
8) Remove pressure gauges from FL and FR cali-
per bodies.
9) Remove air bleeder screws from the RL and RR
caliper bodies.
10) Connect the air bleeder screws to the FL and
FR caliper bodies.
11) Connect two pressure gauges to the RL and
RR caliper bodies.
12) Bleed air from the pressure gauges and the FL
and FR caliper bodies.
13) Perform ABS sequence control.
<Ref. to ABS-11 ABS Sequence Control.> B4M1733B
14) When the hydraulic unit begins to work, at first

the RR side performs decompression, holding, and
compression, and then the RL side performs
15) Read values indicated on the pressure
gauges and check if they meet the standard value.
16) After checking, remove the pressure gauges
from caliper bodies.
17) Connect the air bleeder screws to RL and RR
caliper bodies.
18) Bleed air from brake line.
B4M1730B
(1) Brake tester
4) Operate the brake tester.

<Ref. to ABS-11 ABS Sequence Control.>
6) Hydraulic unit begins to work; and check the
following working sequence.
(1) The FL wheel performs decompression,
holding, and compression in sequence, and
subsequently the FR wheel repeats the cycle.
ABS-9
墌 00.5.31/68j/4abs 墍
ABS
(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 decom-
pressed and compressed, meet the standard val-
ues.
981 N 981 N
Initial value
(100 kg, 221 lb) (100 kg, 221 lb)
490 N 490 N
When
(50 kg, 110 lb) (50 kg, 110 lb)
decompressed
or less or less
981 N 981 N
When
(100 kg, 221 lb) (100 kg, 221 lb)
compressed
or more or more
8) After checking, also check if any irregular brake

pedal tightness is felt.
ABS-10
墌 00.5.31/68j/4abs 墍
ABS SEQUENCE CONTROL
ABS
3. ABS Sequence Control S401187

2. ABS SEQUENCE CONTROL WITH
SELECT MONITOR S401187A1602
NOTE:
1) Under the ABS sequence control, after the 쐌 In the event of any trouble, the sequence con-
hydraulic unit solenoid valve is driven, the opera- trol may not be operative. In such a case, activate
tion of the hydraulic unit can be checked by means the sequence control, referring to “ABS
of the brake tester or pressure gauge. SEQUENCE CONTROL WITH DIAGNOSIS CON-
2) ABS sequence control can be started by diag- NECTOR”.
nosis connector or select monitor. <Ref. to ABS-11 ABS SEQUENCE CONTROL
WITH DIAGNOSIS CONNECTOR, OPERATION,
1. ABS SEQUENCE CONTROL WITH ABS Sequence Control.>
DIAGNOSIS CONNECTOR S401187A1601 쐌 When the diagnosis terminal is connected to the
1) Connect diagnosis terminals to terminals No. 5 diagnosis connector, the sequence control will not
and No. 8 of the diagnosis connector beside driv- operate.
er’s seat heater unit. 1) Connect select monitor to data link connector
under driver’s seat instrument panel lower cover.
3) Turn select monitor switch ON.
4) Put select monitor to “BRAKE CONTROL”
mode.
5) When “Function check sequence” is selected,
‘ABS sequence control’ will start.
6) The message ‘Press Brake Pedal Firmly’ is dis-
played as follows:
(1) When using the brake tester, depress brake
B4M1767F pedal with braking force of 981 N (100 kg, 221
lb).
(1) Diagnosis connector (2) When using the pressure gauge, depress
(2) Diagnosis terminal brake pedal so as to make the pressure gauge
(3) 8 terminal indicate 3,432 kPa (35 kg/cm2, 498 psi).
(4) 5 terminal
CAUTION:
2) Set the speed of all wheels at 2.75 km/h (2 Do not depress the clutch pedal.
MPH) or less. 7) When the message “Press YES” is displayed,
3) Turn ignition switch OFF. press YES key.
4) Within 0.5 seconds after the ABS warning light 8) Operation points will be displayed on select
goes out, depress the brake pedal and hold it monitor.
immediately after ignition switch is turned to ON.
CAUTION:
Do not depress the clutch pedal.
NOTE:
쐌 When the ignition switch is set to on, the brake
pedal must not be depressed.
쐌 Engine must not operate.
5) After completion of ABS sequence control, turn
ignition switch OFF.
ABS-11
墌 00.5.31/68j/4abs 墍
ABS
3. CONDITIONS FOR ABS SEQUENCE CONTROL S401187A1603
B4M1001C
NOTE:
쐌 When select monitor is used, control operation starts at point A. The patterns from IGN key ON to the
point A show that operation is started by diagnosis connector.
쐌 HIGH means high voltage.
쐌 LOW means low voltage.
ABS-12
墌 00.5.31/68j/4abs 墍
ABS
B: SPECIFICATION S401187A22
1. CONDITIONS FOR COMPLETION OF

ABS SEQUENCE CONTROL S401187A2201
When the following conditions develop, the ABS
sequence control stops and ABS operation is
returned to the normal control mode.
1) When the speed of at least one wheel reaches
10 km/h (6 MPH).
2) When terminal No. 5 or No. 8 are separated
from diagnosis terminals. (When select monitor is
not used.)
3) When the brake pedal is released during
sequence control and the braking lamp switch is
set to off.
4) When brake pedal is depressed after ignition
key is turned to ON, and before ABS warning light
goes out. (When select monitor is not used.)
5) When brake pedal is not depressed after igni-
tion key is turned to ON, and within 0.5 seconds
after ABS warning light goes out. (When select
monitor is not used.)
6) After completion of the sequence control.
7) When malfunction is detected. (When select
monitor is used.)
ABS-13
墌 00.5.31/68j/4abs 墍
FRONT ABS SENSOR
ABS
4. Front ABS Sensor S401190 B: INSTALLATION S401190A11
1) Temporarily install front ABS sensor on hous-
ing.
2) Disconnect front ABS sensor connector located CAUTION:
next to front strut mounting house in engine com- Be careful not to strike ABS sensor’s pole
partment. piece and tone wheel’s teeth against adjacent
3) Remove bolts which secure sensor harness to metal parts during installation.
strut.
B4M2209
B4M1442
2) Install front ABS sensor on strut and wheel
4) Remove bolts which secure sensor harness to apron bracket.
body.
Tightening torque:
32 N·m (3.3 kgf-m, 24 ft-lb)
B4M1728C
(1) To front ABS sensor connector B4M1728C

(2) Bracket
(1) To front ABS sensor connector
5) Remove bolts which secure front ABS sensor to (2) Bracket
housing, and remove front ABS sensor.
CAUTION:
쐌 Be careful not to damage pole piece located
at tip of the sensor and teeth faces during
removal.
쐌 Do not pull sensor harness during removal.
B4M2209
ABS-14
墌 00.5.31/68j/4abs 墍
FRONT ABS SENSOR
ABS
3) Place a thickness gauge between ABS sensor’s C: INSPECTION S401190A10

and tone wheel’s tooth face. After standard clear-
ance is obtained over the entire perimeter, tighten 1. ABS SENSOR S401190A1001
ABS sensor on housing to specified torque. 1) Check pole piece of ABS sensor for foreign par-
ABS sensor standard clearance: ticles or damage. If necessary, clean pole piece or
0.3 — 0.8 mm (0.012 — 0.031 in) replace ABS sensor.
Tightening torque: 2) Measure ABS sensor resistance.
32 N·m (3.3 kgf-m, 24 ft-lb)
B4M0248
B4M2209
Terminal No. Standard
CAUTION: 1 and 2 1.25±0.25 kΩ
Check the marks on the harness to make sure
that no distortion exists. CAUTION:
If resistance is outside the standard value,
Model LH RH replace ABS sensor with new one.
Except OUTBACK Yellow White
NOTE:
OUTBACK Brown Light blue
Check ABS sensor cable for discontinuity. If
NOTE: necessary, replace with a new one.
If the clearance is outside specifications, readjust.
2. SENSOR GAP S401190A1002
4) After confirmation of the ABS sensor clearance,
connect connector to ABS sensor. 1) Measure the distance “A” between ABS sensor
5) Connect connector to battery ground cable. surface and sensor pole face.
S4M0509A
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.
ABS-15
墌 00.5.31/68j/4abs 墍
FRONT ABS SENSOR
ABS
Adjust the gap using spacer (Part No. 26755A000).
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 valves in the formula below and cal-
culating.
ABS sensor clearance = B − A
ABS sensor standard clearance:
0.3 — 0.8 mm (0.012 — 0.031 in)
NOTE:
3. OUTPUT VOLTAGE S401190A1003
Output voltage can be checked by the following

method. Install resistor and condenser, then rotate
wheel about 2.75 km/h (2 MPH) or equivalent.
NOTE:
Regarding terminal No., please refer to item 1.
ABS SENSOR.
B4M0118B
ABS-16
墌 00.5.31/68j/4abs 墍
REAR ABS SENSOR
ABS
5. Rear ABS Sensor S401185

6) Remove bolts which hold rear sensor harness
brackets.

3) Remove fuel tank cover.
B4M2062
B4M1760
4) Disconnect rear ABS sensor connector.
B4M1791
B2M3184
5) Remove rear sensor harness from clip on body

side.
B4M1763
7) Remove rear ABS sensor from rear arm.

With disc brake model:
B4M1761
B4M2063
ABS-17
墌 00.5.31/68j/4abs 墍
REAR ABS SENSOR
ABS
With drum brake model: B: INSTALLATION S401185A11
1) Install rear drive shaft to the vehicle.

<Ref. to DS-33 Rear Drive Shaft.>
2) Temporarily install rear ABS sensor on rear
arm.
CAUTION:
Be careful not to strike ABS sensor’s pole
piece and tone wheel’s teeth against adjacent
metal parts during installation.
With disc brake model:
B4M1708
8) When inspecting rear tone wheel, remove rear

drive shaft as rear tone wheel is unitized with BJ
assembly of rear drive shaft.
CAUTION:
쐌 Be careful not to damage pole piece located
at tip of the sensor and teeth faces during
removal.
쐌 Do not pull sensor harness during removal.
B4M2063
With drum brake model:
B4M1708
ABS-18
墌 00.5.31/68j/4abs 墍
REAR ABS SENSOR
ABS
3) Install rear sensor harness brackets in the origi- 4) Place a thickness gauge between ABS sensor’s
nal positions and install harness on the clip. and tone wheel’s tooth face. After standard clear-
ance is obtained over the entire perimeter, tighten
Tightening torque:
ABS sensor on rear arm to specified torque.
32 N·m (3.3 kgf-m, 24 ft-lb)
ABS sensor standard clearance:
0.44 — 0.94 mm (0.0173 — 0.0370 in)
Tightening torque:
32 N·m (3.3 kgf-m, 24 ft-lb)
CAUTION:
Check the marks on the harness to make sure
that no distortion exists. (RH: white, LH: yel-
low)
NOTE:
B4M1763
5) After confirmation of the ABS sensor clearance,
connect connector to ABS sensor and install fuel
tank cover.
B4M1791
Tightening torque: B4M1760

32 N·m (3.3 kgf-m, 24 ft-lb)
6) Connect connector to battery ground cable.
B4M1762
B4M1761
ABS-19
墌 00.5.31/68j/4abs 墍
REAR ABS SENSOR
ABS
C: INSPECTION S401185A10 2) Measure the distance “B” between surface

where the front axle housing meets the ABS
1. ABS SENSOR S401185A1001
sensor, and the tone wheel.
1) Check pole piece of ABS sensor for foreign par- NOTE:
ticles or damage. If necessary, clean pole piece or Measure so that the gauge touches the tone wheel
replace ABS sensor. teeth top.
2) Measure ABS sensor resistance.
S4M0510A
B4M0248
(1) Axle housing
(2) Tone wheel
Terminal No. Standard
1 and 2 1.25±0.25 kΩ 3) Find the gap between the ABS sensor pole face
and the surface of the tone wheel teeth by putting
CAUTION:
the measured valves in the formula below and cal-
If resistance is outside the standard value,
culating.
replace ABS sensor with new one.
ABS sensor clearance = B − A
NOTE:
Check ABS sensor cable for discontinuity. If ABS sensor standard clearance:
necessary, replace with a new one. 0.44 — 0.94 mm (0.0173 — 0.0370 in)
2. SENSOR GAP S401185A1002 NOTE:
1) Measure the distance “A” between ABS sensor
surface and sensor pole face.
S4M0509A
ABS-20
墌 00.5.31/68j/4abs 墍
REAR ABS SENSOR
ABS
3. OUTPUT VOLTAGE S401185A1003 D: ADJUSTMENT S401185A01
Output voltage can be checked by the following Adjust the gap using spacer (Part No.
method. Install resistor and condenser, then rotate 26755AA000).
wheel about 2.75 km/h (2 MPH) or equivalent.
NOTE:
Regarding terminal No., please refer to item 1.
ABS SENSOR.
B4M0118B
ABS-21
墌 00.5.31/68j/4abs 墍
FRONT TONE WHEEL
ABS
6. Front Tone Wheel S401184
Refer to Front Drive Shaft, because front tone

wheel is integrated with front drive shaft.
<Ref. to DS-28 REMOVAL, Front Drive Shaft.>
Refer to Front Drive Shaft, because front tone

wheel is integrated with front drive shaft.
<Ref. to DS-28 INSTALLATION, Front Drive
Shaft.>
Visually check tone wheels teeth (44 pieces) for

cracks or dents. If necessary, replace tone wheel
with a new one.
NOTE:
Replace BJ assembly with new one as a single unit
if there are any defects found on tone wheel is
unitized with BJ assembly of drive shaft.
ABS-22
REAR TONE WHEEL
ABS
7. Rear Tone Wheel S401182
Refer to Rear Drive Shaft, because rear tone

wheel is integrated with rear drive shaft.
<Ref. to DS-33 REMOVAL, Rear Drive Shaft.>
Refer to Rear Drive Shaft, because rear tone

wheel is integrated with rear drive shaft.
<Ref. to DS-33 INSTALLATION, Rear Drive
Shaft.>
Visually check tone wheels teeth (44 pieces) for

cracks or dents. If necessary, replace tone wheel
with a new one.
NOTE:
Replace BJ assembly with new one as a single unit
if there are any defects found on tone wheel is
unitized with BJ assembly of drive shaft.
ABS-23
G SENSOR
ABS
8. G Sensor S401183 B: INSTALLATION S401183A11
1) Disconnect battery ground terminal. NOTE:
Do not install G sensor in the wrong direction.
There is an arrow mark on the sensor showing
which side faces the vehicle front.
G6M0095
2) Remove console cover.

<Ref. to EI-36 Console Box.> B4M1729A
3) Disconnect connector from G sensor.
4) Remove G sensor from body.
CAUTION:
Do not drop or bump G sensor.
B4M1734
ABS-24
G SENSOR
ABS

1 CHECK SUBARU SELECT MONITOR. Do you have SUBARU Go to step 5. Go to step 2.
SELECT MONITOR?
2 CHECK G SENSOR. Is the voltage 2.3±0.2 V Go to step 3. Replace G sen-
1) Turn ignition switch to OFF. when G sensor is horizon- sor.
2) Remove G sensor from vehicle. tal?
3) Connect connector to G sensor.
nector terminals.
Connector & terminal:
(R70) No. 2 (+) — No. 3 (−)
3 CHECK G SENSOR. Is the voltage 3.9±0.2 V Go to step 4. Replace G sen-
Measure voltage between G sensor connector when G sensor is inclined sor.
terminals. forwards to 90°?
(R70) No. 2 (+) — No. 3 (−)
4 CHECK G SENSOR. Is the voltage 0.7±0.2 V G sensor is nor- Replace G sen-
Measure voltage between G sensor connector when G sensor is inclined mal. sor.
terminals. backwards to 90°?
(R70) No. 2 (+) — No. 3 (−)
5 CHECK G SENSOR. Is the indicated reading Go to step 6. Replace G sen-
1) Turn ignition switch to OFF. 2.3±0.2 V when the vehicle sor.
2) Connect select monitor connector to data is in horizontal position?
link connector.
3) Turn select monitor into {BRAKE CON-
TROL} mode.
4) Set the display in the {Current Data Display
& Save} mode.
5) Read the G sensor output voltage.
6 CHECK G SENSOR. Is the indicated reading Go to step 7. Replace G sen-
1) Remove console box. 3.9±0.2 V when G sensor sor.
2) Remove G sensor from vehicle. (Do not is inclined forwards to 90°?
7 CHECK G SENSOR. Is the indicated reading G sensor is nor- Replace G sen-
Read the select monitor display. 0.7±0.2 V when G sensor mal. sor.
is inclined backwards to
90°?
ABS-25
G SENSOR
ABS
MEMO:
ABS-26
GENERAL DESCRIPTION
Brake
Size 14 inch type 15 inch type 16 inch type

Type Disc (Floating type, ventilated)
Effective disc diameter 210 mm (8.27 in) 228 mm (8.98 in) 248 mm (9.76 in)
Front Disc thickness × Outer diam- 24 × 260 mm 24 × 277 mm 24 × 294 mm
disc eter (0.94 × 10.24 in) (0.94 × 10.91 in) (0.94 × 11.57 in)
brake Effective cylinder diameter 57.2 mm (2.252 in) 42.8 mm (1.685 in) × 2
Pad dimensions 112.4 × 44.3 × 11.0 mm 112.3 × 50.0 × 11.0 mm
(length × width × thickness) (4.425 × 1.744 × 0.433 in) (4.421 × 1.969 × 0.433 in)
Clearance adjustment Automatic adjustment
Type — Disc (Floating type)
Effective disc diameter — 254 mm (10.0 in)
Disc thickness × Outer diam- 10 × 290 mm
Rear —
eter (0.39 × 11.42 in)
disc
Effective cylinder diameter — 38.1 mm (1.500 in)
brake
Pad dimensions 82.4 × 33.7 × 9.0 mm
—
(length × width × thickness) (3.244 × 1.327 × 0.354 in)
Clearance adjustment — Automatic adjustment
Drum
Type — —
(Leading-Trailing type)
Rear Effective drum diameter 228.6 mm (9 in) — —
drum Effective cylinder diameter 20.6 mm (0.811 in) — —
brake Lining dimensions 218.8 × 35.0 × 4.1 mm
— —
(length × width × thickness) (8.61 × 1.378 × 0.161 in)
Clearance adjustment Automatic adjustment — —
Type Tandem
Master Effective diameter 25.4 mm (1 in) 26.99 mm (1-1/16 in)
cylinder Reservoir type Sealed type
Brake fluid reservoir capacity 205 cm3 (12.51 cu in)
Type Vacuum suspended
Brake
booster 180 + 205 mm 205 + 230 mm
Effective diameter
(7.09 + 8.07 in) (8.07 + 9.06 in)
Propor- 3,678 kPa 2,942 kPa 3,678 kPa
Split point
tioning (37.5 kg/cm2, 533 psi) (30 kg/cm2, 427 psi) (37.5 kg/cm2, 533 psi)
valve Reducing ratio 0.3
Brake line Dual circuit system
Brake fluid
CAUTION:
쐌 Avoid mixing brake fluid of differ-
ent brands to prevent the fluid perfor-
mance from degrading.
쐌 When brake fluid is supplemented, FMVSS No. 116, DOT3 or DOT4
be careful not to allow any dust into
the reservoir.
쐌 Use fresh DOT3 or 4 brake fluid
when replacing or refilling the fluid.
NOTE:
Refer to “PB section” for parking brake SPECIFICATIONS.
BR-2
墌 00.5.31/68j/4br 墍
GENERAL DESCRIPTION
Brake
ITEM STANDARD SERVICE LIMIT

Pad thickness
17 mm (0.67 in) 7.5 mm (0.295 in)
(including back metal)
Front brake
Disc thickness 24 mm (0.94 in) 22 mm (0.87 in)
Disc runout — 0.075 mm (0.0030 in)
Pad thickness
14 mm (0.55 in) 6.5 mm (0.256 in)
(including back metal)
Rear brake (Disc type)
Disc thickness 10 mm (0.39 in) 8.5 mm (0.335 in)
Disc runout — 0.075 mm (0.0030 in)
Inside diameter 228.6 mm (9 in) 230.6 mm (9.08 in)
Rear brake (Drum type)
Lining thickness 4.1 mm (0.161 in) 1.5 mm (0.059 in)
Inside diameter 170 mm (6.69 in) 171 mm (6.73 in)
Rear brake (Disc type parking)
Lining thickness 3.2 mm (0.126 in) 1.5 mm (0.059 in)
Parking brake Lever stroke 7 to 8 notches/196 N (20 kg, 44 lb)
Brake pedal Fluid pressure

force 14 inch type 15 inch type 16 inch type
147 N 785 kPa 686 kPa
Brake fluid pressure (8 kg/cm2, 114 psi)
(15 kg, 33 lb) (7 kg/cm2, 100 psi)
without engine run-
ning 294 N 1,961 kPa 1,765 kPa
(30 kg, 66 lb) (20 kg/cm2, 284 psi) (18 kg/cm2, 256 psi)
Brake
booster Brake fluid pressure 147 N 6,375 kPa 5,688 kPa
with engine running (15 kg, 33 lb) (65 kg/cm2, 924 psi) (58 kg/cm2, 825 psi)
and vacuum at 66.7
kPa (500 mmHg, 294 N 9,121 kPa 9,905 kPa
19.69 inHg) (30 kg, 66 lb) (93 kg/cm2, 1,322 psi) (101 kg/cm2, 1,436 psi)
1 — 3 mm (0.04 — 0.12 in)

Brake pedal Free play
[Depress brake pedal pad with a force of less than 10 N (1 kg, 2 lb).]
BR-3
墌 00.5.31/68j/4br 墍
GENERAL DESCRIPTION
Brake
1. 14 inch TYPE S405001A0501
B4M1208D
(1) Caliper body (9) Support Tightening torque: N·m (kgf-m, ft-lb)
(2) Air bleeder screw (10) Pad clip
T1: 8 (0.8, 5.8)
(3) Guide pin (Green) (11) Outer shim
T2: 18 (1.8, 13.0)
(4) Pin boot (12) Inner shim
T3: 37 (3.8, 27.5)
(5) Piston seal (13) Pad (Outside)
(6) Piston (14) Pad (Inside) T4: 78 (8.0, 58)
(7) Piston boot (15) Disc rotor
(8) Lock pin (Yellow) (16) Disc cover
BR-4
墌 00.5.31/68j/4br 墍
GENERAL DESCRIPTION
Brake
2. 15 inch AND 16 inch TYPE S405001A0502
B4M1151C
(1) Caliper body (9) Lock pin (Yellow) (17) Disc cover
(2) Air bleeder screw (10) Support
(3) Guide pin (Green) (11) Pad clip Tightening torque: N·m (kgf-m, ft-lb)
(4) Pin boot (12) Outer shim T1: 8 (0.8, 5.8)
(5) Piston seal (13) Inner shim T2: 18 (1.8, 13.0)
(6) Piston (14) Pad (Outside) T3: 39 (4.0, 28.9)
(7) Piston boot (15) Pad (Inside) T4: 78 (8.0, 58)
(8) Boot ring (16) Disc rotor
BR-5
墌 00.5.31/68j/4br 墍
GENERAL DESCRIPTION
Brake
3. REAR DISC BRAKE S405001A0503
B4M1835A
(1) Caliper body (14) Shim (27) Primary shoe return spring
(2) Air bleeder screw (15) Shoe hold-down pin (28) Adjusting spring
(3) Guide pin (Green) (16) Cover (29) Adjuster
(4) Pin boot (17) Back plate (30) Shoe hold-down cup
(5) Piston seal (18) Retainer (31) Shoe hold-down spring
(6) Piston (19) Spring washer (32) Disc rotor
(7) Piston boot (20) Parking brake lever
(8) Boot ring (21) Parking brake shoe (Secondary) Tightening torque: N·m (kgf-m, ft-lb)
(9) Lock pin (Yellow) (22) Parking brake shoe (Primary) T1: 8 (0.8, 5.8)
(10) Support (23) Strut T2: 39 (4.0, 28.9)
(11) Pad clip (24) Strut shoe spring T3: 52 (5.3, 38.3)
(12) Inner pad (25) Shoe guide plate
(13) Outer pad (26) Secondary shoe return spring
BR-6
墌 00.5.31/68j/4br 墍
GENERAL DESCRIPTION
Brake
4. REAR DRUM BRAKE S405001A0504
B4M1836A
(1) Air bleeder cap (11) Upper shoe return spring (21) Lower shoe return spring
(2) Air bleeder screw (12) Retainer (22) Adjusting spring
(3) Boot (13) Washer (23) Drum
(4) Piston (14) Parking brake lever (24) Plug
(5) Cup (15) Brake shoe (Trailing)
(6) Spring (16) Brake shoe (Leading) Tightening torque: N·m (kgf-m, ft-lb)
(7) Wheel cylinder body (17) Shoe hold-down spring T1: 8 (0.8, 5.8)
(8) Pin (18) Cup T2: 10 (1.0, 7.2)
(9) Plug (19) Adjusting lever
(10) Back plate (20) Adjuster
BR-7
墌 00.5.31/68j/4br 墍
GENERAL DESCRIPTION
Brake
5. MASTER CYLINDER S405001A0505
쐌 Without VDC model
S4M0325B
(1) Cap (6) Secondary piston Tightening torque: N·m (kgf-m, ft-lb)
(2) Filter (7) Cylinder body
T: 14 (1.4, 10.1)
(3) Reservoir tank (8) Cylinder pin (With ABS)
(4) Piston retainer (9) Seal
(5) Primary piston (10) Pin
BR-8
墌 00.5.31/68j/4br 墍
GENERAL DESCRIPTION
Brake
쐌 With VDC model
B4M2286A
(1) Cap (6) Secondary piston Tightening torque: N·m (kgf-m, ft-lb)
(2) Filter (7) Cylinder body
T: 14 (1.4, 10.1)
(3) Reservoir tank (8) Cylinder pin
(4) C-ring (9) Seal
(5) Primary piston (10) Pin
BR-9
墌 00.5.31/68j/4br 墍
GENERAL DESCRIPTION
Brake
6. BRAKE PIPES AND HOSE S405001A0506
B4M2344A
(1) Front brake pipe assembly (9) Rear brake pipe LH (Disc brake (14) Rear brake pipe RH (Disc brake
(2) Proportioning valve model) model)
(3) Front brake hose RH (10) Rear brake pipe LH (Drum brake (15) Rear brake hose rear RH
(4) Front brake hose LH model)
(5) Center brake pipe assembly (11) Rear brake hose rear LH Tightening torque: N·m (kgf-m, ft-lb)
(6) Two-way connector (12) Rear brake hose RH T1: 15 (1.5, 10.8)
(7) Rear brake pipe assembly (13) Rear brake pipe RH (Drum T2: 18 (1.8, 13.0)
(8) Rear brake hose LH brake model)
BR-10
墌 00.5.31/68j/4br 墍
GENERAL DESCRIPTION
Brake
7. BRAKE BOOSTER S405001A0507
B4M1974A
(1) Push rod (5) Filter (9) Valve body

(2) Return spring (6) Silencer (10) Plunger valve
(3) Reaction disc (7) Operating rod (11) Diaphragm plate
(4) Key (8) Poppet valve (12) Valve return spring
BR-11
墌 00.5.31/68j/4br 墍
GENERAL DESCRIPTION
Brake
8. BRAKE PEDAL FOR MT MODEL S405001A0508
B4M2345A
(1) Stopper (13) Assist rod A (24) Clutch switch (With cruise con-
(2) Bushing (14) Clip trol)
(3) Spring pin (15) Assist spring (25) Stop light switch
(4) Snap pin (16) Assist bushing (26) Pedal bracket
(5) Brake pedal pad (17) Assist rod B (27) Clutch master cylinder bracket
(6) Brake pedal (18) Spring S (28) Lever
(7) Clevis pin (19) Rod S
(8) Brake pedal spring (20) Bushing S Tightening torque: N·m (kgf-m, ft-lb)
(9) Clutch pedal pad (21) O-ring T1: 8 (0.8, 5.8)
(10) Clutch pedal (22) Clip T2: 18 (1.8, 13.0)
(11) Bushing C (23) Clutch switch (Starter interlock)
(12) Clutch clevis pin
BR-12
墌 00.5.31/68j/4br 墍
GENERAL DESCRIPTION
Brake
9. BRAKE PEDAL FOR AT MODEL S405001A0509
B4M2346A
(1) Stopper (7) Snap pin Tightening torque: N·m (kgf-m, ft-lb)
(2) Bushing (8) Brake pedal pad
T1: 8 (0.8, 5.8)
(3) Plug (9) Brake pedal
T2: 18 (1.8, 13.0)
(4) Pedal bracket (10) Clevis pin
T3: 29 (3.0, 21.7)
(5) Stop light switch (11) Brake spacer
(6) Spacer (12) Brake pedal spring
BR-13
墌 00.5.31/68j/4br 墍
GENERAL DESCRIPTION
Brake

tion.
tect them from dust or dirt
ment.
쐌 Use SUBARU genuine grease etc. or the
equivalent. Do not mix grease etc. with that of
another grade or from other manufacturers.
fied points.
쐌 Apply grease onto sliding or revolution surfaces
쐌 Before installing O-rings or snap rings, apply
sufficient amount of grease to avoid damage and
deformation
쐌 Before securing a part on a vice, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vice.
쐌 Do not put fluid on body. If the body is tainted,
wash away with water.
BR-14
墌 00.5.31/68j/4br 墍
GENERAL DESCRIPTION
Brake

26699AE000 WHEEL CYLINDER Used for installing cup onto wheel cylinder pis-
13/16″ ADAPTER ton (Size 13/16 in).
B4M2406
TOOL NAME REMARKS

SNAP RING PLIERS Used for removing and installing snap ring.
BR-15
墌 00.5.31/68j/4br 墍
FRONT BRAKE PAD
Brake
2. Front Brake Pad S405178 B: INSTALLATION S405178A11
1) Apply thin coat of Molykote AS880N (Part No.
26298AC000) to the frictional portion between pad
1) Remove lock pin. and pad clip.
2) Raise caliper body. 2) Apply thin coat of Molykote AS880N (Part No.
3) Remove pad. 26298AC000) to the frictional portion between pad
and pad inner shim.
B4M1167
B4M1169A
NOTE:
If brake pad is difficult to remove, proceed as fol- 3) Install pads on support.
lows: 4) Install caliper body on support.
(1) Remove caliper body and fasten it provi- Tightening torque:
sionally to coil spring. 39 N·m (4.0 kgf-m, 28.9 ft-lb)
(2) Remove support. NOTE:
(3) Place a support in a vise between wooden If it is difficult to push piston during pad
blocks. replacement, loosen air bleeder to facilitate work.
B4M2230B
(1) Support
(2) Wooden blocks
(4) Attach a rod of less than 12 mm (0.47 in)

dia. to the shaded area of brake pad, and strike
the rod with a hammer to drive brake pad out of
place.
B4M2231
BR-16
墌 00.5.31/68j/4br 墍
FRONT BRAKE PAD
Brake
Check pad thickness A.
B4M1168A
Pad thickness Standard value 17 mm (0.67 in)

(including back
metal) Wear limit 7.5 mm (0.295 in)
CAUTION:
쐌 Always replace the pads for both the left and
right wheels at the same time. Also replace pad
clips if they are twisted or worn.
쐌 A wear indicator is provided on the inner
disc brake pad. If the pad wears down to such
an extent that the end of the wear indicator
contacts the disc rotor, a squeaking sound is
produced as the wheel rotates. If this sound is
heard, replace the pad.
쐌 Replace pad if there is oil or grease on it.
BR-17
墌 00.5.31/68j/4br 墍
FRONT DISC ROTOR
Brake
3. Front Disc Rotor S405173 B: INSTALLATION S405173A11
1) Install the disc rotor.
2) Install the support.
1) Remove the brake pad.
<Ref. to BR-16 REMOVAL, Front Brake Pad.> Tightening torque:
2) Remove the support. 78 N·m (8 kgf-m, 58 ft-lb)
NOTE: CAUTION:
Remove support only when replacing it or the rotor. 쐌 Always replace the pads for both the left and
If need not be removed when servicing caliper right wheels at the same time. Also replace pad
body assembly. clips if they are twisted or worn.
쐌 When replacing the pad, replace pads of the
left and right wheels at the same time.
3) Install the pads and the caliper body.
<Ref. to BR-21 INSTALLATION, Front Disc Brake
B4M1192
Assembly.>
3) Remove the disc rotor.

NOTE:
If disc rotor seizes up within the hub, drive disc
rotor out by installing an 8-mm bolt in holes B on
the rotor.
G4M0365
4) Clean mud and foreign particles from caliper

body assembly and support.
BR-18
墌 00.5.31/68j/4br 墍
FRONT DISC ROTOR
Brake
1) Install disc rotor by tightening the five wheel

nuts.
2) Set a dial gauge on the disc rotor. Turn disc
rotor to check runout.
B4M2353
NOTE:
Make sure that dial gauge is set 5 mm (0.20 in)
inward of rotor outer perimeter.
Disc rotor runout limit:
0.075 mm (0.0030 in)
3) Measure disc rotor thickness.
G4M0365
NOTE:
Make sure that micrometer is set 5 mm (0.20 in)
inward of rotor outer perimeter.
Standard Service limit Disc outer
value dia.
24.0 mm 22.0 mm 260 mm
14″
(0.945 in) (0.866 in) (10.24 in)
Disc rotor 24.0 mm 22.0 mm 277 mm
15″
thickness A (0.945 in) (0.866 in) (10.91 in)
24.0 mm 22.0 mm 294 mm
16″
(0.945 in) (0.866 in) (11.57 in)
BR-19
墌 00.5.31/68j/4br 墍
FRONT DISC BRAKE ASSEMBLY
Brake
4. Front Disc Brake Assembly 5) Remove disc rotor from hub.

S405176 NOTE:
If disc rotor seizes up within hub, drive disc rotor
out by installing an 8-mm bolt in holes B on the
1) Remove union bolt and disconnect brake hose rotor.
from caliper body assembly.
G4M0365
B4M1844 6) Clean mud and foreign particles from caliper

2) Remove bolt securing lock pin to caliper body.
B4M1845
3) Raise caliper body and move it toward vehicle

center to separate it from support.
4) Remove support from housing.
NOTE:
Remove support only when replacing it or the rotor.
It need not be removed when servicing caliper
body assembly.
B4M1192
BR-20
墌 00.5.31/68j/4br 墍
Brake
B: INSTALLATION S405176A11 C: DISASSEMBLY S405176A06
1) Install disc rotor on hub. 1. 14 inch TYPE S405176A0602
2) Install support on housing.

Tightening torque: body assembly and support.
78 N·m (8 kgf-m, 58 ft-lb)
CAUTION:
CAUTION: Be careful not to allow foreign particles to enter
쐌 Always replace the pads for both the left and inlet (at brake hose connector).
clips if they are twisted or worn. 2) Gradually supply compressed air via caliper
쐌 A wear indicator is provided on the inner body brake hose to force piston out.
disc brake pad. If the pad wears down to such CAUTION:
an extent that the end of the wear indicator 쐌 Place a wooden block as shown in Figure to
contacts the disc rotor, a squeaking sound is prevent damage to piston.
produced as the wheel rotates. If this sound is 쐌 Do not apply excessively high-pressure.
쐌 When replacing the pads, replace pads of the
right and left wheels at the same time.
and pad clip.
and inner shim.
B4M1174C
(1) Place a 30 mm (1.18 in) wide wooden block here.
3) Remove piston boot.

4) Remove piston seal from caliper body cylinder.
B4M1169A
5) Install pads on support.

6) Install caliper body on support.
Tightening torque:
14 inch type
37 N·m (3.8 kgf-m, 27.5 ft-lb)
Except 14 inch type B4M1173
39 N·m (4.0 kgf-m, 28.9 ft-lb)
5) Remove guide pin and boot from caliper body.
7) Connect brake hose.
Tightening torque: 2. 15 inch AND 16 inch TYPE S405176A0603
18 N·m (1.8 kgf-m, 13.0 ft-lb) 1) Clean mud and foreign particles from caliper
CAUTION: body assembly and support.
Replace brake hose gaskets with new ones. CAUTION:
8) Bleed air from brake system. Be careful not to allow foreign particles to enter
inlet (at brake hose connector).
BR-21
墌 00.5.31/68j/4br 墍
Brake
2) Using a standard screwdriver, remove boot ring D: ASSEMBLY S405176A02

from piston.
1. 14 inch TYPE S405176A0202
1) Clean caliper body interior using brake fluid.

2) Apply a coat of brake fluid to piston seal and fit
piston seal in groove on caliper body.
3) Apply a coat of brake fluid to the entire inner
surface of cylinder and outer surface of piston.
4) Apply a coat of specified grease to boot and fit
in groove on ends of cylinder and install piston boot
onto cylinder.
B4M1164C
Grease:
NIGLUBE RX-2 (Part No. 003606000)
(1) Boot ring
5) Insert piston into cylinder.
3) Remove boot from piston end. CAUTION:
4) Gradually supply compressed air via caliper Do not force piston into cylinder.
body brake hose to force piston out.
CAUTION:
Place a wooden block as shown in Figure to
prevent damage to piston.
B4M1175B
(1) Piston
(2) Piston boot
B4M1165C
6) Position boot in grooves on cylinder and piston.
5) Remove piston seal from caliper body cylinder.
B4M0072B
(1) Piston
B4M1172B (2) Piston boot
(3) Caliper body
(1) Piston pin (4) Piston seal
6) Remove lock pin boot and guide pin boot.
BR-22
墌 00.5.31/68j/4br 墍
Brake
7) Apply a coat of specified grease to lock pin and 5) Apply a coat of specified grease to boot and fit
guide pin outer surface, cylinder inner surface, and in groove on ends of cylinder and piston.
boot grooves. Grease:
Grease: NIGLUBE RX-2 (Part No. 003606000)
NIGLUBE RX-2 (Part No. 003606000) To facilitate installation, fit boot starting with piston
8) Install lock and guide pin boot on support. end.
B4M1176B S4M0448A
(1) Pin boot (1) Piston boot

(2) Lock pin or guide pin (2) Boot ring
(3) Apply grease. (3) Piston seal
(4) Caliper body
2. 15 inch AND 16 inch TYPE S405176A0203
6) Position boot in grooves on cylinder and piston.
1) Clean caliper body interior using brake fluid. 7) Install boot ring. Be careful not scratch boot.
2) Apply a coat of brake fluid to piston seal and fit 8) Apply a coat of specified grease to lock pin and
piston seal in groove on caliper body. guide pin, outer surface, cylinder inner surface,
3) Apply a coat of brake fluid to the entire inner and boot grooves.
surface of cylinder and outer surface of piston. Grease:
4) Insert piston into cylinder. NIGLUBE RX-2 (Part No. 003606000)
CAUTION:
Do not force piston into cylinder.
B4M1176B
(1) Pin boot

B4M0771 (2) Lock pin or guide pin
(3) Apply grease.
9) Install lock pin boot and guide pin boot on sup-

port.
BR-23
墌 00.5.31/68j/4br 墍
Brake
1) Repair or replace faulty parts.

2) Check caliper body and piston for uneven wear,
damage or rust.
3) Check rubber parts for damage or deterioration.
BR-24
墌 00.5.31/68j/4br 墍
REAR BRAKE PAD
Brake
5. Rear Brake Pad S405175 B: INSTALLATION S405175A11
1) Remove lock pin. and pad clip.
2) Install pad on support.
3) Install caliper body on support.
Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
NOTE:
If it is difficult to push piston during pad
replacement, loosen air bleeder to facilitate work.
B4M1769
2) Raise caliper body.

3) Remove pad from support.
NOTE:
If brake pad is difficult to remove, use the same
procedure as for front disc brake pad.
<Ref. to BR-16 REMOVAL, Front Brake Pad.>
B4M1770
BR-25
REAR BRAKE PAD
Brake
Check pad thickness (including back metal).

Pad thickness: A
Standard value
14.0 mm (0.551 in)
Wear limit
6.5 mm (0.256 in)
S4M0187A
CAUTION:
쐌 Always replace the pads for both the left and
clips if they are twisted or worn.
쐌 Replace pad if there is oil or grease on it.
BR-26
REAR DISC BRAKE ASSEMBLY
Brake
6. Rear Disc Brake Assembly B: INSTALLATION S405172A11
S405172
1) Install disc rotor on hub.
2) Install support on back plate.
1) Lift-up vehicle and remove wheels. Tightening torque:

2) Disconnect brake hose from caliper body 78 N·m (8.0 kgf-m, 58 ft-lb)
assembly. CAUTION:
CAUTION: 쐌 Always replace the pads for both the left and
Do not allow brake fluid to come in contact with right wheels at the same time. Also replace pad
vehicle body; wipe off completely if spilled. clips if they are twisted or worn.
쐌 Replace pads if there is oil or grease on
them.
B4M1772
and pad clip.
4) Install pads on support.
3) Remove lock pin. 5) Install caliper body on support.
Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
6) Connect brake hose.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
CAUTION:
쐌 The brake hose must be connected without
any twist.
쐌 Replace brake hose gaskets with new ones.
B4M1769
7) Bleed air from brake system.
4) Raise caliper body and move it toward vehicle
center to separate it from support.
5) Remove support from back plate.
NOTE:
Remove support only when replacing it or the rotor.
It need not be removed when servicing caliper
body assembly.
CAUTION:
Be careful not to allow foreign particles to enter
inlet (at brake hose connector).
BR-27
墌 00.5.31/68j/4br 墍
Brake
C: DISASSEMBLY S405172A06 4) Remove piston seal from caliper body cylinder.

1) Remove the boot ring.
S4M0122
S4M0120B 5) Remove lock pin sleeve and boot from caliper

body.
(1) Boot ring 6) Remove guide pin boot.
2) Remove the piston boot.
S4M0121
3) Gradually supply compressed air via inlet of

caliper body to force piston out.
CAUTION:
쐌 Place a wooden block as shown in Figure to
prevent damage to piston.
쐌 Do not apply excessively high-pressure.
B4M1174C
BR-28
墌 00.5.31/68j/4br 墍
Brake
D: ASSEMBLY S405172A02 E: INSPECTION S405172A10
1) Clean caliper body interior using brake fluid. 1) Repair or replace faulty parts.
2) Apply a coat of brake fluid to piston seal and fit 2) Check caliper body and piston for uneven wear,
piston seal in groove on caliper body. damage or rust.
3) Apply a coat of brake fluid to the entire inner 3) Check rubber parts for damage or deterioration.
surface of cylinder and outer surface of piston.
4) Insert piston into cylinder.
CAUTION:
Do not force piston into cylinder.
5) Apply a coat of specified grease to boot and fit
in groove on ends of cylinder and piston.
Grease:
6) Install the piston boot to the caliper body, and
attach boot ring.
S4M0448A
(1) Piston boot

(2) Boot ring
(3) Piston seal
(4) Caliper body
7) Apply a coat of specified grease to guide pin,

outer surface, sleeve outer surface, cylinder inner
surface, and boot grooves.
Grease:
B4M1176B
(1) Pin boot

(2) Lock pin or guide pin
(3) Apply grease.
8) Install guide pin boot on caliper body.

9) Install lock pin boot on caliper body and insert
lock pin sleeve into place.
BR-29
墌 00.5.31/68j/4br 墍
REAR DRUM BRAKE SHOE
Brake
7. Rear Drum Brake Shoe S405174

6) Disconnect lower shoe return spring from
shoes.
1) Loosen wheel nuts, jack-up vehicle, support it

with rigid racks, and remove wheel.
2) Release parking brake.
3) Remove brake drum from brake assembly.
NOTE:
쐌 If it is difficult to remove brake drum, remove
adjusting hole cover from drum, and then turn
adjuster assembly pawls using a slot-type screw-
driver until brake shoe separates from the drum. S4M0452
7) Remove shoes one by one from back plate with

adjuster.
CAUTION:
Be careful not to bend parking brake cable
excessively when removing brake shoes.
B4M1766
쐌 If brake drum is difficult to remove, drive it out by

installing an 8-mm bolt into bolt hole in brake drum.
B4M1838
8) Disconnect parking brake cable from parking

lever.
B4M1707
4) Hold hold-down pin by securing rear of back

plate with your hand.
B4M1839B
(1) Parking brake cable
S4M0451A
(1) Hold-down cup

(2) Hold-down pin
5) Disconnect hold-down cup from hold-down pin

by rotating hold-down cup.
BR-30
墌 00.5.31/68j/4br 墍
Brake
B: INSTALLATION S405174A11 6) While positioning shoes (one at a time) in

groove on wheel cylinder, secure shoes.
1) Clean back plate and wheel cylinder.
2) Apply grease to portions indicated by arrows in
Figure.
Brake grease:
Dow Corning Molykote No. 7439 (Part No.
725191460)
B4M1838
7) Fix shoes by connecting hold-down cup to hold-

down pin.
8) Connect lower shoe return spring.
9) Set the outside diameter of brake shoes less
than 0.5 to 0.8 mm (0.020 to 0.031 in) in compari-
G4M0407 son with the inside diameter of brake drum.
10) Match the holes on hub and drum and install
3) Apply grease to adjusting screw and both ends drum on hub.
of adjuster.
Brake grease:
725191460)
B4M1978
S4M0457B
4) Connect upper shoe return spring to shoes.

5) Connect parking brake cable to parking lever.
B4M1839B
BR-31
墌 00.5.31/68j/4br 墍
Brake
1) Measure the lining thickness.

Lining thickness:
Standard 4.1 mm (0.161 in)
Service limit 1.5 mm (0.059 in)
2) If the deformation or wear of back plate, shoe,
etc. are notable, replace them.
3) When the shoe return spring tension is exces-
sively weakened, replace it, taking care to identify
upper and lower springs.
BR-32
墌 00.5.31/68j/4br 墍
REAR DRUM BRAKE DRUM
Brake
8. Rear Drum Brake Drum S405180 B: INSTALLATION S405180A11
1) Loosen wheel nuts, jack-up vehicle, support it son with the inside diameter of brake drum.
with rigid racks, and remove wheel. 2) Match the holes on hub and drum and install
2) Release parking brake. drum on hub.
NOTE:
driver until brake shoe separates from the drum.
B4M1978
B4M1766

B4M1707
BR-33
墌 00.5.31/68j/4br 墍
REAR DRUM BRAKE DRUM
Brake
1) If the inside surface of brake drum is streaked,

correct the surface. And, if it is unevenly worn,
taperingly streaked, or the outside surface of brake
drum is damaged, correct or replace it.
2) Measure the drum inner diameter.
Drum inner diameter: “L”
Standard 228.6 mm (9 in)
G4M0403
BR-34
墌 00.5.31/68j/4br 墍
REAR DRUM BRAKE ASSEMBLY
Brake
9. Rear Drum Brake Assembly 5) Disconnect hold-down cup from hold-down pin
S405179
by rotating hold-down cup.
6) Disconnect lower shoe return spring from
A: REMOVAL S405179A18 shoes.
1) Loosen wheel nuts, jack-up vehicle, support it
with rigid racks, and remove wheel.
2) Release parking brake.
NOTE:
driver until brake shoe separates from the drum.
S4M0452
7) Remove shoes one by one from back plate with

adjuster.
CAUTION:
Be careful not to bend parking brake cable
excessively when removing brake shoes.
B4M1766

B4M1838
8) Disconnect parking brake cable from parking

lever.
B4M1707
4) Hold hold-down pin by securing rear of back

plate with your hand.
B4M1839B
S4M0451A
(1) Hod-down cup

(2) Hold-down pin
BR-35
墌 00.5.31/68j/4br 墍
Brake
9) Unscrew the brake pipe flare nut and discon- B: INSTALLATION S405179A11
nect brake pipe.
1) Install wheel cylinder on back plate, and tighten
bolts.
Tightening torque:
10 N·m (1.0 kgf-m, 7.2 ft-lb)
B4M1773
10) Remove hub.

<Ref. to DS-22 REMOVAL, Hub Unit Bearing.>
11) Remove brake assembly.
12) Remove the bolts installing wheel cylinder on S4M0454
back plate, and remove it.

2) Clean back plate and wheel cylinder.
3) Apply grease to portions indicated by arrows in
Figure.
Brake grease:
725191460)
S4M0454
G4M0407
4) Apply grease to adjusting screw and both ends

of adjuster.
Brake grease:
725191460)
S4M0457B
5) Connect upper shoe return spring to shoes.
BR-36
墌 00.5.31/68j/4br 墍
Brake
6) Connect parking brake cable to parking lever. 12) Install hub.

<Ref. to DS-23 INSTALLATION, Hub Unit Bear-
ing.>
13) Connect brake pipe, and tighten brake pipe
flange nut.
Tightening torque:
15 N·m (1.5 kgf-m, 10.8 ft-lb)
B4M1839B
7) While positioning shoes (one at a time) in

groove on wheel cylinder, secure shoes.
B4M1773
14) Install shoes.

<Ref. to BR-31 INSTALLATION, Rear Drum Brake
Shoe.>
15) Install brake drum.
16) After installing brake assembly, bleed air from
brake line.
B4M1838
8) Fix shoes by connecting hold-down cup to hold-

down pin.
9) Connect lower shoe return spring.
son with the inside diameter of brake drum.
11) Match the holes on hub and drum and install
drum on hub.
B4M1978
BR-37
墌 00.5.31/68j/4br 墍
Brake
C: DISASSEMBLY S405179A06 D: ASSEMBLY S405179A02
1) Remove right and left dust boots from wheel 1) Clean all parts in brake fluid. Check and replace
cylinder. faulty parts.
쐌 Cup and boot for damage or fatigue
쐌 Cylinder, piston and spring or damage or rust
formation
2) Assembly is the reverse order of disassembly.
(1) When installing the cup, use ST, apply
brake fluid to the frictional surface for smooth
installation and pay attention to cup direction.
(2) STs are available in different sizes.
CAUTION:
쐌 When replacing the repair kit, make sure that
B4M1126B
the sizes of cylinder and cup are the same as
(1) Bleeder cap those which were replaced.
(2) Bleeder screw 쐌 Use only the tool of the correct size.
(3) Spring
(4) Cylinder ST: ADAPTER
(5) Cup Applicable size Part No.
(6) Piston 20.6 mm (13/16 in) 26699AE000
(7) Boot
CAUTION:
2) Remove piston, cup, spring and air bleeder While assembling, be careful to prevent any
screw and cap. metal chip, dust or dirt from entering the wheel
cylinder.
S4M0455A
(1) Cup
(2) Piston
BR-38
墌 00.5.31/68j/4br 墍
Brake
3) Apply rubber grease to the boot inside as E: INSPECTION S405179A10

shown in Figure.
1) If the inside surface of brake drum is streaked,
CAUTION: correct the surface. And, if it is unevenly worn,
Never use brake grease. taperingly streaked, or the outside surface of brake
Grease: drum is damaged, correct or replace it.
NIGLUBE RX-2 (Part No. 003606000) 2) Measure the drum inner diameter.
Drum inner diameter: “L”
Standard 228.6 mm (9 in)
S4M0456B
G4M0403
3) Measure the lining thickness.

Lining thickness:
etc. are notable, replace them.
5) When the shoe return spring tension is exces-
upper and lower springs.
BR-39
墌 00.5.31/68j/4br 墍
MASTER CYLINDER
Brake
10. Master Cylinder S405168 B: INSTALLATION S405168A11
To install the master cylinder to the body, reverse
the sequence of removal procedure.
1) Thoroughly drain brake fluid from reservoir
tank. Tightening torque:
2) Disconnect fluid level indicator harness connec- Master cylinder mounting nut
tor. 14 N·m (1.4 kgf-m, 10.1 ft-lb)
3) Remove brake pipes from master cylinder. Piping flare nut
4) Remove master cylinder mounting nuts, and 15 N·m (1.5 kgf-m, 10.8 ft-lb)
take out master cylinder from brake booster. CAUTION:
CAUTION: Be sure to use recommended brake fluid.
Be extremely careful not to spill brake fluid.
Brake fluid spilt on the vehicle body will harm
the painted surface; wipe it off quickly if spilt.
BR-40
墌 00.5.31/68j/4br 墍
MASTER CYLINDER
Brake
C: DISASSEMBLY S405168A06 4) Using pliers, remove C-ring. (With VDC)

1. PRECAUTIONS FOR DISASSEMBLING NOTE:
S405168A0602
Piston may jump out from master cylinder.
1) Remove mud and dirt from the surface of brake

master cylinder.
2) Prepare tools necessary for disassembly
operation, and arrange them neatly on work bench.
3) Clean work bench.
2. DISASSEMBLING PROCEDURE S405168A0603
1) Remove pin with drift pin which secures reserve

tank to master cylinder.
2) Remove cylinder pin with magnetic pick-up tool B4M2287
while pushing in primary piston.
5) Extract primary piston assembly and secondary
piston assembly.
CAUTION:
쐌 Do not disassemble the piston assembly;
otherwise, the spring set value may be
changed.
쐌 Use brake fluid or methanol to wash inside
wall of cylinder, pistons and piston cups. Be
careful not to damage parts when washing. If
methanol is used for washing, do not dip rub-
ber parts, such as piston cups, in it for more
S4M0123B
than 30 seconds; otherwise, they may become
(1) Cylinder pin swelled.
3) Pry up the pawl and remove the piston retainer.

(Without VDC)
NOTE:
Piston may jump out from master cylinder.
S4M0124
BR-41
墌 00.5.31/68j/4br 墍
MASTER CYLINDER
Brake
D: ASSEMBLY S405168A02 5) Install seal to reservoir tank.

1. PRECAUTIONS FOR ASSEMBLING
S405168A0201
1) When assembling, be sure to use recom-

mended brake fluid.
2) Ensure that the inside wall of cylinder, pistons,
and piston cups are free from dirt when assem-
bling.
3) Be extremely careful not to damage, scratch, or
dent cylinder inside wall, pistons, and piston cups.
4) Do not drop parts. Never attempt to use any B4M1450C
part that has been dropped accidentally. (1) Seal

2. ASSEMBLING PROCEDURE S405168A0202
6) Install pin with drift pins which secures reservoir
1) Assembling piston assembly: tank to master cylinder.
Apply recommended brake fluid to inside wall of
cylinder, and to outer surface of piston assembly,
and install piston assemblies carefully into cylinder.
2) Assembling cylinder pin:
3) Press the pawl and install the piston retainer
into the master cylinder. (Without VDC)
S4M0124
4) Using pliers, install C-ring in its groove. (With

VDC)
CAUTION:
Make sure to install it firmly to groove.
B4M2287
BR-42
墌 00.5.31/68j/4br 墍
MASTER CYLINDER
Brake
If any damage, deformation, wear, swelling, rust,

and other faults are found on the primary piston
assembly, secondary piston assembly, supply
valve stopper, or gasket, replace the faulty part.
CAUTION:
쐌 The primary and secondary pistons must be
replaced as complete assemblies.
쐌 The service limit of the clearance between
each piston and the master cylinder inner dia.
is 0.11 mm (0.0043 in).
쐌 When handling parts, be extremely careful
not to damage or scratch the parts, or let any
foreign matter get on them.
BR-43
墌 00.5.31/68j/4br 墍
BRAKE BOOSTER
Brake
11. Brake Booster S405166

CAUTION:
If external force is applied from above when
A: REMOVAL S405166A18 brake booster is placed in this position, the
resin portion as indicated by “P”, may be dam-
1) Remove or disconnect the following parts at aged.
engine compartment.
(1) Disconnect connector for brake fluid level
indicator.
(2) Remove brake pipes from master cylinder.
(3) Remove master cylinder installing nuts.
(4) Disconnect vacuum hose from brake
booster.
2) Remove the following parts from the pedal
bracket.
(1) Snap pin and clevis pin
(2) Four brake booster installing nuts S4M0464A
3) Remove brake booster while shunning brake
pipes. (1) Force
NOTE:
쐌 Be careful not to drop brake booster. Brake
booster should be discarded if it has been
dropped.
쐌 Use special care when handling operating rod.
If excessive force is applied to operating rod, suf-
ficient to cause a change in the angle in excess of
±3°, it may result in damage to the power piston
cylinder.
쐌 Use care when placing brake booster on the
floor.
쐌 Do not change the push rod length. If it has been
changed, reset the projected length “L” to the stan-
dard length.
Standard:
Without VDC
L = 10 mm (0.39 in)
With VDC
L = 1.8 mm (0.071 in)
G4M0424
BR-44
墌 00.5.31/68j/4br 墍
BRAKE BOOSTER
Brake
B: INSTALLATION S405166A11 7) Adjust operating rod of brake booster.

1) Mount brake booster in position. Standard: L
2) Connect operating rod to brake pedal with cle- 145.3 mm (5.72 in)
vis pin and snap pin. If it is not in specified value, adjust it by adjusting
brake booster operating rod.
B4M0616A
8) Measure the clearance between threaded end

of stop light switch and stopper.
If it is not in specified value, adjust it by adjusting
position of stop light switch.
CAUTION:
Be careful not to rotate stop light switch.
Stop light switch clearance: A
0.3 mm (0.012 in)
B4M0117C
(1) Nuts
(2) Clevis pin
(3) Snap pin
(4) Operating rod
3) Connect vacuum hose to brake booster.
B4M0617H
9) Apply grease to operating rod connecting pin to

prevent it from wearing.
10) Bleed air from brake system.
Tightening torque (Air bleeder screw):
8 N·m (0.8 kgf-m, 5.8 ft-lb)
S4M0125 11) Conduct road tests to ensure brakes do not
drag.
4) Mount master cylinder onto brake booster.
5) Connect brake pipes to master cylinder.
6) Connect electric connector for brake fluid level
indicator.
BR-45
墌 00.5.31/68j/4br 墍
BRAKE BOOSTER
Brake
C: INSPECTION S405166A10 쐌 Operation check

1. OPERATION CHECK (WITHOUT 1) With engine off, depress brake pedal several
GAUGES) S405166A1001 times applying the same pedal force and make
sure that the pedal height does not vary with each
CAUTION: depression of the pedal.
When checking operation, be sure to securely
apply the hand brake.
쐌 Checking without gauges
This method cannot determine the exact portion
which has failed, but it can provide a rough under-
standing of the nature of the failure if checking is
conducted in accordance with the following proce-
dures.
쐌 Air tightness check
S4M0466A
Start engine, and run it for 1 to 2 minutes, then turn
it off. Depress brake pedal several times applying (1) When engine is stopped
the same pedal force as that used in ordinary brak- (2) When engine is started
ing operations. The pedal stroke should be great- 2) With brake pedal depressed, start engine.
est on the 1st depression, and it should become 3) As engine starts, brake pedal should move
smaller with each successive depression. If no slightly toward the floor. If no change occurs in the
change occurs in the pedal height while in a pedal height, brake booster is faulty.
depressed state, brake booster is faulty.
NOTE:
If faulty, check precisely with gauges.
쐌 Loaded air tightness check
Depress brake pedal while engine is running, and
turn off engine while the pedal is still depressed.
Keep the pedal depressed for 30 seconds; if no
change occurs in the pedal height, brake booster
is functioning normally; if the pedal height
increases, it is faulty.
NOTE:
S4M0465A
If faulty, check precisely with gauges.
(1) OK
(2) NOT OK
(3) 1st
(4) 2nd
(5) 3rd
NOTE:
쐌 In the event of defective operation, inspect the
condition of the check valve and vacuum hose.
쐌 Replace them if faulty and conduct the test
again.
쐌 If no improvement is observed, check precisely
with gauges.
BR-46
墌 00.5.31/68j/4br 墍
BRAKE BOOSTER
Brake
2. OPERATION CHECK (WITH GAUGES) 2) Stop engine and watch the gauge. If the
S405166A1002 vacuum drop range is less than 3.3 kPa (25
mmHg, 0.98 inHg) within 15 seconds after stop-
CAUTION: ping engine, brake booster is functioning properly.
When checking operation, be sure to securely If defective, the cause may be one of those listed
apply the hand brake. below.
쐌 Checking with gauges 쐌 Check valve malfunction
쐌 Leak from vacuum hose
Connect gauges as shown in Figure. After bleed- 쐌 Leak from the shell jointed portion or stud bolt
ing air from pressure gauges, proceed to each welded portion
check. 쐌 Damaged diaphragm
쐌 Leak from valve body seal and bearing portion
쐌 Leak from plate and seal assembly portion
쐌 Leak from poppet valve assembly portion
쐌 Loaded air tightness check
1) Start engine and depress brake pedal with
pedal force of 196 N (20 kg, 44 lb). Keep engine
running until a vacuum of 66.7 kPa (500 mmHg,
19.69 inHg) = point B is indicated on vacuum
gauge while the pedal is still depressed.
S4M0467A
(1) Pressure gauge

(2) Vacuum gauge
(3) Adapter hose
(4) Vacuum hose
(5) Pedal force gauge
쐌 Air tightness check

1) Start engine and keep it running until a vacuum
of 66.7 kPa (500 mmHg, 19.69 inHg) = point A is S4M0469A
indicated on vacuum gauge. Do not depress brake
(1) Pressure gauge
pedal.
(2) Vacuum gauge
(3) Pedal force gauge
(4) Depress
2) Stop engine and watch vacuum gauge.

If the vacuum drop range is less than 3.3 kPa (25
mmHg, 0.98 inHg) within 15 seconds after stop-
ping engine, brake booster is functioning properly.
If defective, refer to “AIR TIGHTNESS CHECK”.
<Ref. to BR-46 INSPECTION, Brake Booster.>
S4M0468A
(1) Pressure gauge

(2) Vacuum gauge
BR-47
墌 00.5.31/68j/4br 墍
BRAKE BOOSTER
Brake
쐌 Lack of boosting action check

Turn off engine, and set the vacuum gauge read-
ing at “0”. Then, check the fluid pressure when
brake pedal is depressed. The pressure must be
greater than the standard value listed.
Brake pedal 147 N 294 N
force (15 kg, 33 lb) (30 kg, 66 lb)
785 kPa 1,961 kPa
14″
Fluid (8 kg/cm2, 114 psi) (20 kg/cm2, 284 psi)
pressure 15″ 686 kPa 1,765 kPa
2 2
16″ (7 kg/cm , 100 psi) (18 kg/cm , 256 psi)
쐌 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 147 N 294 N
force (15 kg, 33 lb) (30 kg, 66 lb)
6,375 kPa 9,121 kPa
14″ (65 kg/cm2, (93 kg/cm2,
Fluid 924 psi) 1,322 psi)
pressure 15″ 5,688 kPa 9,905 kPa
(58 kg/cm2, (101 kg/cm2,
16″ 825 psi) 1,436 psi)
BR-48
墌 00.5.31/68j/4br 墍
PROPORTIONING VALVE
Brake
12. Proportioning Valve S405167 B: INSTALLATION S405167A11
1) Install proportioning valve to bracket.
2) Connect brake pipes correctly to proportioning
valve.
3) Bleed air, then check each joint of brake pipe
for oil leaks.
Tightening torque:
Proportioning valve to brake pipe flare nut:
15 N·m (1.5 kgf-m, 10.8 ft-lb)
Proportioning valve to bracket:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
B4M1177
1) Remove brake pipe from proportioning valve at

four places.
2) Remove proportioning valve from its bracket.
CAUTION:
Do not disassemble or adjust the proportioning
valve. (The proportioning valve must be
replaced as an assembly.)
BR-49
PROPORTIONING VALVE
Brake
1) Install the oil pressure gauges to measure the

master cylinder fluid pressure (front wheel brake
fluid pressure) and rear wheel cylinder fluid pres-
sure.
2) Bleed air from the oil pressure gauges.
3) Check the master cylinder fluid pressure and
rear wheel cylinder fluid pressure.
The standard values are shown in Figure.
B4M1198A
4) For the oil pressure in case of split point, refer

to “SPECIFICATIONS”.
<Ref. to BR-2 SPECIFICATIONS, General
Description.>
BR-50
BRAKE FLUID
Brake
13. Brake Fluid S405162 B: REPLACEMENT S405162A20
CAUTION:
쐌 To always maintain the brake fluid
1) Check that brake fluid level remains between characteristics, replace the brake fluid accord-
“MIN” and “MAX”. If out of the specified range, refill ing to maintenance schedule or earlier than
or drain fluid. If fluid level becomes close to “MIN”, that when used in severe condition.
refill fluid. 쐌 The FMVSS No. 116, fresh DOT3 or 4 brake
2) Check fluid for discoloration. If fluid color has
fluid must be used.
excessively changed, drain the fluid and refill with
쐌 Cover bleeder with waste cloth, when loos-
new fluid.
ening it, to prevent brake fluid from being
splashed over surrounding parts.
쐌 Avoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
쐌 Be careful not to allow dirt or dust to get into
the reservoir tank.
NOTE:
쐌 During bleeding operation, keep the brake res-
ervoir tank filled with brake fluid to eliminate entry
of air.
쐌 Brake pedal operating must be very slow.
쐌 For convenience and safety, two people should
do the work.
쐌 The amount of brake fluid required is approxi-
mately 500 m (16.9 US fl oz, 17.6 Imp fl oz) for
total brake system.
1) Either jack-up vehicle and place a safety stand
under it, or left up vehicle.
2) Remove both front and rear wheels.
3) Draw out the brake fluid from master cylinder
with syringe.
4) Refill reservoir tank with recommended brake
fluid.
Recommended brake fluid:
FMVSS No. 116, fresh DOT3 or 4 brake
fluid
BR-51
墌 00.5.31/68j/4br 墍
BRAKE FLUID
Brake
5) Install one end of a vinyl tube onto the air NOTE:

bleeder of and insert the other end of the tube into Add brake fluid as necessary while performing the
a container to collect the brake fluid. 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 N·m (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.
S4M0246
11) Depress brake pedal with a force of approxi-
mately 294 N (30 kg, 66 lb) and hold it there for
approximately 20 seconds. At this time check
pedal to see if it shows any unusual movement.
Visually inspect bleeder screws and brake pipe
joints to make sure that there is no fluid leakage.
12) Install wheels, and drive vehicle for a short
distance between 2 to 3 km (1 to 2 miles) to make
sure that brakes are operating properly.
B4M1977
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 bleeder screw approximately 1/4 turn
until a small amount of brake fluid drains into
container, and then quickly tighten screw.
8) Repeat steps 6) and 7) above until there are no
air bubbles in drained brake fluid and new fluid
flows through vinyl tube.
BR-52
墌 00.5.31/68j/4br 墍
AIR BLEEDING
Brake
14. Air Bleeding S405163

4) Repeat above steps 2) and 3) until master cyl-
inder is completely bled.
A: PROCEDURE S405163E45 5) Install brake pipes to master cylinder.
CAUTION: Tightening torque:
쐌 The FMVSS No. 116, fresh DOT3 or 4 brake 8 N·m (0.8 kgf-m, 5.8 ft-lb)
fluid must be used. 2. BRAKE LINE S405163E4502
쐌 Cover bleeder with waste cloth when loosen-
ing it to prevent brake fluid from being NOTE:
splashed over surrounding parts. 쐌 During bleeding operation, keep the brake res-
쐌 Avoid mixing different brands of brake fluid ervoir tank filled with brake fluid to eliminate entry
to prevent degrading the quality of the fluid. of air.
쐌 Be careful not to allow dirt or dust to get into 쐌 Brake pedal operating must be very slow.
the reservoir tank. 쐌 For convenience and safety, two people should
do the work.
NOTE:
쐌 Start with the brakes (wheels) connected to the 1) Make sure that there is no leak from joints and
secondary chamber of the master cylinder. connections of the brake system.
쐌 The time interval between two brake pedal 2) Fit one end of vinyl tube into the air bleeder and
operations (from the time when the pedal is put the other end into a brake fluid container.
released to the time when it is depressed another
time) shall be approximately 3 seconds.
쐌 The air bleeder on each brake shall be released
for 1 to 2 seconds.
1. MASTER CYLINDER S405163E4501
NOTE:
If master cylinder is disassembled or reservoir tank
is empty, bleed master cylinder.
1) Disconnect brake line at primary and secondary
sides. S4M0246
2) Carefully depress and hold brake pedal.
CAUTION:
Brake fluid replacement sequence; (A) Front
right → (B) Rear left → (C) Front left → (D) Rear
right
B4M2351
3) Close outlet plug with your finger, and release

brake pedal.
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 air bleeder for 1 to 2 seconds.
B4M2352
Next, with the bleeder closed, slowly release the
brake pedal.
BR-53
墌 00.5.31/68j/4br 墍
AIR BLEEDING
Brake
Repeat these steps until there are no more air 8) Operate hydraulic control unit in the sequence
bubbles in the vinyl tube. control mode.
Allow 3 to 4 seconds between two brake pedal With ABS: <Ref. to ABS-11 ABS Sequence Con-
operations. trol.>
With VDC: <Ref. to VDC-21 VDC Sequence Con-
CAUTION: trol.>
Cover bleeder with waste cloth, when loosen- 9) Recheck the brake stroke.
ing it, to prevent brake fluid from being 10) If the distance is more than specifications,
splashed over surrounding parts. there is a possibility air is in the inside of the
NOTE: hydraulic unit. Repeat above steps 2) to 9) above
Brake pedal operating must be very slow. until pedal stroke meets the specification.
11) Add brake fluid to the required level (MAX.
4) Tighten air bleeder securely when no air level) of reservoir tank.
bubbles are visible. 12) As a final step, test run the vehicle at low
Air bleeder tightening torque: speed and apply brakes relatively hard 2 to 3 times
8 N·m (0.8 kgf-m, 5.8 ft-lb) to ensure that brakes provide normal braking
action on all four wheels without dragging and
5) Perform these steps for the brakes connecting uneven braking.
to the secondary chamber of master cylinder, first,
and then for the ones connecting to primary cham-
ber. With all procedures completed, fully depress
the brake pedal and keep it in that position for
approximately 20 seconds to make sure that there
is no leak evident in the entire system.
6) Check the pedal stroke.
While the engine is idling, depress the brake pedal
with a 490 N (50 kg, 110 lb) load and measure the
distance between the brake pedal and steering
wheel. With the brake pedal released, measure the
distance between the pedal and steering wheel
again. The difference between the two measure-
ments must be more than specified.
S4M0467A
(1) Steering wheel

(2) Toe board
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 specifications, there
is a possibility that air is in the brake line. Bleed
brake line until pedal stroke meets the specifica-
tion.
BR-54
墌 00.5.31/68j/4br 墍
BRAKE HOSE
Brake
15. Brake Hose S405164
1. FRONT BRAKE HOSE S405164A1801
1) Separate brake pipe from brake hose.

(Always use flare nut wrench and be careful not to
deform flare nut.)
B4M1781B
(1) Brake pipe
2) Pull out clamp to remove brake hose.
B4M1843B
(1) Brake hose

(2) Brake pipe
2) Pull out clamp to remove brake hose.

3) Remove bolt at strut and union bolt.
2. REAR BRAKE HOSE S405164A1802
1) Separate brake pipe from brake hose.

NOTE:
Always use flare nut wrench and be careful not to
deform flare nut.
B4M1775B
(1) Brake pipe

(2) Brake hose
BR-55
墌 00.5.31/68j/4br 墍
BRAKE HOSE
Brake
B: INSTALLATION S405164A11 2. REAR BRAKE HOSE S405164A1102
1. FRONT BRAKE HOSE S405164A1101

1) Pass brake hose through the hole of bracket,
and lightly tighten flare nut to connect brake pipe.
1) Route end of brake hose (on caliper side) 2) Insert clamp upward to fix brake hose.
through hole in brake hose bracket at strut loca- 3) While holding hexagonal part of brake hose fit-
tion. ting with a wrench, tighten flare nut to the specified
2) Tighten end of brake hose at caliper using a torque.
union bolt.
Tightening torque (Brake pipe flare nut):
Tightening torque (Union bolt): 15 N·m (1.5 kgf-m, 10.8 ft-lb)
18 N·m (1.8 kgf-m, 13.0 ft-lb)
B4M1775B
B4M1844
(1) Brake pipe
3) Secure middle fitting of brake hose to bracket at (2) Brake hose
strut location using a clamp.
4) Position disc in straight-forward direction and
route brake hose through hole in bracket on wheel
apron side.
CAUTION:
Be sure brake hose is not twisted.
5) Temporarily tighten flare nut to connect brake
pipe and hose.
6) Fix brake hose with clamp at wheel apron
bracket.
7) While holding hexagonal part of brake hose fit- B4M1781B
ting with a wrench, tighten flare nut to the specified
torque. (1) Brake pipe
Tightening torque (Brake pipe flare nut): 4) Bleed air from the brake system.
15 N·m (1.5 kgf-m, 10.8 ft-lb)
8) Bleed air from the brake system.
BR-56
墌 00.5.31/68j/4br 墍
BRAKE HOSE
Brake
Ensure there are no cracks, breakage, or damage

on hoses. Check joints for fluid leakage. If any
cracks, breakage, damage or leakage is found,
repair or replace hose.
BR-57
墌 00.5.31/68j/4br 墍
BRAKE PIPE
Brake
16. Brake Pipe S405165 B: INSTALLATION S405165A11
NOTE:
NOTE: center brake pipe.
center brake pipe. CAUTION:
CAUTION: nectors are colored yellow. Do not use electri-
쐌 All Airbag system wiring harness and con- cal test equipment on these circuits.
nectors are colored yellow. Do not use electri- 쐌 Be careful not to damage Airbag system wir-
cal test equipment on these circuits. ing harness when servicing the center brake
쐌 Be careful not to damage Airbag system wir- pipe.
ing harness when servicing the center brake 쐌 When installing the brake pipe, make sure
pipe. that it is not bent.
쐌 When removing the brake pipe, make sure 쐌 After installing the brake pipe and hose,
that it is not bent. bleed the air.
쐌 After installing the brake hose, make sure
that it does not touch the tire or suspension
assembly, etc.
Brake pipe tightening torque:
15 N·m (1.5 kg-m, 10.8 ft-lb)
BR-58
BRAKE PIPE
Brake
Ensure there are no cracks, breakage, or damage

on pipes. Check joints for fluid leakage. If any
cracks, breakage, damage or leakage is found,
repair or replace pipe.
NOTE:
Use a mirror when inspecting low-visible part or
back side.
BR-59
BRAKE PEDAL
Brake
17. Brake Pedal S405541

2. AT MODEL S405541A1802

2) Remove instrument panel lower cover from
1. MT MODEL S405541A1801 instrument panel.
3) Remove clevis pin which secures brake pedal
1) Remove steering column.
to brake booster operating rod. Also disconnect
<Ref. to PS-20 REMOVAL, Tilt Steering Column.>
stop light switch connector.
2) Disconnect connectors from stop light and
4) Remove two bolts and four nuts which secure
clutch switches.
brake pedal to pedal.
3) Remove snap pins which secure lever to push
rod and operating rod.
4) Remove clevis pins which secure lever to push
rod and operating rod.
G4M0324
B4M1743A
(A) Operating rod

(B) Push rod
(C) Snap pin
(D) Clevis pin
5) Remove nut which secures clutch master cylin-

der.
B4M1744
6) Remove bolts and nuts which secure brake and

clutch pedals, and remove pedal assembly.
BR-60
墌 00.5.31/68j/4br 墍
BRAKE PEDAL
Brake
B: INSTALLATION S405541A11 C: DISASSEMBLY S405541A06
1) Install in the reverse order of removal. 1. MT MODEL S405541A0601
CAUTION: 1) Remove the brake switch.

쐌 If cable clamp is damaged, replace it with a <Ref. to BR-64 REMOVAL, Stop Light Switch.>
new one. 2) Remove the clutch pedal.
쐌 Never fail to cover outer cable end with boot. <Ref. to CL-21 DISASSEMBLY, Clutch Pedal.>
쐌 Be careful not to kink accelerator cable. 3) Remove the clutch master cylinder bracket.
쐌 Always use new clevis pins.
2) Adjustment of clutch pedal <Ref. to BR-62
ASSEMBLY, Brake Pedal.>
3) Inspect after pedal installation <Ref. to BR-63
INSPECTION, Brake Pedal.>
B4M2349
4) Remove bush, spring and stopper.
B4M2350A
(1) Stopper
(2) Bushing
(3) Brake pedal
(4) Brake pedal spring
5) Remove the brake pedal pad.

2. AT MODEL S405541A0602
1) Remove the brake switch.

2) Unbolt, and then remove the brake pedal.
B4M2347
BR-61
墌 00.5.31/68j/4br 墍
BRAKE PEDAL
Brake
3) Remove bush, spacer and spring. D: ASSEMBLY S405541A02
1) Attach stop light switch, etc. to pedal bracket

temporarily.
2) Clean inside of bores of clutch pedal and brake
pedal, apply grease, and set bushings into bores.
3) Align bores of pedal bracket, clutch pedal and
brake pedal, attach brake pedal return spring and
clutch pedal effort reducing spring (vehicle with hill
holder), and then install pedal bolt.
NOTE:
B4M2348A
Clean up inside of bushings and apply grease
before installing spacer.
(1) Spacer
Tightening torque:
(2) Plug
T: 29 N·m (3.0 kgf-m, 21.7 ft-lb)
(3) Stopper
(4) Brake pedal
(5) Brake spacer
(6) Brake pedal spring
4) Remove the brake pedal pad.
B4M1753C
4) Set brake pedal position by adjusting position of

stop light switch.
Pedal position: L
125.9 mm (4.96 in)
Tightening torque:
T: 8 N·m (0.8 kgf-m, 5.8 ft-lb)
B4M1754B
BR-62
墌 00.5.31/68j/4br 墍
BRAKE PEDAL
Brake
1) Move brake and clutch pedal pads in the lateral

direction with a force of approximately 10 N (1 kg,
2 lb) to ensure pedal deflection is in specified
range.
CAUTION:
If excessive deflection is noted, replace bush-
ings with new ones.
Deflection of brake and clutch pedal: B4M0366B
Service limit
5.0 mm (0.197 in) or less (1) Stop light switch
(2) Mat
(3) Toe board
(4) Brake booster operating rod
3) If it is not in specified value, adjust it by adjust-

ing brake booster operating rod length.
S4M0135B
(1) Clutch pedal

(2) Brake pedal
G4M0326
2) Check position of pedal pad.

Pedal height: L
148 mm (5.83 in)
Brake pedal free play: A
1 — 3 mm (0.04 — 0.12 in) [Depress
brake pedal pad with a force of less than
10 N (1 kg, 2 lb).]
BR-63
墌 00.5.31/68j/4br 墍
STOP LIGHT SWITCH
Brake
18. Stop Light Switch S405542 B: INSTALLATION S405542A11
1) Screw the stop light switch onto a bracket and
secure it temporarily with a nut.
1) Disconnect ground terminal from battery. 2) Adjust stop light switch position, and then
2) Disconnect stop light switch connector. tighten the nut.
3) Loosen nuts, and unscrew stop light switch to <Ref. to BR-65 ADJUSTMENT, Stop Light
remove. Switch.>
Tightening torque:
8 N·m (0.8 kgf-m, 5.8 ft-lb)
B4M1753D
(1) Stop light switch

B4M1753E
BR-64
STOP LIGHT SWITCH
Brake
C: INSPECTION S405542A10 D: ADJUSTMENT S405542A01
1) If stop light switch does not operate properly (or Loosen the lock nut, and adjust stop light switch
if it does not stop at the specified position), replace position until the clearance between threaded end
with a new one. of the stop light switch and the stopper becomes
Specified position: L 0.3 mm (0.012 in). Then, tighten the lock nut.
2+1.5/0 mm (0.079+0.059/0 in)
B4M0617E
G4M0327
2) Measure the clearance between threaded end

of stop light switch and stopper.
CAUTION:
Stop light switch clearance: A
0.3 mm (0.012 in)
B4M0617E
(1) Stop light switch

(2) Stopper
(3) Brake pedal
3) If it is not in specified value, adjust it by adjust-

ing position of stop light switch.
CAUTION:
BR-65
墌 00.5.31/68j/4br 墍
GENERAL DIAGNOSTICS
Brake
19. General Diagnostics S405278
Trouble and possible cause Corrective action

1. Insufficient braking (1) Fluid leakage from the hydraulic mechanism Repair or replace (cup, piston seal, piston boot,
master cylinder piston kit, pipe or hose).
(2) Entry of air into the hydraulic mechanism Bleed the air.
(3) Excessively wide shoe clearance Adjust the clearance.
(4) Wear, deteriorated surface material, adhering Replace, grind or clean.
water or fluid on the lining
(5) Improper operation of master cylinder, disc Correct or replace.
caliper, brake booster or check valve
2. Unstable or uneven (1) Fluid on the lining, drum or rotor Eliminate cause of fluid leakage, clean, or
braking replace.
(2) Drum or rotor eccentricity Correct or replace the drum or rotor.
(3) Worn brake drum, or damage to the drum Correct by grinding, or replace.
caused by sand
(4) Improper lining contact, deteriorated surface Correct by grinding, or replace.
material, improper inferior material, or wear
(5) Deformed back plate Correct or replace.
(6) Improper tire inflation Inflate to correct pressure.
(7) Disordered wheel alignment Adjust alignment.
(8) Loosened back plate or the support installing Retighten.
bolts
(9) Loosened wheel bearing Retighten to normal tightening torque or replace.
(10) Trouble in the hydraulic system Replace the cylinder, brake pipe or hose.
(11) Uneven effect of the parking brake Check, adjust, or replace the rear brake and
cable system.
3. Excessive pedal (1) Entry of air into the hydraulic mechanism Bleed the air.
stroke (2) Excessive play in the master cylinder push Adjust.
rod
(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.
4. Brake dragging or (1) Insufficient pedal play Adjust play.
improper brake return (2) Improper master cylinder return Clean or replace the cylinder.
(3) Clogged hydraulic system Replace.
(4) Improper return or adjustment of parking Correct or adjust.
brake
(5) Weakened spring tension or breakage of Replace the spring.
shoe 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.
5. Brake noise (1) (1) Hardened or deteriorated lining Replace the shoe assembly or pad.
(creak sound) (2) Worn lining Replace the shoe assembly or pad.
(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.
BR-66
GENERAL DIAGNOSTICS
Brake

6. Brake noise (2) (1) Worn lining Replace the shoe assembly or pad.
(hissing sound) (2) Improper installed shoe or pad Correct or replace the shoe assembly or pad.
(3) Loose or bent drum or rotor Retighten or replace.
7. Brake noise (3) In the case of the disc brake:
(click sound) (1) Excessively worn pad or the support Replace the pad or the support.
In the case of the drum brake:
(1) Excessively worn shoe ridge Replace the back plate.
(2) Lack of oil on the shoe ridge surface and Add more grease.
anchor
BR-67
GENERAL DIAGNOSTICS
Brake
MEMO:
BR-68
GENERAL DESCRIPTION
Parking Brake
Rear disc brake

Model Rear drum brake
15 inch type
Type Mechanical on rear brakes, drum in disc
Effective drum diameter mm (in) 228.6 (9) 170 (6.69)
Lining dimensions 218.8 × 35.0 × 4.1 162.6 × 30.0 × 3.2
mm (in)
(length × width × thickness) (8.61 × 1.378 × 0.161) (6.40 × 1.181 × 0.126)
Clearance adjustment Automatic adjustment Manual adjustment
Lever stroke noches/N (kg, lb) 7 to 8/196 (20, 44)
PB-2
墌 00.5.31/68j/4pb 墍
GENERAL DESCRIPTION
Parking Brake
1. PARKING BRAKE (REAR DISC BRAKE) S404001A0501
B4M1840A
(1) Back plate (7) Strut spring (13) Adjuster

(2) Retainer (8) Strut (14) Shoe hold-down cup
(3) Spring washer (9) Shoe guide plate (15) Shoe hold down spring
(4) Lever (10) Primary return spring (16) Shoe hold down pin
(5) Parking brake shoe (Primary) (11) Secondary return spring (17) Adjusting hole cover
(6) Parking brake show (Secondary) (12) Adjusting spring
PB-3
墌 00.5.31/68j/4pb 墍
GENERAL DESCRIPTION
Parking Brake
2. PARKING BRAKE CABLE S404001A0502
B4M1975A
(1) Parking brake lever (7) Clamp Tightening torque: N·m (kgf-m, ft-lb)
(2) Parking brake switch (8) Parking brake cable RH
T1: 5.9 (0.60, 4.3)
(3) Lock nut (9) Clamp (Rear disc brake model
T2: 18 (1.8, 13.0)
(4) Adjusting nut only)
T3: 32 (3.3, 24)
(5) Equalizer (10) Parking brake cable LH
(6) Bracket
PB-4
墌 00.5.31/68j/4pb 墍
GENERAL DESCRIPTION
Parking Brake

tion.
ment.
part on the vehicle is hot after running.
fied points.
deformation.
쐌 Keep grease etc. away from parking brake
shoes.
PB-5
墌 00.5.31/68j/4pb 墍
PARKING BRAKE LEVER
Parking Brake
2. Parking Brake Lever S404171 C: INSPECTION S404171A10
While pulling parking brake lever upward, count
the notches.
2) Remove rear tire and wheel. Lever stroke:
3) Remove rear cushion. 7 to 8 notches when pulled with a force
4) Loosen parking cable adjusting nut and console of 196 N (20 kg, 44 lb)
bracket. Incorrect, adjust the parking brake. <Ref. to PB-11
5) Remove parking brake lever. ADJUSTMENT, Parking Brake Assembly (Rear
Disc Brake).>

2) Forcibly pull parking brake lever 3 to 5 times.
3) Adjust parking brake lever by turning adjuster
until parking brake lever stroke is set at 7 to 8
notches with operating force of 196 N (20 kg, 44
lb).
4) Tighten lock nut.
B4M1777
Lever stroke:
6) Unbend parking brake lever pawls and remove 7 to 8 notches when pulled with a force
cable. of 196 N (20 kg, 44 lb)
Tightening torque (Lock nut):
5.9 N·m (0.60 kgf-m, 4.3 ft-lb)
S4M0471A
(1) Parking brake lever

(2) Cable B4M0050B

(2) Lock nut
Install in the reverse order of removal. (3) Adjusting nut
Tightening torque: 5) Install console cover.
Parking brake lever;
18 N·m (1.8 kgf-m, 13.0 ft-lb)
Adjusting nut;
5.9 N·m (0.6 kgf-m, 4.3 ft-lb)
NOTE:
쐌 Be sure to pass cable through guide inside the
tunnel.
쐌 Be sure to adjust the lever stroke. <Ref. to PB-6
ADJUSTMENT, Parking Brake Lever.>
PB-6
墌 00.5.31/68j/4pb 墍
PARKING BRAKE CABLE
Parking Brake
3. Parking Brake Cable S404170

10) Remove inner cable end from equalizer.
1) Lift-up vehicle.
2) Remove rear tires and wheels.
3) Remove rear cushion.
4) Remove console box from front floor.
5) Loosen parking cable adjusting nut and console
bracket.
6) Remove parking brake lever.
S4M0473A
(1) Equalizer
(2) Inner cable end
11) Pull out parking brake cable from rear brake.

<Ref. to PB-9 REMOVAL, Parking Brake Assembly
(Rear Disc Brake).>
12) Pull out clamp from rear brake.
13) Remove bolt and bracket from trailing link
bracket.
B4M1777
14) Remove bolt and clamp from rear floor.
7) Unbend parking brake lever pawls and remove
cable.
B2M3185
15) Detach grommet from rear floor.

S4M0471A 16) Remove cable assembly from cabin by forc-
ibly pulling it backward.
17) Detach parking brake cable from cable guide
(2) Cable
at rear trailing link.
8) Roll up floor mat and remove clamps.
B4M1778
9) Remove equalizer cover.
PB-7
墌 00.5.31/68j/4pb 墍
PARKING BRAKE CABLE
Parking Brake
Install (new) parking brake assembly in the reverse Check the removed cable and replace if damaged,
order of removal. rusty, or malfunctioning.
NOTE: 1) Check for smooth operation of the cable.
쐌 Be sure to pass cable through cable guide inside 2) Check the inner cable for damage and rust.
the tunnel. 3) Check the outer cable for damage, bends, and
쐌 Be sure to adjust the lever stroke. <Ref. to PB-6 cracks.
ADJUSTMENT, Parking Brake Lever.> 4) Check the boot for damage, cracks, and dete-
rioration.
PB-8
墌 00.5.31/68j/4pb 墍
PARKING BRAKE ASSEMBLY (REAR DISC BRAKE)
Parking Brake
4. Parking Brake Assembly (2) If disc rotor seizes up within hub, drive disc
rotor out by installing an 8-mm bolt in holes B on
(Rear Disc Brake) S404552
the rotor.
1) Remove the two mounting bolts and remove

the disc brake assembly.
G4M0383
5) Remove shoe return spring from parking brake

assembly.
6) Using a standard screwdriver, remove front
B4M1710
shoe hold down spring and pin.
2) Suspend the disc brake assembly so that the
hose is not stretched.
3) Pull down and release parking brake.
4) Remove the disc rotor.
NOTE:
If the disc rotor is difficult to remove try the follow-
ing two methods in order.
(1) Turn adjusting screw using a slot-type
screwdriver until brake shoe gets away enough
from the disc rotor. B4M1842
7) Remove strut and strut spring.

8) Remove adjuster assembly from parking brake
assembly.
9) Using a standard screwdriver, remove rear
shoe hold-down spring and pin.
10) Remove brake shoe.
11) Remove parking cable from parking lever.
S4M0463A
(1) Adjusting screw

(2) Cover (rubber)
(3) Slot-type screwdriver
(4) Back plate
B4M1774B

12) Using a standard screwdriver, raise retainer.

Remove parking lever and washer from brake
shoe.
PB-9
墌 00.5.31/68j/4pb 墍
Parking Brake
B: INSTALLATION S404552A11 NOTE:

Ensure that shoe return spring is installed as
CAUTION: shown in Figure.
Be sure lining surface is free from oil contami-
nation.
Brake grease:
725191460)
1) Apply brake grease to the following places.
쐌 Six contact surfaces of shoe rim and back plate
packing
쐌 Contact surface of shoe wave and anchor pin
쐌 Contact surface of lever and strut S4M0462A
쐌 Contact surface of shoe wave and adjuster
assembly (1) Back plate
쐌 Contact surface of shoe wave and strut (2) Shoe guide plate
쐌 Contact surface of lever and shoe wave (3) Retainer
2) Install in reverse order of removal. (4) Spring washer
(5) Lever
CAUTION: (6) Primary shoe return spring (Blue)
쐌 Use new retainers and clinch them when (7) Secondary shoe return spring (Yellow)
installing brake shoes to levers. (8) Parking brake shoe (Primary)
쐌 Ensure that parking lever moves smoothly. (9) Parking brake shoe (Secondary)
쐌 Do not confuse left parking lever with right
one. 3) Adjust parking brakes. <Ref. to PB-11
쐌 Do not confuse left strut with right one. ADJUSTMENT, Parking Brake Assembly (Rear
Disc Brake).>
NOTE:
Ensure that adjuster assembly is securely installed CAUTION:
with screw in the left side, facing vehicle front. After replacing parking brake lining, be sure to
drive vehicle for “break-in” purposes.
(1) Drive the vehicle about 35 km/h (22 MPH).
(2) With the parking brake release button
pushed in, pull the parking brake lever gently.
(3) Drive the vehicle for about 200 meter (0.12
mile) in this condition.
(4) Wait 5 to 10 minutes for the parking brake
to cool down. Repeat this procedure once
more.
(5) After breaking-in, re-adjust parking brakes.
S4M0461A
(1) LEFT
PB-10
墌 00.5.31/68j/4pb 墍
Parking Brake
C: INSPECTION S404552A10 D: ADJUSTMENT S404552A01
1) Measure brake disc inside diameter. If the disc 1. SHOE CLEARANCE S404552A0101
is scored or worn, replace the brake disc.

1) Remove adjusting hole cover from back plate.
Disc inside diameter: 2) Turn adjusting screw using a slot-type screw-
Standard driver until brake shoe is in close contact with disc
170 mm (6.69 in) rotor.
Service limit
171 mm (6.73 in)
2) Measure the lining thickness. If it exceeds the
limit, replace shoe assembly.
Lining thickness:
Standard
3.2 mm (0.126 in)
Service limit
1.5 mm (0.059 in)
CAUTION: S4M0463A
Replace the brake shoes on the right and left
brake assembly at the same time. (1) Adjusting screw
(2) Cover (rubber)
(3) Slot-type screwdriver
(4) Back plate
3) Turn back (downward) adjusting screw 3 or 4

notches.
4) Install adjusting hole cover to back plate.
2. LEVER STROKE S404552A0102
1) Remove console box lid.

2) Forcibly pull parking brake lever 3 to 5 times.
3) Adjust parking brake lever by turning adjuster
until parking brake lever stroke is set at 6 notches
with operating force of 196 N (20 kg, 44 lb).
B4M0050B

(2) Lock nut
(3) Adjusting nut
4) Tighten lock nut.

5) Install console box lid.
Lever stroke:
7 to 8 notches when pulled with a force
of 196 N (20 kg, 44 lb)
Tightening torque (Adjuster lock nut):
5.9 N·m (0.60 kgf-m, 4.3 ft-lb)
PB-11
墌 00.5.31/68j/4pb 墍
GENERAL DIAGNOSTIC TABLE
Parking Brake
5. General Diagnostic Table S404257
Symptom Possible cause Remedy

쐌 Parking brake lever is maladjusted. 쐌 Adjustment.
쐌 Parking brake cable does not move. 쐌 Repair or replace.
Brake drag
쐌 Parking brake shoe clearance is maladjusted. 쐌 Adjustment.
쐌 Return spring is faulty. 쐌 Replace.
쐌 Return spring is faulty. 쐌 Replace.
Noise from brake
쐌 Shoe hold down spring is faulty. 쐌 Replace.
PB-12
VDC (DIAGNOSTICS)
1. Basic Diagnostic Procedure

S005501
1. WITHOUT SUBARU SELECT MONITOR S005501E4501

1) Ask the customer when and how the the VDC problem normal? each unit.
<Ref. to VDC-5 Check List for Interview.>
which might influence the VDC problem. <Ref.
to VDC-8 INSPECTION, General Descrip-
tion.>
2 CHECK INDICATION OF TROUBLE CODE. Is trouble code readable? Go to step 3. Inspect using
Calling up trouble code. <Ref. to VDC-22 diagnostic chart
WITHOUT SUBARU SELECT MONITOR, for warning light
OPERATION, Read Diagnostic Trouble failure. <Ref. to
Code.> VDC-34 Diagnos-
tics Chart with
Diagnosis Con-
nector.>
NOTE:
Call up trouble
code again after
inspecting warn-
ing light. <Ref. to
VDC-22 WITH-
OUT SUBARU
SELECT
MONITOR,
OPERATION,
Read Diagnostic
Trouble Code.>
3 CHECK TROUBLE CODE. Is only the start code Go to step 4. Go to step 5.
NOTE: issued?
Record all trouble codes.
4 PERFORM THE GENERAL DIAGNOSTICS. Is only the start code Complete the Go to step 5.
1) Inspect using “General Diagnostics Table”. issued? diagnosis.
<Ref. to VDC-251 General Diagnostic Table.>
VDC-24 WITHOUT SUBARU SELECT
Mode.>
VDC-23 Inspection Mode.>
Calling up the trouble code. <Ref. to VDC-22
WITHOUT SUBARU SELECT MONITOR,
OPERATION, Read Diagnostic Trouble
Code.>
VDC-2
VDC (DIAGNOSTICS)

5 PERFORM THE DIAGNOSIS. Is only the start code Complete the Inspect using
1) Inspect using “Diagnostics Chart with Diag- issued? diagnosis. “Diagnostics Chart
nostic Connector”. <Ref. to VDC-34 Diagnos- with Diagnostic
tics Chart with Diagnosis Connector.> Connector”. <Ref.
NOTE: to VDC-34 Diag-
For trouble code list, refer to “List of Diagnos- nostics Chart with
tics Trouble Code”. <Ref. to VDC-26 WITH- Diagnosis Con-
OUT SUBARU SELECT MONITOR, LIST, List nector.>
Mode.>
VDC-23 Inspection Mode.>
MONITOR, OPERATION, Read Diagnostic
Trouble Code.>
CAUTION:
Remove foreign matter (dust, water, etc.) from the VDCCM connector during removal and installa-
tion.
NOTE:
쐌 When ABS and/or VDC warning light illuminates, read and record trouble code indicated by ABS warn-
ing light.
VDC (DIAGNOSTICS)
2. WITH SUBARU SELECT MONITOR S005501E4502

1) Ask the customer when and how the the VDC problem normal? each unit.
<Ref. to VDC-5 Check List for Interview.>
which might influence the VDC problem. <Ref.
to VDC-8 INSPECTION, General Descrip-
tion.>
2 CHECK INDICATION OF TROUBLE CODE Is the corresponding Go to step 3. Go to step 4.
DISPLAY. trouble encoding?
2) Connect the SUBARU SELECT MONITOR
to data link connector.
3) Turn ignition switch to ON and SUBARU
SELECT MONITOR to ON.
VDC-22 WITH SUBARU SELECT MONITOR,
Code.>
5) Record all trouble codes and frame data.
3 PERFORM THE GENERAL DIAGNOSTICS. Is no trouble code desig- Complete the Go to step 4.
1) Inspect using “General Diagnostics Table”. nated or do VDC and ABS diagnosis.
<Ref. to VDC-251 INSPECTION, General warning lights constantly
Diagnostic Table.> remain on?
OPERATION, Clear Memory Mode.>
VDC-23 OPERATION, Inspection Mode.>
Code.>
4 PERFORM THE DIAGNOSIS. Is no trouble code desig- Complete the Inspect using
1) Inspect using “Diagnostics Chart with nated or do VDC and ABS diagnosis. “Diagnostics Chart
Subaru Select Monitor”. <Ref. to VDC-126 warning lights constantly with Subaru
Diagnostics Chart with Select Monitor.> remain on? Select Monitor”.
NOTE: <Ref. to VDC-126
For trouble code list, refer to “List of Diagnos- Diagnostics Chart
tics Trouble Code”. <Ref. to VDC-29 WITH with Select Moni-
SUBARU SELECT MONITOR, LIST, List of tor.>
Diagnostics Trouble Code.>
OPERATION, Clear Memory Mode.>
VDC-23 OPERATION, Inspection Mode.>
NOTE:
쐌 Check list for interview. <Ref. to VDC-5 Check List for Interview.>
VDC-4
VDC (DIAGNOSTICS)
A: CHECK S005502A04
Check the following items about the vehicle’s state.

1. STATE OF ABS AND/OR VDC WARNING LIGHT
ABS and/or VDC 쏔 Always

warning light comes 쏔 Sometimes
on. 쏔 Only once
쏔 ACC
쏔 START
MPH to MPH
MPH to MPH
Steering time : sec
Steering time : sec
쐌 Parts name :
2. STATE OF VDC OFF INDICATOR LIGHT
VDC OFF indicator 쏔 Always

light comes on. 쏔 Sometimes
쏔 Only once
쏔 ACC
쏔 START
MPH to MPH
MPH to MPH
Steering time : sec
Steering time : sec
쐌 Parts name :
VDC-5
VDC (DIAGNOSTICS)
3. STATE OF VDC OPERATION INDICATOR LIGHT
VDC operation indi- 쏔 Always

cator light comes on. 쏔 Sometimes
쏔 Only once
쏔 ACC
쏔 START
MPH to MPH
MPH to MPH
Steering time : sec
Steering time : sec
쐌 Parts name :
4. CONDITIONS UNDER WHICH TROUBLE OCCURS
Environment a) Weather 쏔 Fine

쏔 Cloudy
쏔 Rainy
쏔 Snowy
쏔 Various/Others :
b) Ambient temperature °C (°F)
c) Road 쏔 Urban area
쏔 Suburbs
쏔 Highway
쏔 General road
쏔 Ascending slope
쏔 Descending slope
쏔 Paved road
쏔 Gravel road
쏔 Muddy road
쏔 Sandy place
쏔 Straight
쏔 Sharp curve
쏔 Slow curve
쏔 S-shaped curve
쏔 Road with inclination on each side
쏔 Others :
d) Road surface 쏔 Dry
쏔 Wet
쏔 New-fallen snow
쏔 Compressed snow
쏔 Frozen slope
쏔 Others :
VDC-6
VDC (DIAGNOSTICS)
Condition a) Brakes Deceleration : g

b) Accelerator Acceleration : g
c) Vehicle speed km/h MPH
쏔 Advancing
쏔 Accelerating
쏔 Reducing speed
쏔 Low speed
쏔 Turning
쏔 Others :
d) Tire inflation pressure Front RH tire : kPa
Front LH tire : kPa
Rear RH tire : kPa
Rear LH tire : kPa
e) Degree of wear Front RH tire :
Front LH tire :
Rear RH tire :
Rear LH tire :
f) Steering wheel 쏔 Sharp turn
쏔 Slow turn
쏔 Straight-ahead operation
쏔 Returned slowly
쏔 Returned quickly
g) Tire/wheel size 쏔 Specified
쏔 Other than specified ( )
h) Tire type 쏔 Summer tire
쏔 Studless tire (Brand name: )
i) Chain is passed around tires. : 쏔 Yes / 쏔 No
j) T tire is used. : 쏔 Yes / 쏔 No
k) Condition of suspension alignment :
l) Loading state :
m) Repair parts are used. : 쏔 Yes / 쏔 No
쐌 What :
n) Others :
VDC-7
GENERAL DESCRIPTION
VDC (DIAGNOSTICS)
Before performing diagnostics, check the following
items which might affect VDC problems:
1. SUPPLEMENTAL RESTRAINT SYSTEM
“AIRBAG” S005001A0301 1. BATTERY S005001A1001
Airbag system wiring harness is routed near the Measure battery voltage and specific gravity of
ABS sensor, ABS control module and hydraulic electrolyte.
control unit. Standard voltage: 12 V, or more
CAUTION: Specific gravity: Above 1.260
nectors are colored yellow. Do not use electri- 2. BRAKE FLUID S005001A1002
cal test equipment on these circuit. 1) Check brake fluid level.

쐌 Be careful not to damage Airbag system wir- 2) Check brake fluid leakage.
ing harness when servicing the ABS sensor,
ABS control module and hydraulic control unit. 3. HYDRAULIC UNIT S005001A1006
Check the hydraulic unit VDC.

쐌 With brake tester <Ref. to VDC-17 CHECKING
THE HYDRAULIC UNIT VDC OPERATION WITH
BRAKE TESTER, INSPECTION, Hydraulic Control
Unit (H/U).>
쐌 Without brake tester <Ref. to VDC-16 CHECK-
ING THE HYDRAULIC UNIT VDC OPERATION
BY PRESSURE GAUGE, INSPECTION, Hydraulic
Control Unit (H/U).>
4. BRAKE DRAG S005001A1003
Check brake drag.

5. BRAKE PAD AND ROTOR S005001A1004
Check brake pad and rotor.

쐌 Front <Ref. to BR-17 INSPECTION, Front Brake
Pad.>, <Ref. to BR-19 INSPECTION, Front Disc
Rotor.>
쐌 Rear <Ref. to BR-26 INSPECTION, Rear Brake
Pad.>, <Ref. to BR-29 INSPECTION, Rear Disc
Brake Assembly.>
6. TIRE S005001A1005
Check tire specifications, tire wear and air pres-

sure. <Ref. to WT-2 SPECIFICATIONS, General
Description.>
VDC-8
GENERAL DESCRIPTION
VDC (DIAGNOSTICS)

B2M3876
B2M3877
TOOL NAME REMARKS

Circuit Tester Used for measuring resistance, voltage and ampere.
VDC-9
VDC (DIAGNOSTICS)
B4M2335A
(1) VDC hydraulic control unit (7) VDC warning light (13) Tone wheel
(VDCH/U) (8) VDC operating indicator light (14) Wheel cylinder
(2) Proportioning valve (9) VDC OFF indicator light (15) Yaw rate & lateral G sensor
(3) Engine control module (10) Steering angle sensor (16) Transmission control module
(4) Master cylinder (11) Data link connector (for (17) VDC control module (VDCCM)
(5) Diagnosis connector SUBARU select monitor) (18) Pressure sensor
(6) ABS warning light (12) ABS sensor
VDC-10
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
B4M2112B B4M2113B B4M2114B
B4M2177C B4M2115C
B4M2262B
B4M2120B
B4M2456A
VDC-11
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
5. Control Module I/O Signal S005524
B4M1024C
NOTE:
쐌 The terminal numbers in the VDC control module connector are as shown in the figure.
쐌 When the connector is removed from the VDCCM, the connector switch closes the circuit between ter-
minal No. 53, No. 54 and No. 55. The ABS and VDC warning light illuminate.
VDC-12
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
Terminal No. Input/Output signal

Contents (+)—(−) Measured value and measuring condition
Ignition switch 28—1 10 — 15 V when ignition switch is ON.
ABS sen- Front left wheel 49—19
sor Front right wheel 14—15
(Wheel 0.12 — 1 V (When it is 20 Hz.)
speed Rear left wheel 18—46
sensor) Rear right wheel 16—17
Output (Lateral G sensor) 70—64 2.2 — 2.8 V when vehicle is in horizontal position.
Power supply 63—64 10 — 15 V when ignition switch is ON.
Output (Yaw rate sensor) 65—64 Wave form <Ref. to VDC-15 WAVE FORM, MEASUREMENT, Control Mod-
Yaw rate ule I/O Signal.>
and lateral
G sensor Reference (Yaw rate sensor) 66—64 2.1 — 2.9 V
40 ms pulse signal with a cycle of 5 — 1 V <Ref. to VDC-15 WAVE FORM,
Test 67—64 MEASUREMENT, Control Module I/O Signal.>
Ground 64 —
CAN communication line (+) 81—1 2.5 — 1.5 V pulse signal <Ref. to VDC-15 WAVE FORM, MEASUREMENT,
Control Module I/O Signal.>
CAN communication line (−) 83—1 3.5 — 2.5 V pulse signal <Ref. to VDC-15 WAVE FORM, MEASUREMENT,
AET 21—1 1.5 V or less (ABS/TCS/VDC operating); 10 V or more (ABS/TCS/VDC not
operating)
AEB 43—1 10 — 15 V (Ignition switch ON and vehicle at standstill)
Engine AEC 8—1 10 — 15 V (Ignition switch ON and vehicle at standstill)
module
EAS 75—1 3.5 — 1.5 V pulse signal
EAC 45—1 3.5 — 1.5 V pulse signal
Revolution 9—1 10 — 1.5 V pulse signal
Valve relay power supply 27—1 10 — 15 V when ignition switch is ON.
Valve relay coil 47—1 Less than 1.5 V when ignition switch is ON.
Relay box Motor relay coil 22—1 1.5 V or less (ABS/TCS/VDC operating); 10 V or more (ABS/TCS/VDC not
operating)
Motor monitoring 10—1 10 V or less (ABS/TCS/VDC operating); 1.5 V or more (ABS/TCS/VDC not
operating)
Front left inlet solenoid valve 24—1
Front right inlet solenoid valve 30—1
Rear left inlet solenoid valve 31—1
Rear right inlet solenoid valve 23—1
Front left outlet solenoid valve 51—1
Hydraulic Front right outlet solenoid valve 3—1
control 10 — 15 V when the valve is OFF and less than 1.5 V when the valve is
unit Rear left outlet solenoid valve 4—1 ON.
Rear right outlet solenoid valve 50—1
Primary cut solenoid valve 25—1
Secondary cut solenoid valve 26—1
Primary suction solenoid valve 29—1
Secondary suction solenoid valve 2—1
Power supply 78—76 4.75 — 5.25 V when ignition switch is ON.
Pressure Primary output 77—76 0.6 V (Brake pedal released)
sensor Ground 76 —
Secondary output 36—76 0.6 V (Brake pedal released)
VDC operation indicator light 32—1 Less than 1.5 V during 1.5 seconds when ignition switch is ON, and 10 —
15 V after 1.5 seconds.
1.5 V or less (Ignition switch ON and VDC OFF indicator light ON); 10 — 15
VDC OFF indicator light 52—1 V (Ignition switch ON and VDC OFF indicator light OFF)
VDC warning light 53—1 Less than 1.5 V during 1.5 seconds when ignition switch is ON, and 10 —
ABS warning light 54—1 Less than 1.5 V during 1.5 seconds when ignition switch is ON, and 10 —
Diagnosis Terminal No. 8 13 —
connector Terminal No. 5 74 —
Select Data is received. 11—1 Less than 1.5 V when no data is received.
monitor Data is sent. 38—1 4.75 — 5.25 V when no data is sent.
VDC OFF switch 40—1 10 — 15 V when ignition switch is ON.
0 V (Fuse installed)
Ground 1 —
Ground 55 —
VDC-13
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
B4M2457A
(1) VDC control module (14) Primary suction solenoid valve (26) Ignition relay
(2) Relay box (15) Primary cut solenoid valve (27) BATTERY
(3) Valve relay (16) Secondary suction solenoid (28) Front left ABS sensor
(4) Motor relay valve (29) Front right ABS sensor
(5) Hydraulic control unit (17) Secondary cut solenoid valve (30) Rear left ABS sensor
(6) Front left inlet solenoid valve (18) Motor (31) Rear right ABS sensor
(7) Front left outlet solenoid valve (19) Primary pressure sensor (32) Yaw rate and lateral G sensor
(8) Front right inlet solenoid valve (20) Secondary pressure sensor (33) Engine control module
(9) Front right outlet solenoid valve (21) VDC OFF switch (34) Transmission control module
(10) Rear left inlet solenoid valve (22) ABS warning light (35) Steering angle sensor
(11) Rear left outlet solenoid valve (23) VDC warning light (36) Diagnosis connector
(12) Rear right inlet solenoid valve (24) VDC operating indicator light (37) Data link connector
(13) Rear right outlet solenoid valve (25) VDC OFF indicator light
VDC-14
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
C: MEASUREMENT S005524A14
Measure input/output signal voltage.

NOTE:
Measure with the VDCCM connector cover removed. <Ref. to VDC-17 VDCCM Connector Cover.>
1. WAVE FORM S005524A1401
B4M2475A
VDC-15
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
B4M2264A
VDC-16
墌 00.5.31/68j/0vdc 墍
VDCCM CONNECTOR COVER
VDC (DIAGNOSTICS)
6. VDCCM Connector Cover S005598 B: INSTALLATION S005598A11
A: REMOVE S005598E47
1) Turn ignition switch OFF. NOTE:
2) Disconnect connector from VDCCM. Align connector cover rib with connector hole
3) Remove band. before installation.
4) Remove cable clamp cover.
5) Remove screws securing connector cover.
CAUTION:
Do not allow harness to catch on adjacent
parts during installation.
B4M1027B
(1) Rib
(2) Hole
B4M0815B
(1) Connector cover

(2) Band
(3) Cable clamp cover
6) Remove connector cover.
B4M1026
VDC-17
墌 00.5.31/68j/0vdc 墍
DATA LINK CONNECTOR
VDC (DIAGNOSTICS)
A: NOTE S005505A15
Refer to “EN(H6)” section for information about the

data link connector.
VDC-18
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

5) Turn ignition switch to ON (engine OFF) and
Subaru Select Monitor switch to ON.

S005503A1601
S2M0288D
(1) Power switch

S2M0285
2) Connect diagnosis cable to Subaru Select screen, select the {Brake Control System} and
Monitor. press the [YES] key.
3) Insert cartridge into Subaru Select Monitor. 8) Press the [YES] key after displayed the infor-
<Ref. to VDC-9 SPECIAL TOOLS, PREPARATION mation of engine type.
TOOL, General Description.> 9) On the ⰆBrake DiagnosisⰇ display screen,
select the {Diagnostic Code(s) Display} and press
the [YES] key.
10) On the ⰆDiagnostic Code(s) DisplayⰇ display
screen, select the {Current Diagnostic Code(s)} or
{History Diagnostic Code(s)} and press the [YES]
key.
NOTE:
MANUAL.
S2M0286
4) Connect Subaru Select Monitor to data link codes, refer to the DIAGNOSTIC TROUBLE
connector. CODE LIST.
(1) Data link connector located in the lower por- <Ref. to VDC-26 List of Diagnostics Trouble
tion of the instrument panel (on the driver’s Code.>
side). 쐌 A maximum of 3 trouble codes are displayed in
order of occurrence.
B2M2960G
(1) Data link connector B4M2173A
(2) Connect diagnosis cable to data link con- *a* refers to the troubles in order of occurrence
nector. (Latest, Old, Older).
VDC-19
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

The most recent trouble code appears
Latest
The second most recent trouble code
Old
appears on the select monitor display.
The third most recent trouble code
Older
appears on the select monitor display.
2. READ CURRENT DATA S005503A1602
1) On the ⰆMain MenuⰇ display screen, select {Each System Check} and press the ⰆYESⰇ key.
2) On the ⰆSystem Selection MenuⰇ display screen, select {Brake Control System} and press ⰆYESⰇ
key.
3) Press the ⰆYESⰇ key after the VDC type is displayed.
4) On the ⰆBrake Control DiagnosisⰇ display screen, select {Current Data Display & Save} and press the
ⰆYESⰇ key.
5) On the ⰆData Display MenuⰇ display screen, select {Data Display} and press the ⰆYESⰇ key.
Display screen Contents to be monitored. Unit of measure
FR wheel speed Wheel speed detected by the Front Right ABS sensor is displayed. km/h or MPH
FL wheel speed Wheel speed detected by the Front Left ABS sensor is displayed. km/h or MPH
RR wheel speed Wheel speed detected by the Rear Right ABS sensor is displayed. km/h or MPH
RL wheel speed Wheel speed detected by the Rear Left ABS sensor is displayed. km/h or MPH
Steering wheel angle detected by the steering angle sensor is dis-
Steering angle sensor deg
played.
Vehicle’s angular velocity detected by the yaw rate sensor is dis-
Yaw rate sensor deg/s
played.
Vehicle’s lateral acceleration detected by the lateral G sensor is dis-
Lateral G sensor V
played.
Brake fluid pressure detected by the primary pressure sensor is dis-
Pressure sensor 1 V
played.
Brake fluid pressure detected by the secondary pressure sensor is
Pressure sensor 2 V
displayed.
Longitudinal G sensor is not equipped on vehicles after ’00MY.
Longitudinal G sensor But longitudinal G sensor will remain on monitor and 0 V will be dis- V
played.
ABS CM power voltage Voltage supplied to VDCCM is displayed. V
Torque driver requires Engine torque requested by the driver is displayed. N·m
Current torque Current engine torque is displayed. N·m
Valve relay signal Drive condition of the valve relay is displayed. ON or OFF
Motor relay signal Drive condition of the motor relay is displayed. ON or OFF
VDC OFF lamp ON operation of the VDC OFF indicator lamp is displayed. ON or OFF
Motor relay monitor Operating condition of the motor relay is displayed. High or Low
PW signal Accelerator position signal is displayed. 1 or 0
AET signal Engine control start signal is displayed. OPEN or GND
AEB signal Engine control signal is displayed. OPEN or GND
AEC signal Engine control signal is displayed. OPEN or GND
EAM signal Engine control command signal is displayed. 1 or 0
NOTE:
VDC-20
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
3. CLEAR MEMORY MODE S005503A1603
1) On the ⰆMain MenuⰇ display screen, select {2. Each System Check} and press the ⰆYESⰇ key.
2) On the ⰆSystem Select MenuⰇ display screen, select {Brake System} and press the ⰆYESⰇ key.
3) Press the ⰆYESⰇ key after the engine type is displayed.
4) On the ⰆBrake Control DiagnosisⰇ display screen, select {Clear Memory} and press the ⰆYESⰇ key.
5) When ‘Done’ and ‘turn ignition switch OFF’ are shown on the display screen, turn the Subaru Select
Monitor and ignition switch to OFF.
NOTE:
4. FUNCTION CHECK S005503A1604
Display screen Contents to be monitored Index No.

Perform ABS sequence control by operating
ABS sequence control mode <Ref. to VDC-18 ABS Sequence Control.>
valve and pump motor sequentially.
Perform VDC sequence control by operating
VDC check mode <Ref. to VDC-21 VDC Sequence Control.>
valve and pump motor sequentially.
Set both the neutral position of the steering
Set mode St. r. A. Sen. N &
angle sensor and the zero “0” point of the lat- <Ref. to VDC-27 Steering Angle Sensor.>
Lat. G Sen. Op
eral G sensor.
VDC-21
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
9. Read Diagnostic Trouble 2) Turn ignition switch OFF.

3) Connect diagnosis connector terminal 8 to
Code S005508
diagnosis terminal.
5) ABS warning light is set in the diagnostic mode
1. WITHOUT SUBARU SELECT MONITOR and blinks to identify trouble code.
S005508A1602
1) Take out diagnosis connector from side of driv-

er’s seat heater unit.
B4M1767F

(3) 8 terminal
(4) 5 terminal
6) After the start code (11) is shown, the trouble codes will be shown in order of the last information first.
These repeat for a maximum of 5 minutes.
NOTE:
쐌 When there are no trouble codes in memory, only the start code (11) is shown.
쐌 When on-board diagnosis of the VDC control module detects a problem, the information (up to a maxi-
mum of three) will be stored in the EEP ROM as a trouble code. When there are more than three, the most
recent three will be stored. (Stored codes will stay in memory until they are cleared.)
B4M0232A
Refer to SUBARU SELECT MONITOR for information about how to obtain and understand trouble codes.
<Ref. to VDC-19 Subaru Select Monitor.>
VDC-22
INSPECTION MODE
VDC (DIAGNOSTICS)
Reproduce the condition under which the problem

has occurred as much as possible.
Drive the vehicle at least ten minutes.
NOTE:
Make sure vehicle does not pull to one side during
normal driving.
VDC-23
墌 00.5.31/68j/0vdc 墍
CLEAR MEMORY MODE
VDC (DIAGNOSTICS)

S005513A1602
1) After calling up a trouble code, disconnect diag-

nosis connector terminal 8 from diagnosis terminal.
B4M1767F

(3) 8 terminal
(4) 5 terminal
2) Repeat 3 times within approx. 12 seconds; connecting and disconnecting terminal 8 and diagnosis ter-
minal for at least 0.2 seconds each time.
B4M0233H
NOTE:
After 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 trouble codes. <Ref. to VDC-19
VDC-24
WARNING LIGHT ILLUMINATION PATTERN
VDC (DIAGNOSTICS)
12. Warning Light Illumination Pattern S005531
B4M2110A
1) When the warning and/or indicator lights do not conditions will differ from those occurring during
illuminate in accordance with this illumination normal vehicle operation. The ABS sensor will
pattern, there must be an electrical malfunction. detect this condition. The ABS and VDC warning
2) When the warning and/or indicator lights lights will illuminate. If the vehicle is operated with
remain constantly OFF, repair the warning and/or the four wheels lifted off the ground or with the four
indicator lights circuit or diagnosis circuit. <Ref. to wheels placed on rollers, the VDCCM will detect a
VDC-34 ABS WARNING LIGHT, VDC WARNING problem with the speed sensor and the ABS and
LIGHT, VDC OPERATING INDICATOR LIGHT OR VDC warning lights may illuminate. In this case,
VDC OFF INDICATOR LIGHT DOES NOT COME there is no abnormality. Clear the diagnostic code
ON., Diagnostics Chart with Diagnosis Connec- from memory.
tor.> 쐌 When the engine is started and vehicle move-
ment begins, the VDCH/U motor pump and sole-
NOTE: noid valve will operate for a few seconds. This
쐌 Even though the ABS warning light does not go permits checking of VDC function. Normal motor
out 1.5 seconds after it illuminates, the VDC sys- pump and solenoid valve operational noise will be
tem operates normally when the warning light goes heard. Normal brake pedal kick back will be felt
out while driving at approximately 12 km/h (7 when the brake pedal is depressed. In this case,
MPH). However, the Anti-lock brakes do not work there is no abnormality.
while the ABS warning light is illuminated.
쐌 It may take a few minutes for the VDC OFF
indicator light to go out when the vehicle is
exposed for some time in a low temperature area.
This is not a problem because of low engine cool-
ant temperatures.
쐌 If a vehicle wheel is stuck or free-spinning for
approximately 1 minute, power transfer fluctuation
to the remaining wheels will occur. Power transfer
VDC-25
VDC (DIAGNOSTICS)
13. List of Diagnostics Trouble Code S005511
A: LIST S005511A12
1. WITHOUT SUBARU SELECT MONITOR S005511A1201
Trouble
code
Start code
11 쐌 Trouble code is shown after start code. —
쐌 Only start code is shown in normal condition.
<Ref. to VDC-48 TROUBLE CODE 21 (FRONT RH) ABNORMAL
21 Front right ABS sensor ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO
HIGH), Diagnostics Chart with Diagnosis Connector.>
<Ref. to VDC-48 TROUBLE CODE 23 (FRONT LH) ABNORMAL
23 Front left ABS sensor ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO
Abnormal ABS sensor
(Open circuit or input
voltage too high) <Ref. to VDC-48 TROUBLE CODE 25 (REAR RH) ABNORMAL
25 Rear right ABS sensor ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO
<Ref. to VDC-48 TROUBLE CODE 27 (REAR LH) ABNORMAL
27 Rear left ABS sensor ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO
<Ref. to VDC-54 TROUBLE CODE 22 (FRONT RH) ABNORMAL
22 Front right ABS sensor ABS SENSOR (ABNORMAL ABS SENSOR SIGNAL), Diagnos-
<Ref. to VDC-54 TROUBLE CODE 24 (FRONT LH) ABNORMAL
24 Front left ABS sensor ABS SENSOR (ABNORMAL ABS SENSOR SIGNAL), Diagnos-
Abnormal ABS sensor <Ref. to VDC-54 TROUBLE CODE 26 (REAR RH) ABNORMAL
26 (Abnormal ABS sensor Rear right ABS sensor ABS SENSOR (ABNORMAL ABS SENSOR SIGNAL), Diagnos-
signal) tics Chart with Diagnosis Connector.>
<Ref. to VDC-54 TROUBLE CODE 28 (REAR LH) ABNORMAL
28 Rear left ABS sensor ABS SENSOR (ABNORMAL ABS SENSOR SIGNAL), Diagnos-
<Ref. to VDC-60 TROUBLE CODE 29 ABNORMAL ABS SEN-
29 Any one of four SOR SIGNAL (ANY ONE OF FOUR), Diagnostics Chart with
VDC-26
VDC (DIAGNOSTICS)
Trouble
code
<Ref. to VDC-64 TROUBLE CODE 31 (FRONT RH INLET)
31 Front right inlet valve ABNORMAL INLET AND CUT SOLENOID VALVE CIRCUIT(S),
<Ref. to VDC-70 TROUBLE CODE 32 (FRONT RH OUTLET)
32 Front right outlet valve ABNORMAL OUTLET AND SUCTION SOLENOID VALVE
CIRCUIT(S), Diagnostics Chart with Diagnosis Connector.>
<Ref. to VDC-64 TROUBLE CODE 33 (FRONT LH INLET)
33 Front left inlet valve ABNORMAL INLET AND CUT SOLENOID VALVE CIRCUIT(S),
<Ref. to VDC-70 TROUBLE CODE 34 (FRONT LH OUTLET)
34 Front left outlet valve ABNORMAL OUTLET AND SUCTION SOLENOID VALVE
<Ref. to VDC-64 TROUBLE CODE 35 (REAR RH INLET)
35 Rear right inlet valve ABNORMAL INLET AND CUT SOLENOID VALVE CIRCUIT(S),
<Ref. to VDC-70 TROUBLE CODE 36 (REAR RH OUTLET)
36 Rear right outlet valve ABNORMAL OUTLET AND SUCTION SOLENOID VALVE
Abnormal solenoid CIRCUIT(S), Diagnostics Chart with Diagnosis Connector.>
valve circuit(s) <Ref. to VDC-64 TROUBLE CODE 37 (REAR LH INLET)
37 Rear left inlet valve ABNORMAL INLET AND CUT SOLENOID VALVE CIRCUIT(S),
<Ref. to VDC-70 TROUBLE CODE 38 (REAR LH OUTLET)
38 Rear left outlet valve ABNORMAL OUTLET AND SUCTION SOLENOID VALVE
<Ref. to VDC-64 TROUBLE CODE 61 (PRIMARY CUT) ABNOR-
61 Primary cut valve MAL INLET AND CUT SOLENOID VALVE CIRCUIT(S), Diagnos-
<Ref. to VDC-64 TROUBLE CODE 62 (SECONDARY CUT)
62 Secondary cut valve ABNORMAL INLET AND CUT SOLENOID VALVE CIRCUIT(S),
<Ref. to VDC-70 TROUBLE CODE 63 (PRIMARY SUCTION)
63 Primary suction valve ABNORMAL OUTLET AND SUCTION SOLENOID VALVE
<Ref. to VDC-70 TROUBLE CODE 64 (SECONDARY SUCTION)
64 Secondary suction valve ABNORMAL OUTLET AND SUCTION SOLENOID VALVE
<Ref. to VDC-76 TROUBLE CODE 41 ABNORMAL VDC CON-
41 Abnormal VDC control module
TROL MODULE, Diagnostics Chart with Diagnosis Connector.>
<Ref. to VDC-78 TROUBLE CODE 42 SOURCE VOLTAGE IS
42 Source voltage is abnormal.
ABNORMAL., Diagnostics Chart with Diagnosis Connector.>
<Ref. to VDC-80 TROUBLE CODE 43 FAULTY VDCCM — ECM
43 Faulty VDCCM-ECM communication line COMMUNICATION LINE, Diagnostics Chart with Diagnosis Con-
nector.>
<Ref. to VDC-84 TROUBLE CODE 44 A COMMUNICATION
44 A communication with AT control abnormal WITH AT CONTROL ABNORMAL, Diagnostics Chart with Diag-
nosis Connector.>
<Ref. to VDC-86 TROUBLE CODE 45 CONTROL MODULE OUT
45 Control module out of specification OF SPECIFICATION, Diagnostics Chart with Diagnosis Connec-
tor.>
<Ref. to VDC-88 TROUBLE CODE 46 ABNORMAL VOLTAGE
46 Abnormal voltage of 5 V power supply OF 5 V POWER SUPPLY, Diagnostics Chart with Diagnosis Con-
nector.>
<Ref. to VDC-90 TROUBLE CODE 47 FAULTY CAN COMMUNI-
47 Faulty CAN communication line
CATION LINE, Diagnostics Chart with Diagnosis Connector.>
VDC-27
VDC (DIAGNOSTICS)
Trouble
code
<Ref. to VDC-94 TROUBLE CODE 48 FAULTY ECM — VDCCM
48 Faulty ECM-VDCCM communication line COMMUNICATION LINE, Diagnostics Chart with Diagnosis Con-
nector.>
<Ref. to VDC-96 TROUBLE CODE 49 ABNORMAL ENGINE
49 Abnormal engine speed signal
SPEED SIGNAL, Diagnostics Chart with Diagnosis Connector.>
<Ref. to VDC-98 TROUBLE CODE 51 ABNORMAL VALVE
51 Abnormal valve relay
RELAY, Diagnostics Chart with Diagnosis Connector.>
<Ref. to VDC-104 TROUBLE CODE 52 ABNORMAL MOTOR
52 Abnormal motor and/or motor relay AND/OR MOTOR RELAY, Diagnostics Chart with Diagnosis Con-
nector.>
<Ref. to VDC-110 TROUBLE CODE 71 ABNORMAL STEERING
71 Abnormal steering angle sensor
ANGLE SENSOR, Diagnostics Chart with Diagnosis Connector.>
<Ref. to VDC-114 TROUBLE CODE 72 ABNORMAL YAW RATE
72 Abnormal yaw rate sensor
SENSOR, Diagnostics Chart with Diagnosis Connector.>
<Ref. to VDC-118 TROUBLE CODE 73 ABNORMAL LATERAL G
73 Abnormal lateral G sensor
<Ref. to VDC-122 TROUBLE CODE 74 ABNORMAL PRESSURE
74 Abnormal pressure sensor
If any of the following multiple trouble codes are present in memory, check the area corresponding to the
first trouble code. If no problem is detected, check the areas corresponding to the other trouble codes in
order of their appearance.
Combina-
tion of
Problem area Index No.
trouble
codes
<Ref. to VDC-88 TROUBLE CODE 46 ABNORMAL VOLTAGE OF
(F87) — No. 78, 68 or 69 lead circuit is
46, 74 5 V POWER SUPPLY, Diagnostics Chart with Diagnosis Connec-
shorted to ground or battery.
tor.>
44, 71 (F87) — No. 83 or 81 lead circuit is open.
51, 48, 71 (F87) — No. 27 lead circuit is open.
71, 51, 44 (F87) — No. 27 lead circuit is open.
<Ref. to VDC-118 TROUBLE CODE 73 ABNORMAL LATERAL G
72, 73 (F87) — No. 63 lead circuit is open.
VDC-28
VDC (DIAGNOSTICS)

<Ref. to VDC-126 COMMUNICATION FOR INITIALIZING IMPOS-
Communication for Select monitor communi-
— SIBLE (SELECT MONITOR COMMUNICATION FAILURE), Diag-
initializing impossible cation failure
nostics Chart with Select Monitor.>
Although no trouble
code appears on the
select monitor display,
— No trouble code and/or VDC warning <Ref. to VDC-34 Diagnostics Chart with Diagnosis Connector.>
light and/or VDC operat-
ing indicator light and/or
VDC OFF indicator light
remains on.
Although no trouble
code appears on the
select monitor display,
— No trouble code and/or VDC warning <Ref. to VDC-34 Diagnostics Chart with Diagnosis Connector.>
light and/or VDC operat-
ing indicator light and/or
remains off.
Front right ABS sen- Open or short circuit in <Ref. to VDC-128 TROUBLE CODE 21 FRONT RIGHT ABS SEN-
21 sor circuit open or front right ABS sensor SOR CIRCUIT OPEN OR SHORTED BATTERY, Diagnostics Chart
shorted battery circuit with Select Monitor.>
Front right ABS sen- Front right ABS sensor <Ref. to VDC-134 TROUBLE CODE 22 FRONT RIGHT ABS SEN-
22
sor signal abnormal signal SOR SIGNAL, Diagnostics Chart with Select Monitor.>
Front left ABS sensor Open or short circuit in <Ref. to VDC-128 TROUBLE CODE 23 FRONT LEFT ABS SEN-
23 circuit open or shorted front left ABS sensor SOR CIRCUIT OPEN OR SHORTED BATTERY, Diagnostics Chart
battery circuit with Select Monitor.>
Front left ABS sensor Front left ABS sensor <Ref. to VDC-134 TROUBLE CODE 24 FRONT LEFT ABS SEN-
24
signal abnormal signal SOR SIGNAL, Diagnostics Chart with Select Monitor.>
Rear right ABS sensor Open or short circuit in <Ref. to VDC-128 TROUBLE CODE 25 REAR RIGHT ABS SEN-
25 circuit open or shorted rear right ABS sensor SOR CIRCUIT OPEN OR SHORTED BATTERY, Diagnostics Chart
battery circuit with Select Monitor.>
Rear right ABS sensor Rear right ABS sensor <Ref. to VDC-134 TROUBLE CODE 26 REAR RIGHT ABS SEN-
26
Rear left ABS sensor Open or short circuit in <Ref. to VDC-128 TROUBLE CODE 27 REAR LEFT ABS SEN-
27 circuit open or shorted rear left ABS sensor cir- SOR CIRCUIT OPEN OR SHORTED BATTERY, Diagnostics Chart
battery cuit with Select Monitor.>
Rear left ABS sensor Rear left ABS sensor <Ref. to VDC-134 TROUBLE CODE 28 REAR LEFT ABS SEN-
28
Abnormal ABS sensor
Any one of four ABS <Ref. to VDC-140 TROUBLE CODE 29 ANY ONE OF FOUR ABS
29 signal on any one of
sensor signal SENSOR SIGNAL, Diagnostics Chart with Select Monitor.>
four sensor
<Ref. to VDC-144 TROUBLE CODE 31 FR HOLD VALVE MAL-
FR hold valve mal- Front right inlet solenoid
31 FUNCTION (FRONT RIGHT INLET VALVE MALFUNCTION), Diag-
function valve
<Ref. to VDC-150 TROUBLE CODE 32 FR PRESSURE REDUC-
FR pressure reducing Front right outlet sole-
32 ING VALVE MALFUNCTION (FRONT RIGHT OUTLET VALVE
valve malfunction noid valve malfunction
MALFUNCTION), Diagnostics Chart with Select Monitor.>
<Ref. to VDC-144 TROUBLE CODE 33 FL HOLD VALVE MAL-
FL hold valve mal- Front left inlet solenoid
33 FUNCTION (FRONT LEFT INLET VALVE MALFUNCTION), Diag-
function valve malfunction
<Ref. to VDC-150 TROUBLE CODE 34 FL PRESSURE REDUC-
FL pressure reducing Front left outlet solenoid
34 ING VALVE MALFUNCTION (FRONT LEFT OUTLET VALVE
valve malfunction valve
VDC-29
VDC (DIAGNOSTICS)

<Ref. to VDC-144 TROUBLE CODE 35 RR HOLD VALVE MAL-
RR hold valve mal- Rear right inlet solenoid
35 FUNCTION (REAR RIGHT INLET VALVE MALFUNCTION), Diag-
<Ref. to VDC-150 TROUBLE CODE 36 RR PRESSURE REDUC-
RR pressure reducing Rear right outlet sole-
36 ING VALVE MALFUNCTION (REAR RIGHT OUTLET VALVE
valve malfunction noid valve
<Ref. to VDC-144 TROUBLE CODE 37 RL HOLD VALVE MAL-
RL hold valve mal- Rear left inlet solenoid
37 FUNCTION (REAR LEFT INLET VALVE MALFUNCTION), Diag-
<Ref. to VDC-150 TROUBLE CODE 38 RL PRESSURE REDUC-
RL pressure reducing Rear left outlet solenoid
38 ING VALVE MALFUNCTION (REAR LEFT OUTLET VALVE
valve malfunction valve
<Ref. to VDC-156 TROUBLE CODE 41 ELECTRICAL CONTROL
Electrical control mod- VDC control module
41 MODULE (VDC CONTROL MODULE MALFUNCTION), Diagnos-
ule malfunction
tics Chart with Select Monitor.>
Power supply voltage Power supply voltage <Ref. to VDC-158 TROUBLE CODE 42 POWER SUPPLY VOLT-
42
low too low AGE LOW, Diagnostics Chart with Select Monitor.>
AET communication AET communication line <Ref. to VDC-160 TROUBLE CODE 43 AET COMMUNICATION
43
line malfunction malfunction LINE MALFUNCTION, Diagnostics Chart with Select Monitor.>
AEB communication AEB communication line <Ref. to VDC-162 TROUBLE CODE 43 AEB COMMUNICATION
43
AEC communication AEC communication line <Ref. to VDC-164 TROUBLE CODE 43 AEC COMMUNICATION
43
TCM communication TCM communication line <Ref. to VDC-166 TROUBLE CODE 44 TCM COMMUNICATION
44
circuit malfunction CIRCUIT, Diagnostics Chart with Select Monitor.>
Incorrect VDC control Incorrect VDC control <Ref. to VDC-168 TROUBLE CODE 45 INCORRECT VDC CON-
45
module module TROL MODULE, Diagnostics Chart with Select Monitor.>
TCM malfunction TCM malfunction specifi- <Ref. to VDC-169 TROUBLE CODE 45 TCM MALFUNCTION
45
specifications cations SPECIFICATIONS, Diagnostics Chart with Select Monitor.>
Abnormal voltage of 5 Abnormal voltage of 5 V <Ref. to VDC-170 TROUBLE CODE 46 ABNORMAL VOLTAGE
46
V power supply power supply OF 5 V POWER SUPPLY, Diagnostics Chart with Select Monitor.>
Improper CAN com- CAN communication line <Ref. to VDC-172 TROUBLE CODE 47 IMPROPER CAN
47
munication malfunction COMMUNICATION, Diagnostics Chart with Select Monitor.>
Improper EAC com- EAC communication line <Ref. to VDC-176 TROUBLE CODE 48 IMPROPER EAC
48
munication malfunction COMMUNICATION, Diagnostics Chart with Select Monitor.>
<Ref. to VDC-178 TROUBLE CODE 48 EAS COMMUNICATION
EAS communication EAS communication line
48 LINE GROUNDING SHORTED, Diagnostics Chart with Select
line grounding shorted grounding
Monitor.>
Erroneous communi- <Ref. to VDC-180 TROUBLE CODE 48 ERRONEOUS COMMUNI-
Faulty ECM-VDCCM
48 cation from EGI to CATION FROM EGI TO VDC, Diagnostics Chart with Select Moni-
communication line
VDC tor.>
Abnormal engine Abnormal engine speed <Ref. to VDC-182 TROUBLE CODE 49 ABNORMAL ENGINE
49
speed signal signal SPEED SIGNAL, Diagnostics Chart with Select Monitor.>
<Ref. to VDC-184 TROUBLE CODE 51 VALVE RELAY, Diagnos-
51 Valve relay Valve relay malfunction
tics Chart with Select Monitor.>
<Ref. to VDC-190 TROUBLE CODE 51 VALVE RELAY ON
51 Valve relay ON failure Valve relay ON failure
FAILURE, Diagnostics Chart with Select Monitor.>
Motor and motor relay Motor and motor relay <Ref. to VDC-194 TROUBLE CODE 52 MOTOR AND MOTOR
52
OFF failure OFF failure RELAY OFF FAILURE, Diagnostics Chart with Select Monitor.>
Motor and motor relay Motor and motor relay <Ref. to VDC-198 TROUBLE CODE 52 MOTOR AND MOTOR
52
ON failure ON failure RELAY ON FAILURE, Diagnostics Chart with Select Monitor.>
<Ref. to VDC-204 TROUBLE CODE 52 MOTOR MALFUNCTION,
52 Motor malfunction Motor malfunction
Diagnostics Chart with Select Monitor.>
<Ref. to VDC-144 TROUBLE CODE 61 NORMAL OPENING
Normal opening valve Primary cut valve mal-
61 VALVE 2 MALFUNCTION (PRIMARY CUT VALVE
2 malfunction function
VDC-30
VDC (DIAGNOSTICS)

<Ref. to VDC-144 TROUBLE CODE 62 NORMAL OPENING
Normal opening valve Secondary cut valve
62 VALVE 1 MALFUNCTION (SECONDARY CUT VALVE
1 malfunction malfunction
<Ref. to VDC-150 TROUBLE CODE 63 NORMAL CLOSING
Normal closing valve Primary suction valve
63 VALVE 2 MALFUNCTION (PRIMARY SUCTION VALVE
<Ref. to VDC-150 TROUBLE CODE 64 NORMAL CLOSING
Normal closing valve Secondary suction valve
64 VALVE 1 MALFUNCTION (SECONDARY SUCTION VALVE
<Ref. to VDC-208 TROUBLE CODE 71 STEERING ANGLE SEN-
Steering angle sensor Steering angle sensor
71 SOR OFFSET IS TOO BIG., Diagnostics Chart with Select Moni-
offset is too big. offset is too big.
tor.>
Change range of Change range of steer- <Ref. to VDC-210 TROUBLE CODE 71 CHANGE RANGE OF
71 steering angle sensor ing angle sensor is too STEERING ANGLE SENSOR IS TOO BIG., Diagnostics Chart with
is too big. big. Select Monitor.>
Steering angle sensor Steering angle sensor <Ref. to VDC-212 TROUBLE CODE 71 STEERING ANGLE SEN-
71
malfunction malfunction SOR MALFUNCTION, Diagnostics Chart with Select Monitor.>
<Ref. to VDC-214 TROUBLE CODE 71 NO SIGNAL FROM
No signal from steer- No signal from steering
71 STEERING ANGLE SENSOR, Diagnostics Chart with Select Moni-
ing angle sensor angle sensor
tor.>
Abnormal yaw rate Abnormal yaw rate sen- <Ref. to VDC-216 TROUBLE CODE 72 ABNORMAL YAW RATE
72
sensor output sor output SENSOR OUTPUT, Diagnostics Chart with Select Monitor.>
Voltage inputted to Voltage inputted to yaw <Ref. to VDC-218 TROUBLE CODE 72 VOLTAGE INPUTTED TO
72 yaw rate sensor rate sensor exceeds YAW RATE SENSOR EXCEEDS SPECIFICATION., Diagnostics
exceeds specification. specification. Chart with Select Monitor.>
Abnormal yaw rate <Ref. to VDC-222 TROUBLE CODE 72 ABNORMAL YAW RATE
Abnormal yaw rate sen-
72 sensor reference volt- SENSOR REFERENCE VOLTAGE, Diagnostics Chart with Select
sor reference voltage
age Monitor.>
Change range of yaw Change range of yaw <Ref. to VDC-226 TROUBLE CODE 72 CHANGE RANGE OF
72 rate sensor signal is rate sensor signal is too YAW RATE SENSOR SIGNAL IS TOO BIG., Diagnostics Chart
too big. big. with Select Monitor.>
Lateral G sensor off- Lateral G sensor offset <Ref. to VDC-230 TROUBLE CODE 73 LATERAL G SENSOR
73
set is too big. is too big. OFFSET IS TOO BIG., Diagnostics Chart with Select Monitor.>
Abnormal lateral G Abnormal lateral G sen- <Ref. to VDC-230 TROUBLE CODE 73 ABNORMAL LATERAL G
73
sensor output sor output SENSOR OUTPUT, Diagnostics Chart with Select Monitor.>
Change range of lat- <Ref. to VDC-230 TROUBLE CODE 73 CHANGE RANGE OF
Change range of lateral
73 eral G sensor is too LATERAL G SENSOR IS TOO BIG., Diagnostics Chart with Select
G sensor is too big.
big. Monitor.>
Excessive lateral G Excessive lateral G sen- <Ref. to VDC-230 TROUBLE CODE 73 EXCESSIVE LATERAL G
73
sensor signal sor signal SENSOR SIGNAL, Diagnostics Chart with Select Monitor.>
Voltage inputted to Voltage inputted to lat- <Ref. to VDC-234 TROUBLE CODE 73 VOLTAGE INPUTTED TO
73 lateral G sensor eral G sensor exceeds LATERAL G SENSOR EXCEEDS SPECIFICATION., Diagnostics
exceeds specification. specification. Chart with Select Monitor.>
Voltage inputted to Voltage inputted to pri- <Ref. to VDC-238 TROUBLE CODE 74 VOLTAGE INPUTTED TO
74 pressure sensor 1 mary pressure sensor PRESSURE SENSOR 1 EXCEEDS SPECIFICATION. (PRIMARY
exceeds specification. exceeds specification. PRESSURE SENSOR), Diagnostics Chart with Select Monitor.>
<Ref. to VDC-242 TROUBLE CODE 74 VOLTAGE INPUTTED TO
Voltage inputted to Voltage inputted to sec-
PRESSURE SENSOR 2 EXCEEDS SPECIFICATION. (SECOND-
74 pressure sensor 2 ondary pressure sensor
ARY PRESSURE SENSOR), Diagnostics Chart with Select Moni-
exceeds specification. exceeds specification.
tor.>
<Ref. to VDC-246 TROUBLE CODE 74 PRESSURE SENSOR 1
Pressure sensor 1 Primary pressure sensor
74 OFFSET IS TOO BIG. (PRIMARY PRESSURE SENSOR), Diag-
offset is too big. offset is too big.
<Ref. to VDC-246 TROUBLE CODE 74 PRESSURE SENSOR 2
Pressure sensor 2 Secondary pressure
74 OFFSET IS TOO BIG. (SECONDARY PRESSURE SENSOR),
offset is too big. sensor offset is too big.
Diagnostics Chart with Select Monitor.>
VDC-31
VDC (DIAGNOSTICS)

Differential pressure Differential pressure of <Ref. to VDC-248 TROUBLE CODE 74 DIFFERENTIAL PRES-
74 of pressure sensor is pressure sensor is too SURE OF PRESSURE SENSOR IS TOO BIG., Diagnostics Chart
too big. big. with Select Monitor.>
If any of the following multiple trouble codes are present in memory, check the area corresponding to the
first trouble code. If no problem is detected, check the areas corresponding to the other trouble codes in
order of their appearance.
Combination of trouble codes Problem area Index No.
<Ref. to VDC-170 TROUBLE CODE 46
46 Abnormal voltage of 5 V power supply
(F87) — No. 78, 68 or 69 lead circuit ABNORMAL VOLTAGE OF 5 V POWER
74 Voltage inputted to pressure sensor 2
is shorted to ground or battery. SUPPLY, Diagnostics Chart with Select
exceeds specification.
Monitor.>
44 TCM communication circuit (F87) — No. 83 or 81 lead circuit is NO SIGNAL FROM STEERING ANGLE
71 No signal from steering angle sensor open. SENSOR, Diagnostics Chart with Select
Monitor.>
51 Valve relay
NO SIGNAL FROM STEERING ANGLE
48 Improper EAC communication (F87) — No. 27 lead circuit is open.
SENSOR, Diagnostics Chart with Select
71 No signal from steering angle sensor
Monitor.>
71 No signal from steering angle sensor
NO SIGNAL FROM STEERING ANGLE
51 Valve relay (F87) — No. 27 lead circuit is open.
SENSOR, Diagnostics Chart with Select
44 TCM communication circuit
Monitor.>
73 Voltage inputted to lateral G sensor <Ref. to VDC-230 TROUBLE CODE 73
exceeds specification. EXCESSIVE LATERAL G SENSOR
(F87) — No. 23 lead circuit is open.
72 Voltage inputted to yaw rate sensor SIGNAL, Diagnostics Chart with Select
exceeds specifications. Monitor.>
VDC-32
VDC (DIAGNOSTICS)
MEMO:
VDC-33
VDC (DIAGNOSTICS)
14. Diagnostics Chart with Diagnosis Connector S005522
A: ABS WARNING LIGHT, VDC WARNING LIGHT, VDC OPERATING

INDICATOR LIGHT OR VDC OFF INDICATOR LIGHT DOES NOT COME ON.
S005522E26
DIAGNOSIS:
쐌 VDC warning light circuit is open or shorted.
쐌 VDC operating indicator light circuit is open or shorted.
쐌 VDC OFF indicator light circuit is open or shorted.
TROUBLE SYMPTOM:
쐌 When ignition switch is turned ON (engine OFF), ABS warning light, VDC warning light, VDC operating
indicator light or VDC OFF indicator light does not come on.
VDC-34
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2318
VDC-35
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK IF OTHER WARNING LIGHTS Do other warning lights turn Go to step 2. Repair combina-
TURN ON. on? tion meter. <Ref.
Turn ignition switch to ON (engine OFF). to IDI-17 Combi-
nation Meter
Assembly.>
2 CHECK LIGHT BULB. Is light bulb OK? Go to step 3. Replace faulty
1) Turn ignition switch to OFF. light bulb. <Ref. to
2) Remove combination meter. IDI-17
3) Remove ABS warning light bulb, VDC DISASSEMBLY,
warning light bulb, VDC operating indicator Combination
light bulb or VDC OFF indicator light bulb Meter Assembly.>
from combination meter.
3 CHECK BATTERY SHORT OF LIGHT HAR- Is voltage less than 3 V? Go to step 4. Repair light har-
NESS. ness.
1) Disconnect VDCCM connector from
VDCCM.
2) Place a sheet of thick paper [thickness 1.5
mm (0.059 in)] in switch area of VDCCM con-
nector.
4) Measure voltage between VDC connector
and chassis ground.
ABS warning light
VDC warning light
VDC operating indicator light
4 CHECK WIRING HARNESS. Is voltage between 10 and Go to step 5. Repair wiring har-
1) Turn ignition switch to OFF. 15 V? ness.
2) Install ABS warning light bulb from combi-
nation meter.
3) Install combination meter.
4) Place a sheet of thick paper [thickness 1.5
mm (0.059 in)] in switch area of VDCCM con-
nector.
6) Measure voltage between VDCCM connec-
tor and chassis ground.
ABS warning light
VDC warning light
VDC operating indicator light
TORS. connectors between combi-
Turn ignition switch to OFF. nation meter and VDCCM?
6 CHECK WARNING AND INDICATOR Do ABS warning light, VDC A temporary poor Replace VDCCM.
LIGHTS. warning light, VDC operat- contact. <Ref. to VDC-10
1) Connect connector to VDCCM. ing indicator light and VDC VDC Control Mod-
2) Turn ignition switch to ON. OFF indicator light turn on? ule (VDCCM).>
VDC-36
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-37
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
B: ABS AND VDC WARNING LIGHTS DO NOT GO OFF. S005522F13
DIAGNOSIS:
쐌 VDC warning light circuit is open or shorted.
TROUBLE SYMPTOM:
쐌 When starting the engine and while ABS and/or VDC warning light is kept ON.
VDC-38
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2318
VDC-39
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK INSTALLATION OF VDCCM CON- Is VDCCM connector Go to step 2. Insert VDCCM
NECTOR. inserted into VDCCM until connector into
Turn ignition switch to OFF. the clamp locks onto it? VDCCM until the
clamp locks onto
it.
Terminals
ground:
ground:
2) Connect diagnosis terminal (B81) to diag- between VDCCM
nosis connector (B82) No. 8. and diagnosis
3) Disconnect connector from VDCCM. connector.
4) Measure resistance between VDCCM con-
4 CHECK WIRING HARNESS. Do the ABS warning light Go to step 5. Repair front wiring
1) Place a sheet of thick paper [thickness 1.5 and VDC warning light harness.
mm (0.059 in)] in switch area of VDCCM con- remain off?
nector.
5 CHECK PROJECTION AT VDCCM. Are the projection broken? Go to step 6. Replace VDCCM.
1) Turn ignition switch to OFF. <Ref. to VDC-10
2) Check for broken projection at the VDCCM VDC Control Mod-
terminal. ule (VDCCM).>
6 CHECK POWER SUPPLY OF VDCCM. Is the voltage between 10 Go to step 7. Repair VDCCM
1) Disconnect connector from VDCCM. and 15 V? power supply cir-
2) Start engine. cuit.
3) Idle the engine.
7 CHECK POOR CONTACT IN VDCCM CON- Is there poor contact in Repair connector. Replace VDCCM.
NECTOR. VDCCM connector? <Ref. to VDC-10
VDC Control Mod-
ule (VDCCM).>
VDC-40
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-41
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
C: VDC OPERATING INDICATOR LIGHT DOES NOT GO OFF. S005522E53
DIAGNOSIS:
쐌 VDC operating indicator light circuit is open or shorted.
TROUBLE SYMPTOM:
쐌 When starting the engine and while VDC operating indicator light is kept ON.
WIRING DIAGRAM:
B4M2318
VDC-42
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK WIRING HARNESS. Does the VDC operating Replace VDCCM. Repair wiring har-
1) Turn ignition switch to OFF. indicator light remain off? <Ref. to VDC-10 ness.
2) Disconnect VDCCM connector from VDC Control Mod-
VDCCM. ule (VDCCM).>
VDC-43
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
D: VDC OFF INDICATOR LIGHT DOES NOT GO OFF. S005522E52
DIAGNOSIS:
쐌 VDC OFF indicator light circuit is open or shorted.
쐌 VDC OFF switch is shorted.
TROUBLE SYMPTOM:
쐌 When starting the engine and while VDC OFF indicator light is kept ON.
WIRING DIAGRAM:
B4M2318
VDC-44
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK VDC OFF SWITCH. Is fuse installed to VDC Remove fuse. Go to step 2.
1) Turn ignition switch to OFF. OFF switch?
2) Check VDC OFF switch.
2 CHECK ENGINE COOLANT TEMPERA- Does VDC OFF indicator The VDC is nor- Go to step 3.
TURE. light come on when engine mal.
coolant temperature is too
low? Does it go out after
engine has warmed up?
3 CHECK BRAKE. Does VDC OFF indicator VDC is normal. Go to step 4.
light come on after frequent Stop vehicle and
brake pedal operation? wait until brakes
cool down.
4 CHECK WIRING HARNESS. Does the VDC OFF indica- Go to step 5. Repair wiring har-
1) Turn ignition switch to OFF. tor light remain off? ness.
2) Disconnect VDCCM connector from
VDCCM.
5 CHECK VDC OFF SWITCH LINE. Is the resistance more than Replace VDCCM. Repair VDC OFF
1) Disconnect fuse from VDC OFF switch. 1 MΩ? <Ref. to VDC-10 switch circuit.
2) Measure resistance between VDCCM con- VDC Control Mod-
nector and chassis ground. ule (VDCCM).>
VDC-45
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
E: TROUBLE CODE DOES NOT APPEAR. S005522E50
DIAGNOSIS:
TROUBLE SYMPTOM:
쐌 The ABS warning light turns on or off normally but the start code cannot be read out in the diagnostic
mode.
WIRING DIAGRAM:
B4M2318
VDC-46
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

Terminals
ground:
ground:
2) Connect diagnosis terminal (B81) to diag- between VDCCM
nosis connector (B82) No. 8. and diagnosis
3) Disconnect connector from VDCCM. connector.
3 CHECK POOR CONTACT IN VDCCM CON- Is there poor contact in Repair connector. Replace VDCCM.
NECTOR. VDCCM connector? <Ref. to VDC-10
VDC Control Mod-
ule (VDCCM).>
VDC-47
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
F: TROUBLE CODE 21 (FRONT RH) ABNORMAL ABS SENSOR (OPEN

CIRCUIT OR INPUT VOLTAGE TOO HIGH) S005522C46
NOTE:
For diagnostic procedure, refer to TROUBLE CODE 27. <Ref. to VDC-48 TROUBLE CODE 27 (REAR LH)
ABNORMAL ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH), Diagnostics Chart with
G: TROUBLE CODE 23 (FRONT LH) ABNORMAL ABS SENSOR (OPEN
NOTE:
H: TROUBLE CODE 25 (REAR RH) ABNORMAL ABS SENSOR (OPEN
NOTE:
I: TROUBLE CODE 27 (REAR LH) ABNORMAL ABS SENSOR (OPEN CIRCUIT
OR INPUT VOLTAGE TOO HIGH) S005522C75
DIAGNOSIS:
TROUBLE SYMPTOM:
쐌 VDC does not operate.
VDC-48
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2319
VDC-49
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK ABS SENSOR. Is the resistance between Go to step 2. Replace ABS sen-
1) Turn ignition switch to OFF. 1.0 and 1.5 kΩ? sor. Front <Ref. to
2) Disconnect connector from ABS sensor. VDC-30 Front
tor terminals. Rear <Ref. to
Terminal VDC-31 Rear
Front RH No. 1 — No. 2: ABS Sensor.>
SOR. V? sor. Front <Ref. to
1) Disconnect connector from VDCCM. VDC-30 Front
chassis ground. Rear <Ref. to
Front RH No. 1 (+) — Chassis ground ABS Sensor.>
(−):
(−):
(−):
(−):
1) Turn ignition switch to ON. VDC-30 Front
(−):
(−):
(−):
(−):
4 CHECK HARNESS/CONNECTOR Is the resistance between Go to step 5. Repair harness/
BETWEEN VDCCM AND ABS SENSOR. 1.0 and 1.5 kΩ? connector
1) Turn ignition switch to OFF. between VDCCM
2) Connect connector to ABS sensor. and ABS sensor.
nector terminals.
15:
19:
46:
17:
VDC-50
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

Measure voltage between VDCCM connector V? between VDCCM
and chassis ground. and ABS sensor.
Trouble code 21 / (F87) No. 14 (+) —
Trouble code 23 / (F87) No. 49 (+) —
Trouble code 25 / (F87) No. 18 (+) —
Trouble code 27 / (F87) No. 16 (+) —
1) Turn ignition switch to ON. V? between VDCCM
2) Measure voltage between VDCCM connec- and ABS sensor.
Trouble code 21 / (F87) No. 14 (+) —
Trouble code 23 / (F87) No. 49 (+) —
Trouble code 25 / (F87) No. 18 (+) —
Trouble code 27 / (F87) No. 16 (+) —
Measure tone wheel-to-pole piece gap over fications? NOTE:
entire perimeter of the wheel. Adjust the gap
Specifications using spacers
Front wheel (Part No.
0.3 — 0.8 mm (0.012 — 0.031 in) 26755AA000). If
Rear wheel spacers cannot
replace worn sen-
sor or worn tone
wheel.
9 CHECK HUB AND TONE WHEEL RUNOUT. Is the runout less than 0.05 Go to step 10. Repair hub and
Measure hub and tone wheel runout. mm (0.0020 in)? tone wheel. Front
<Ref. to VDC-32
Front Tone
Wheel.> Rear
<Ref. to VDC-33
Rear Tone
Wheel.>
VDCCM and ABS sensor?
11 CHECK VDCCM. Is the same trouble code Replace VDCCM. Go to step 12.
1) Connect all connectors. as in the current diagnosis <Ref. to VDC-10
2) Erase the memory. still being output? VDC Control Mod-
3) Perform inspection mode. ule (VDCCM).>
VDC-51
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

and connectors
between VDCCM
and ABS sensor.
VDC-52
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-53
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
J: TROUBLE CODE 22 (FRONT RH) ABNORMAL ABS SENSOR (ABNORMAL

ABS SENSOR SIGNAL) S005522C52
NOTE:
ABNORMAL ABS SENSOR (ABNORMAL ABS SENSOR SIGNAL), Diagnostics Chart with Diagnosis Con-
nector.>
K: TROUBLE CODE 24 (FRONT LH) ABNORMAL ABS SENSOR (ABNORMAL
NOTE:
nector.>
L: TROUBLE CODE 26 (REAR RH) ABNORMAL ABS SENSOR (ABNORMAL
NOTE:
nector.>
M: TROUBLE CODE 28 (REAR LH) ABNORMAL ABS SENSOR (ABNORMAL
DIAGNOSIS:
TROUBLE SYMPTOM:
VDC-54
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2319
VDC-55
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

Measure tone wheel to pole piece gap over fications? NOTE:
sor or worn tone
wheel.
3 CHECK OSCILLOSCOPE. Is an oscilloscope avail- Go to step 4. Go to step 5.
able?
3) Remove VDCCM connector cover. <Ref. to
VDC-17 VDCCM Connector Cover.>
NOTE:
VDCCM sometimes stores the trouble code
29.
Trouble code 22 / (F87) No. 14 (+) —
No. 15 (−):
Trouble code 24 / (F87) No. 49 (+) —
No. 19 (−):
Trouble code 26 / (F87) No. 18 (+) —
No. 46 (−):
Trouble code 28 / (F87) No. 16 (+) —
No. 17 (−):
5 CHECK CONTAMINATION OF ABS SEN- Is the ABS sensor pole Thoroughly Go to step 6.
SOR OR TONE WHEEL. piece or the tone wheel remove dirt or
Remove disc rotor or drum from hub in accor- contaminated by dirt or other foreign mat-
dance with trouble code. other foreign matter? ter.
pole piece or the tone Front <Ref. to
wheel? VDC-30 Front
ABS Sensor.> and
<Ref. to VDC-32
Front Tone
Wheel.> Rear
<Ref. to VDC-31
Rear ABS Sen-
sor.> and <Ref. to
VDC-33 Rear
Tone Wheel.>
VDC-56
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

7 CHECK TONE WHEEL RUNOUT. Is the runout less than 0.05 Go to step 8. Repair tone
Measure tone wheel runout. mm (0.0020 in)? wheel. Front <Ref.
to VDC-32 Front
Tone Wheel.>
Rear <Ref. to
VDC-33 Rear
Tone Wheel.>
8 CHECK RESISTANCE OF ABS SENSOR. Is the resistance between Go to step 9. Replace ABS sen-
1) Turn ignition switch OFF. 1.0 and 1.5 kΩ? sor. Front <Ref. to
connector terminals. Rear <Ref. to
SOR. 1 MΩ? sor. Front <Ref. to
Measure resistance between ABS sensor and VDC-30 Front
Terminal Rear <Ref. to
Front RH No. 1 — Chassis ground: VDC-31 Rear
Front LH No. 1 — Chassis ground: ABS Sensor.>
1) Connect connector to ABS sensor. between VDCCM
2) Disconnect connector from VDCCM. and ABS sensor.
3) Measure resistance at VDCCM connector
terminals.
15:
19:
46:
17:
Measure resistance between VDCCM connec- 1 MΩ? connector
tor and chassis ground. between VDCCM
Connector & terminal and ABS sensor.
sis ground:
sis ground:
sis ground:
sis ground:
12 CHECK GROUND CIRCUIT OF VDCCM. Is the resistance less than Go to step 13. Repair VDCCM
Measure resistance between VDCCM and 0.5 Ω? ground harness.
chassis ground.
VDC-57
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

transmitter.
harness.
Chassis ground:
Chassis ground:
NOTE:
For the trouble code 26 and 28, Go to step
17.
sponding to the
trouble code.
VDC-58
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-59
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
N: TROUBLE CODE 29 ABNORMAL ABS SENSOR SIGNAL (ANY ONE OF

FOUR) S005522C84
DIAGNOSIS:
TROUBLE SYMPTOM:
VDC-60
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2319
VDC-61
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK IF THE WHEELS HAVE TURNED Check if the wheels have The VDC is nor- Go to step 2.
when the vehicle
is towed or
jacked-up, or
when steering
wheel is continu-
ously turned all
the way, this
trouble code may
sometimes occur.
correct?
sively?
sure.
sor or worn tone
wheel.
able?
NOTE:
29.
(F87) No. 14 (+) — No. 15 (−) (Front
RH):
(F87) No. 49 (+) — No. 19 (−) (Front
LH):
(F87) No. 18 (+) — No. 46 (−) (Rear
RH):
(F87) No. 16 (+) — No. 17 (−) (Rear LH):
VDC-62
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

Remove disc rotor from hub. contaminated by dirt or other foreign mat-
other foreign matter? ter.
sor pole piece or the tone Front <Ref. to
wheel? VDC-30 Front
ABS Sensor.> and
<Ref. to VDC-32
Front Tone
Wheel.> Rear
<Ref. to VDC-31
Rear ABS Sen-
sor.> and <Ref. to
VDC-33 Rear
Tone Wheel.>
to VDC-32 Front
Tone Wheel.>
Rear <Ref. to
VDC-33 Rear
Tone Wheel.>
1) Turn ignition switch to OFF. as in the current diagnosis <Ref. to VDC-10
2) Connect all connectors. still being output? VDC Control Mod-
3) Erase the memory. ule (VDCCM).>
sponding to the
trouble code.
VDC-63
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
O: TROUBLE CODE 31 (FRONT RH INLET) ABNORMAL INLET AND CUT

SOLENOID VALVE CIRCUIT(S) S005522C90
NOTE:
For diagnostic procedure, refer to TROUBLE CODE 62. <Ref. to VDC-64 TROUBLE CODE 62 (SECOND-
ARY CUT) ABNORMAL INLET AND CUT SOLENOID VALVE CIRCUIT(S), Diagnostics Chart with Diagno-
sis Connector.>
P: TROUBLE CODE 33 (FRONT LH INLET) ABNORMAL INLET AND CUT
SOLENOID VALVE CIRCUIT(S) S005522D00
NOTE:
sis Connector.>
Q: TROUBLE CODE 35 (REAR RH INLET) ABNORMAL INLET AND CUT
NOTE:
sis Connector.>
R: TROUBLE CODE 37 (REAR LH INLET) ABNORMAL INLET AND CUT
NOTE:
sis Connector.>
S: TROUBLE CODE 61 (PRIMARY CUT) ABNORMAL INLET AND CUT
NOTE:
sis Connector.>
T: TROUBLE CODE 62 (SECONDARY CUT) ABNORMAL INLET AND CUT
DIAGNOSIS:
쐌 Faulty solenoid valve in VDCH/U
TROUBLE SYMPTOM:
VDC-64
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2320
VDC-65
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK RESISTANCE OF SOLENOID Is the resistance between Go to step 2. Replace VDCH/U.
VALVE. 8.04 and 9.04 Ω? <Ref. to VDC-13
1) Turn ignition switch to OFF. Hydraulic Control
2) Disconnect two connectors (VDC1, F91) Unit (H/U).>
from VDCH/U.
3) Measure resistance between VDCH/U con-
nector terminals.
Trouble code 31/(VDC5) No. 5 —
(VDC2) No. 2:
(VDC2) No. 2:
(VDC2) No. 2:
(VDC2) No. 2:
(VDC2) No. 2:
(VDC2) No. 2:
2 CHECK GROUND SHORT OF SOLENOID Is the resistance more than Go to step 3. Replace VDCH/U.
VALVE. 1 MΩ? <Ref. to VDC-13
Measure resistance between VDCH/U con- Hydraulic Control
nector and chassis ground. Unit (H/U).>
Trouble code 31/(VDC5) No. 5 — Chas-
sis ground:
sis ground:
sis ground:
sis ground:
sis ground:
Chassis ground:
3 CHECK BATTERY SHORT OF SOLENOID Is the voltage less than 1 Go to step 4. Replace VDCH/U.
VALVE. V? <Ref. to VDC-13
1) Disconnect connector from VDCCM. Hydraulic Control
2) Measure voltage between VDCH/U con- Unit (H/U).>
Trouble code 31/(VDC5) No. 5 (+) —
VDC-66
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1) Turn ignition switch to ON. Hydraulic Control
1) Turn ignition switch to OFF. V? between VDCCM
2) Measure voltage between VDCCM connec- and VDCH/U.
Trouble code 31/(F87) No. 30 (+) —
VDC-67
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1) Turn ignition switch to OFF. 1 MΩ? between VDCCM
2) Measure resistance between VDCCM con- and VDCH/U.
Trouble code 31/(F87) No. 30 — Chas-
sis ground:
sis ground:
sis ground:
sis ground:
sis ground:
sis ground:
BETWEEN VDCCM AND VDCH/U. and 10 Ω? connector
1) Connect connector (F91) to VDCH/U. between VDCCM
nector and VDCH/U connector.
Trouble code 31/(F87) No. 30 — (VDC2)
No. 2:
No. 2:
No. 2:
Trouble code 37/(F87) No. 31— (VDC2)
No. 2:
No. 2:
No. 2:
VDCCM and VDCH/U?
10 CHECK VDCCM. Is the same trouble code Repair VDCCM. Go to step 11.
sponding to the
trouble code.
VDC-68
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-69
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
U: TROUBLE CODE 32 (FRONT RH OUTLET) ABNORMAL OUTLET AND

SUCTION SOLENOID VALVE CIRCUIT(S) S005522C96
NOTE:
ARY SUCTION) ABNORMAL OUTLET AND SUCTION SOLENOID VALVE CIRCUIT(S), Diagnostics Chart
V: TROUBLE CODE 34 (FRONT LH OUTLET) ABNORMAL OUTLET AND
SUCTION SOLENOID VALVE CIRCUIT(S) S005522D05
NOTE:
W: TROUBLE CODE 36 (REAR RH OUTLET) ABNORMAL OUTLET AND
NOTE:
X: TROUBLE CODE 38 (REAR LH OUTLET) ABNORMAL OUTLET AND
NOTE:
Y: TROUBLE CODE 63 (PRIMARY SUCTION) ABNORMAL OUTLET AND
NOTE:
Z: TROUBLE CODE 64 (SECONDARY SUCTION) ABNORMAL OUTLET AND
DIAGNOSIS:
TROUBLE SYMPTOM:
VDC-70
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2320
VDC-71
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

from VDCH/U.
nector terminals.
(VDC2) No. 2:
(VDC2) No. 2:
(VDC2) No. 2:
(VDC2) No. 2:
(VDC2) No. 2:
(VDC2) No. 2:
sis ground:
sis ground:
sis ground:
sis ground:
Chassis ground:
Chassis ground:
VDC-72
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

VDC-73
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

Trouble code 32/(F87) No. 3 — Chassis
ground:
sis ground:
sis ground:
ground:
sis ground:
ground:
No. 1:
No. 1:
No. 1:
No. 1:
No. 1:
No. 1:
VDCCM and VDCH/U?
sponding to the
trouble code.
VDC-74
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-75
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AA: TROUBLE CODE 41 ABNORMAL VDC CONTROL MODULE S005522D30
DIAGNOSIS:
쐌 Faulty VDCCM
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2321
VDC-76
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1) Turn ignition switch to OFF. 0.5 Ω? ground harness.
2) Disconnect connector from VDCCM.
3) Measure resistance between VDCCM and
chassis ground.
VDCCM?
transmitter.
harness.
sponding to the
trouble code.
VDC-77
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AB: TROUBLE CODE 42 SOURCE VOLTAGE IS ABNORMAL. S005522D37
DIAGNOSIS:
쐌 Power source voltage of the VDCCM is low.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2322
VDC-78
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1) Start engine. and 15 V?
2) Idling after warm-up.
3) Measure voltage between generator B ter-
Terminal
ground:
clamped?
3 CHECK INPUT VOLTAGE OF VDCCM. Is the voltage between 10 Go to step 4. Repair harness
1) Disconnect connector from VDCCM. and 15 V? connector
3) Measure voltage between VDCCM connec- ignition switch and
tor and chassis ground. VDCCM.
VDCCM?
sponding to the
trouble code.
VDC-79
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AC: TROUBLE CODE 43 FAULTY VDCCM — ECM COMMUNICATION LINE

S005522D41
DIAGNOSIS:
쐌 AET communication line is broken or short circuited.
쐌 AEB communication line is broken or short circuited.
쐌 AEC communication line is broken or short circuited.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2323
VDC-80
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK HARNESS/CONNECTOR Is the resistance less than Go to step 2. Repair harness/
BETWEEN VDCCM AND ECM. 0.5 Ω? connector
2) Disconnect connector from VDCCM. and ECM.
3) Disconnect connector from ECM.
nector and ECM.
Terminal
(F87) No. 21 — (B135) No. 12:
(F87) No. 43 — (B135) No. 4:
(F87) No. 8 — (B135) No. 11:
Terminal and ECM.
3 CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 0.5 Go to step 4. Repair harness/
Measure voltage between VDCCM connector V? connector
and chassis ground. between VDCCM
Terminal and ECM.
4 CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 Go to step 5. Repair harness/
1) Turn ignition switch to ON. V? connector
2) Measure voltage between VDCCM connec- between VDCCM
tor and chassis ground. and ECM.
Terminal
5 CHECK HARNESS/CONNECTOR Is the voltage between 10 Go to step 6. Go to step 9.
BETWEEN VDCCM AND ECM. and 15 V?
2) Connect connector to ECM.
TORS. connectors between ECM
and VDCCM?
sponding to the
trouble code.
VDC-81
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

9 CHECK ECM. Is the voltage between 10 Repair harness/ Go to step 10.
1) Turn ignition switch to ON. V and 15 V? connector
2) Measure voltage between ECM connector between ECM
terminal and chassis ground. and VDCCM.
(B135) No. 12 (+) — Chassis ground
(−):
(−):
TORS. connector ECM?
11 CHECK ENGINE. Is the engine functioning Replace ECM. Repair engine.

normally?
VDC-82
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-83
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AD: TROUBLE CODE 44 A COMMUNICATION WITH AT CONTROL

ABNORMAL S005522D43
DIAGNOSIS:
쐌 Communication with AT control faults
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2324
VDC-84
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK RESISTANCE OF HARNESS. Is the resistance 60±3 Ω? Go to step 2. Repair harness
1) Turn ignition switch to OFF. between TCM and
2) Disconnect two connectors from TCM. VDCCM.
3) Measure resistance between TCM connec-
tor terminals.
(B56) No. 9 — No. 18:
TORS. TCM connectors?
3 CHECK TCM. Is the same trouble code Replace TCM. Go to step 4.

1) Turn ignition switch to OFF. as in the current diagnosis <Ref. to AT-42
2) Connect all connectors. still being output? Transmission
3) Erase the memory. Control Module
4) Perform inspection mode. (TCM).>
sponding to the
trouble code.
VDC-85
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AE: TROUBLE CODE 45 CONTROL MODULE OUT OF SPECIFICATION S005522D46
DIAGNOSIS:
쐌 Control module out of specification
TROUBLE SYMPTOM:
1 CHECK TCM. Is the same trouble code Go to step 2. Proceed with the
as in the current diagnosis diagnosis corre-
still being output? sponding to the
trouble code.
2 CHECK VDCCM SPECIFICATIONS. Does the VDCCM identifi- Go to step 3. Replace VDCCM.
Check the VDCCM identification mark. cation mark agree with the <Ref. to VDC-10
VDCCM identification mark vehicle specifications? VDC Control Mod-
E1 ule (VDCCM).>
3 CHECK TCM SPECIFICATIONS. Does the TCM identification Go to step 4. Replace TCM.
Check the TCM identification mark. mark agree with the vehicle <Ref. to AT-42
TCM identification mark specifications? Transmission
XD Control Module
(TCM).>
4 CHECK TCM. Is the same trouble code Go to step 5. The original TCM
1) Replace TCM. <Ref. to AT-42 Transmission as in the current diagnosis has been faulty.
Control Module (TCM).> still being output?
2) Erase the memory.
5 CHECK VDCCM. Is the same trouble code Go to step 6. The original
1) Install original TCM. as in the current diagnosis VDCCM has been
2) Replace VDCCM. <Ref. to VDC-10 VDC still being output? faulty.
Control Module (VDCCM).>
6 CHECK VDCCM. Is the same trouble code Replace TCM. Proceed with the
as in the current diagnosis <Ref. to AT-42 diagnosis corre-
still being output? Transmission sponding to the
Control Module trouble code.
(TCM).>
VDC-86
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-87
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AF: TROUBLE CODE 46 ABNORMAL VOLTAGE OF 5 V POWER SUPPLY S005522D51
DIAGNOSIS:
쐌 5 volt power supply is abnormal.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2325
VDC-88
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK GROUND SHORT OF SENSOR Is the resistance more than Go to step 3. Go to step 2.
AND HARNESS. 1 MΩ?
(F87) No. 63 — Chassis ground (Lat-
eral G sensor):
(F87) No. 78 — Chassis ground (Pres-
sure sensor):
2 CHECK GROUND SHORT OF HARNESS. Is the resistance more than Replace faulty Repair or replace
1) Disconnect connector from faulty sensors. 1 MΩ? sensors. harness connector
2) Measure resistance between VDCCM and between VDCCM
chassis ground. and faulty sensor.
eral G sensor):
sure sensor):
3 CHECK BATTERY SHORT OF SENSOR Is the voltage less than 0.5 Go to step 4. Go to step 5.
AND HARNESS. V?
Measure voltage between VDCCM and chas-
sis ground.
(F87) No. 63 (+) — Chassis ground (−)
(Lateral G sensor):
(Pressure sensor):
4 CHECK BATTERY SHORT OF SENSOR Is the voltage less than 0.5 Replace VDCCM. Go to step 5.
AND HARNESS. V?
(Lateral G sensor):
(Pressure sensor):
5 CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 0.5 Go to step 6. Repair or replace
1) Turn ignition switch to OFF. V? harness connector
2) Disconnect connector from faulty sensors. between VDCCM
3) Measure voltage between VDCCM and and faulty sensor.
chassis ground.
(Lateral G sensor):
(Pressure sensor):
6 CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 0.5 Replace faulty Repair or replace
1) Turn ignition switch to ON. V? sensor. harness connector
2) Measure voltage between VDCCM and between VDCCM
(Lateral G sensor):
(Pressure sensor):
VDC-89
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AG: TROUBLE CODE 47 FAULTY CAN COMMUNICATION LINE S005522D52
DIAGNOSIS:
쐌 CAN communication line is broken or short circuited.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2324
VDC-90
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK HARNESS BETWEEN VDCCM, Is the resistance less than Go to step 3. Go to step 2.
STEERING ANGLE SENSOR AND TCM. 0.5 Ω?
2) Disconnect connector from VDCCM, TCM
and steering angle sensor.
3) Measure resistance between VDCCM,
TCM and steering angle sensor.
(F87) No. 83 — (B56) No. 9:
(F87) No. 81 — (B56) No. 18:
(F87) No. 83 — (B231) No. 2:
(F87) No. 81 — (B231) No. 1:
2 CHECK HARNESS BETWEEN STEERING Is the resistance less than Repair or replace Repair or replace
ANGLE SENSOR AND TCM. 0.5 Ω? harness connector harness connector
Measure resistance between TCM and steer- between VDCCM between TCM and
ing angle sensor. and steering steering angle
Connector & terminal angle sensor. sensor.
(B56) No. 9 — (B231) No. 2:
(B56) No. 18 — (B231) No. 1:
3 CHECK GROUND SHORT OF HARNESS. Is the resistance more than Go to step 4. Repair or replace
Measure resistance between VDCCM and 1 MΩ? harness connector
chassis ground. between VDCCM,
Connector & terminal TCM and steering
(F87) No. 83 — Chassis ground: angle sensor.
4 CHECK BATTERY SHORT OF SENSOR. Is the voltage less than 0.5 Go to step 5. Repair or replace
Measure voltage between VDCCM and chas- V? harness connector
sis ground. between VDCCM,
1) Turn ignition switch to ON. V? harness connector
2) Measure voltage between VDCCM and between VDCCM,
chassis ground. TCM and steering
Connector & terminal angle sensor.
6 CHECK STEERING ANGLE SENSOR. Is the resistance 120±6 Ω? Go to step 8. Go to step 7.
2) Connect connector to steering angle sen-
sor.
nector terminals.
(F87) No. 83 — No. 81:
7 CHECK POOR CONTACT IN CONNEC- Is there poor contact in Replace steering Repair or replace
TORS. steering angle sensor? angle sensor. steering angle
sensor connector.
8 CHECK VDCCM. Is the resistance 120±6 Ω? Go to step 10. Go to step 9.
1) Connect connector to VDCCM.
2) Disconnect connector from steering angle
sensor.
3) Measure resistance between steering angle
sensor connector terminals.
(B231) No. 1 — No. 2:
VDC-91
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

9 CHECK POOR CONTACT IN CONNEC- Is there poor contact in Replace VDCCM. Repair or replace
TORS. steering angle sensor? VDCCM connec-
tor.
10 CHECK TCM. Is the resistance more than Go to step 12. Go to step 11.
1) Connect connector to TCM. 1 MΩ?
sensor terminals.
(B231) No. 1 — No. 2:
11 CHECK POOR CONTACT IN CONNEC- Is there poor contact in Replace TCM. Repair or replace
TORS. steering angle sensor? TCM connector.
12 CHECK VDCCM. Are other trouble codes Go to step 13. A temporary poor
1) Connect all connectors. being output? contact.
13 CHECK TROUBLE CODE. Is the same trouble code Go to step 14. Proceed with the
trouble code.
14 CHECK AT SYSTEM TROUBLE CODE. Is the AT system trouble Replace steering Replace VDCCM.
code No. 86? angle sensor.
VDC-92
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-93
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AH: TROUBLE CODE 48 FAULTY ECM — VDCCM COMMUNICATION LINE

S005522D56
DIAGNOSIS:
쐌 EAS communication line is broken or short circuited.
쐌 EAC communication line is broken or short circuited.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2326
VDC-94
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK HARNESS BETWEEN ECM AND Is the resistance less than Go to step 2. Repair or replace
VDCCM. 0.5 Ω? open circuit
2) Disconnect connectors from VDCCM and and ECM.
ECM.
ECM.
(F87) No. 75 — (B137) No. 11:
(F87) No. 45 — (B137) No. 12:
Measure resistance between VDCCM and 1 MΩ? ground short cir-
ECM. cuit between
Connector & terminal VDCCM and
(F87) No. 75 — Chassis ground: ECM.
1) Turn ignition switch to ON. V? battery short cir-
2) Measure voltage between VDCCM and cuit between
chassis ground. VDCCM and
Connector & terminal ECM.
4 CHECK INPUT VOLTAGE TO ECM. Is the voltage between 10 Go to step 6. Go to step 5.
4) Measure voltage between ECM connector
and chassis ground.
(−):
(−):
5 CHECK POOR CONTACT IN ECM CON- Is there poor contact in Replace ECM. Repair or replace
NECTORS. ECM connector? ECM connector.
6 ERASE MEMORY. Can the memory be Go to step 7. Replace VDCCM.

1) Connect all connectors. erased?
7 CHECK TROUBLE CODE. Is the same trouble code Replace ECM. A temporary poor
1) Perform inspection mode. as in the current diagnosis contact.
2) Read out the trouble code. still being output?
VDC-95
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AI: TROUBLE CODE 49 ABNORMAL ENGINE SPEED SIGNAL S005522D58
DIAGNOSIS:
쐌 Engine speed signal line is broken or short circuited.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2327
VDC-96
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK TACHOMETER OPERATION IN Does tachometer operate Go to step 2. Repair tachom-
COMBINATION METER. normally? eter.
2 CHECK HARNESS BETWEEN VDCCM AND Is the resistance less than Go to step 3. Repair harness
ECM. 0.5 Ω? connector
2) Disconnect connector from VDCCM and and ECM.
ECM.
nector and ECM.
(F87) No. 9 — (B137) No. 9:
VDCCM and ECM?
sponding to the
trouble code.
VDC-97
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AJ: TROUBLE CODE 51 ABNORMAL VALVE RELAY S005522D61
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2328
VDC-98
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK RESISTANCE OF VALVE RELAY. Is the resistance between Go to step 2. Replace valve
1) Turn ignition switch to OFF. 93 and 113 Ω? relay.
2) Remove valve relay from relay box.
3) Measure resistance between valve relay
terminals.
Terminals
No. 85 — No. 86:
2 CHECK CONTACT POINT OF VALVE Is the resistance less than Go to step 3. Replace valve
RELAY. 0.5 Ω? relay.
1) Connect battery to valve relay terminals
No. 85 and No. 86.
terminals.
Terminals
No. 30 — No. 87:
3 CHECK CONTACT POINT OF VALVE Is the resistance more than Go to step 4. Replace valve
RELAY. 1 MΩ? relay.
Measure resistance between valve relay ter-
minals.
Terminals
No. 30 — No. 87a:
1) Disconnect battery from valve relay termi-
nals.
terminals.
Terminals
No. 30 — No. 87:
minals.
Terminals
No. 30 — No. 87a:
6 CHECK SHORT OF VALVE RELAY. Is the resistance more than Go to step 7. Replace valve
Measure resistance between valve relay ter- 1 MΩ? relay.
minals.
Terminals
No. 86 — No. 87:
No. 86 — No. 87a:
7 CHECK POWER SUPPLY FOR VALVE Is the voltage between 10 Go to step 8. Repair harness
RELAY. and 15 V? between battery
1) Disconnect connector (F89) from relay box. and relay box
2) Measure voltage between relay box con- connector. Check
nector and chassis ground. fuse No. 8.
8 CHECK OPEN CIRCUIT AND GROUND Is the voltage between 10 Go to step 9. Replace relay box
SHORT IN POWER SUPPLY CIRCUIT OF and 15 V? and check fuse
RELAY BOX. No. 8.
1) Disconnect connector (VDC1) from
VDCH/U.
2) Connect connector (F89) to relay box.
3) Measure voltage of relay box.
(VDC6) No. 87 (+) — Chassis ground
(−):
VDC-99
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

9 CHECK OPEN CIRCUIT IN CONTROL CIR- Is the resistance less than Go to step 10. Replace relay
CUIT OF RELAY BOX. 0.5 Ω? box.
2) Disconnect connector (F90) from relay box.
3) Measure resistance between relay box
connector and valve relay installing point.
(VDC4) No. 5 — (VDC6) No. 85:
(VDC4) No. 1 — (VDC6) No. 86:
10 CHECK GROUND SHORT IN CONTACT Is the resistance more than Go to step 11. Replace relay box
POINT CIRCUIT OF RELAY BOX. 1 MΩ? and check fuse
Measure resistance between relay box con- No. 8.
(VDC4) No. 5 — Chassis ground:
11 CHECK BATTERY SHORT IN CONTACT Is the voltage less than 1 Go to step 12. Replace relay
POINT CIRCUIT OF RELAY BOX. V? box. Check fuse
Measure voltage between relay box connector No. 8.
and chassis ground.
(−):
(−):
1) Turn ignition switch to ON. No. 8.
2) Measure voltage between relay box con-
(−):
(−):
13 CHECK OPEN CIRCUIT IN CONTROL SYS- Is the resistance less than Go to step 14. Repair harness
TEM HARNESS OF VALVE RELAY. 0.5 Ω? between VDCCM
1) Turn ignition switch to OFF. and relay box.
nector and relay box connector.
(F87) No. 47 — (F90) No. 5:
(F87) No. 27 — (F90) No. 1:
14 CHECK GROUND SHORT IN CONTROL Is the resistance more than Go to step 15. Repair harness
SYSTEM HARNESS OF VALVE RELAY. 1 MΩ? between VDCCM
Measure resistance between VDCCM connec- and relay box and
tor and chassis ground. check all fuses.
15 CHECK BATTERY SHORT IN CONTROL Is the voltage less than 1 Go to step 16. Repair harness
SYSTEM HARNESS OF VALVE RELAY. V? between VDCCM
Measure voltage between VDCCM connector and relay box.
and chassis ground.
VDC-100
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1) Turn ignition switch to ON. and relay box.
17 CHECK OPEN CIRCUIT IN CONTACT Is the resistance less than Go to step 18. Replace relay
POINT CIRCUIT OF RELAY BOX. 0.5 Ω? box.
Measure resistance between VDCH/U con-
nector and valve relay installing point.
(VDC1) No. 2 — (VDC6) No. 30:
Measure resistance between VDCH/U con- No. 8.
Measure voltage between VDCH/U connector No. 8.
and chassis ground.
(−):
1) Turn ignition switch to ON. No. 8.
2) Measure voltage between VDCH/U con-
(−):
21 CHECK RESISTANCE OF INLET AND CUT Is the resistance between Go to step 22. Replace VDCH/U.
SOLENOID VALVES. 8.04 and 9.04 Ω?
1) Disconnect connector from VDCH/U.
nector terminals.
(VDC5) No. 8 — (VDC2) No. 2:
(VDC5) No. 5 — (VDC2) No. 2:
(VDC5) No. 6 — (VDC2) No. 2:
(VDC5) No. 7 — (VDC2) No. 2:
(VDC5) No. 9 — (VDC2) No. 2:
(VDC5) No. 12 — (VDC2) No. 2:
22 CHECK RESISTANCE OF OUTLET SOLE- Is the resistance between Go to step 23. Replace VDCH/U.
NOID VALVE. 3.8 and 4.8 Ω?
nector terminals.
(VDC5) No. 4 — (VDC2) No. 2:
(VDC5) No. 1 — (VDC2) No. 2:
(VDC5) No. 2 — (VDC2) No. 2:
(VDC5) No. 3 — (VDC2) No. 2:
(VDC5) No. 10 — (VDC2) No. 2:
(VDC5) No. 11 — (VDC2) No. 2:
VDC-101
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

23 CHECK GROUND SHORT OF SOLENOID Is the resistance more than Go to step 24. Replace VDCH/U
VALVE. 1 MΩ? and check all
Measure resistance between VDCH/U con- fuses.
24 CHECK BATTERY SHORT OF SOLENOID Is the voltage less than 1 Go to step 25. Replace VDCH/U
VALVE. V? and check all
Measure voltage between VDCH/U connector fuses.
and chassis ground.
(−):
1) Turn ignition switch to ON. fuses.
(−):
1) Turn ignition switch to OFF. V? between VDCH/U
2) Disconnect connector from VDCCM. and VDCCM and
3) Measure voltage between VDCCM connec- check all fuses.
1) Turn ignition switch to ON. V? between VDCH/U
2) Measure voltage between VDCCM connec- and VDCCM and
VDC-102
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1) Turn ignition switch to OFF. 1 MΩ? between VDCH/U
2) Measure resistance between VDCCM con- and VDCCM.
BETWEEN VDCCM AND VDCH/U. 8.0 and 10.0 Ω? connector
1) Connect connector (F91) to VDCH/U. between VDCH/U
(F87) No. 30 — (VDC2) No. 2:
(F87) No. 24 — (VDC2) No. 2:
(F87) No. 23 — (VDC2) No. 2:
(F87) No. 31 — (VDC2) No. 2:
(F87) No. 26 — (VDC2) No. 2:
(F87) No. 25 — (VDC2) No. 2:
Measure resistance between VDCCM connec- between VDCH/U
tor and VDCH/U connector. and VDCCM.
(F87) No. 3 — (VDC2) No. 2:
(F87) No. 51 — (VDC2) No. 2:
(F87) No. 50 — (VDC2) No. 2:
(F87) No. 4 — (VDC2) No. 2:
(F87) No. 2 — (VDC2) No. 2:
(F87) No. 29 — (VDC2) No. 2:
VDCCM and VDCH/U?
1) Connect all connectors. as in the current diagnosis
sponding to the
trouble code.
VDC-103
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AK: TROUBLE CODE 52 ABNORMAL MOTOR AND/OR MOTOR RELAY S005522D65
DIAGNOSIS:
쐌 Faulty motor
TROUBLE SYMPTOM:
VDC-104
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2329
VDC-105
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK RESISTANCE OF MOTOR RELAY. Is the resistance between Go to step 2. Replace motor
2) Remove motor relay from relay box.
3) Measure resistance between motor relay
terminals.
Terminals
No. 85 — No. 86:
2 CHECK CONTACT POINT OF MOTOR Is the resistance less than Go to step 3. Replace motor
1) Connect battery to motor relay terminals
No. 85 and No. 86.
terminals.
Terminals
No. 30 — No. 87:
3 CHECK CONTACT POINT OF MOTOR Is the resistance more than Go to step 4. Replace motor
1) Disconnect battery from motor relay termi-
nals.
terminals.
Terminals
No. 30 — No. 87:
4 CHECK SHORT OF MOTOR RELAY. Is the resistance more than Go to step 5. Replace motor
Measure resistance between motor relay ter- 1 MΩ? relay.
minals.
Terminals
No. 85 — No. 30:
No. 85 — No. 87:
5 CHECK INPUT VOLTAGE OF RELAY BOX. Is the voltage between 10 Go to step 6. Repair harness/
1) Disconnect connector (F89) from relay box. and 15 V? connector
2) Disconnect connector from VDCCM. between battery
3) Measure voltage between relay box con- and relay box,
nector and chassis ground. and check fuse
Connector & terminal SBF holder.
6 CHECK INPUT VOLTAGE OF MOTOR Is the voltage between 10 Go to step 7. Replace relay
RELAY. and 15 V? box.
2) Measure voltage between relay box and
chassis ground.
(−):
2) Disconnect connectors (VDC2, F90) from
relay box.
connector unit and motor relay installing por-
tion.
(VDC1) No. 1 — (VDC7) No. 30:
8 CHECK OPEN CIRCUIT IN MONITOR SYS- Is the resistance less than Go to step 9. Replace relay
TEM CIRCUIT OF RELAY BOX. 0.5 Ω? box.
Measure resistance between relay box con-
nector and motor relay installing point.
(VDC4) No. 6 — (VDC7) No. 30:
VDC-106
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

Measure resistance between motor relay
installing point and relay box connector.
(VDC4) No. 4 — (VDC7) No. 85:
installing point and valve relay installing point.
(VDC7) No. 86 — (VDC6) No. 30:
11 CHECK GROUND SHORT IN CIRCUIT OF Is the resistance more than Go to step 12. Replace relay
RELAY BOX. 1 MΩ? box.
nector unit and chassis ground.
12 CHECK BATTERY SHORT IN CIRCUIT OF Is the voltage less than 1 Go to step 13. Replace relay
RELAY BOX. V? box.
Measure voltage between relay box connector
and chassis ground.
(−):
(−):
RELAY BOX. V? box.
(−):
(−):
14 CHECK OPEN CIRCUIT IN RELAY CON- Is the resistance less than Go to step 15. Repair harness
TROL SYSTEM HARNESS. 0.5 Ω? connector
2) Measure resistance between VDCCM con- and relay box.
(F87) No. 22 — (F90) No. 4:
(F87) No. 10 — (F90) No. 6:
15 CHECK GROUND SHORT IN HARNESS Is the resistance more than Go to step 16. Repair harness
BETWEEN RELAY BOX AND VDCCM. 1 MΩ? between VDCCM
Measure resistance between VDCCM connec- and relay box.
tor and chassis ground. Check fuse SBF
Connector & terminal holder.
VDC-107
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

16 CHECK BATTERY SHORT IN HARNESS Is the voltage less than 1 Go to step 17. Repair harness
BETWEEN RELAY BOX AND VDCCM. V? between VDCCM
and chassis ground. Check fuse SBF
2) Measure voltage between VDCCM connec- Check fuse SBF
tor and chassis ground. holder.
18 CHECK CONDITION OF MOTOR GROUND. Is the motor ground termi- Go to step 19. Tighten the clamp
Tightening torque: nal tightly clamped? of motor ground
32±10 N·m (3.3±1.0 kgf-m, 24±7 ft-lb) terminal.
19 CHECK VDCCM MOTOR DRIVE TERMINAL. Does the voltage drop from Go to step 20. Replace VDCCM.
1) Turn ignition switch OFF. between 10 V and 13 V to
2) Remove VDC connector cover. <Ref. to less than 1.5 V, and rise to
VDC-17 VDCCM Connector Cover.> between 10 V and 13 V
3) Connect all connectors. again when carrying out
4) Install motor relay and valve relay to relay the check sequence?
box.
5) Operate the ABS check sequence. <Ref. to
VDC-18 ABS Sequence Control.>
tor terminals.
(F87) No. 22 (+) — No. 1 (−):
20 CHECK MOTOR OPERATION. Can motor revolution noise Go to step 21. Replace VDCH/U.
Operate the check sequence. <Ref. to (buzz) be heard when car-
VDC-21 VDC Sequence Control.> rying out the check
sequence?
Turn ignition switch to OFF. VDCH/U, relay box and
VDCCM?
sponding to the
trouble code.
VDC-108
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-109
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AL: TROUBLE CODE 71 ABNORMAL STEERING ANGLE SENSOR S005522D88
DIAGNOSIS:
쐌 Faulty steering angle sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2324
VDC-110
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK THE STEERING WHEEL. Is the angle of steering Go to step 2. Perform centering
1) Drive the vehicle on a flat road. wheel within 5°? alignment of
2) Stop the vehicle in a straight line. steering.
3) Check the angle of steering wheel.
2 CHECK RUNNING FIELD. Was the vehicle driven on Driving on banked Go to step 3.
Check if the vehicle was driven on banked banked road surfaces or road surfaces or
road surfaces or sandy surfaces (not dirt road sandy surfaces (not dirt sandy surfaces
surfaces). road surfaces)? (not dirt road sur-
faces) sometimes
results in a
VDCCM memory
trouble code.
3 CHECK POWER SUPPLY OF STEERING Is the voltage between 10 Go to step 6. Go to step 4.
ANGLE SENSOR. and 15 V?
sensor.
4) Measure voltage between steering angle
sensor and chassis ground.
4 CHECK OUTPUT VOLTAGE OF VDCCM. Is the voltage between 10 Repair harness Go to step 5.
1) Turn ignition switch to OFF. and 15 V? between yaw rate
2) Disconnect connector from VDCCM. sensor and
3) Remove cover for VDCCM connector. VDCCM.
<Ref. to VDC-17 VDCCM Connector Cover.>
6) Measure voltage between VDCCM and
chassis ground.
5 CHECK POOR CONTACT IN CONNEC- Is there poor contact in Repair or replace Replace VDCCM.
TORS. yaw rate sensor connector? VDCCM connec-
tor.
6 CHECK GROUND CIRCUIT OF STEERING Is the resistance less than Go to step 7. Repair steering
ANGLE SENSOR. 0.5 Ω? angle sensor
Measure resistance between steering sensor ground harness.
and chassis ground.
7 CHECK HARNESS OF STEERING ANGLE Is the resistance 120±6 Ω? Repair harness Go to step 8.
SENSOR. between steering
1) Connect connector to steering angle sen- angle sensor and
sor. VDCCM.
nector terminals.
(F87) No. 81 — No. 83:
8 CHECK STEERING ANGLE SENSOR. Is the same trouble code Go to step 10. Go to step 9.
1) Turn ignition switch to OFF. as in the current diagnosis
2) Connect all connectors. still being output?
VDC-111
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

sponding to the
trouble code.
2) Replace steering angle sensor. still being output? VDC Control Mod-
11 CHECK ANY OTHER TROUBLE CODES Are other trouble codes Proceed with the The original steer-
APPEARANCE. being output? diagnosis corre- ing angle sensor
sponding to the has been faulty.
trouble code.
VDC-112
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-113
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AM: TROUBLE CODE 72 ABNORMAL YAW RATE SENSOR S005522D94
DIAGNOSIS:
쐌 Faulty yaw rate sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2330
VDC-114
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

banked road surfaces or road surfaces or
sandy surfaces (not dirt sandy surfaces
road surfaces) or surfaces (not dirt road sur-
with holes or bumps at high faces) or surfaces
speeds? with holes or
bumps at high
speeds, some-
times results in a
VDCCM memory
trouble code.
3 CHECK INSTALLATION OF YAW RATE AND Is the yaw rate and lateral Go to step 4. Install yaw rate
LATERAL G SENSOR. G sensor fixed securely? and lateral G sen-
Check installation of yaw rate and lateral G sor securely.
sensor.
4 CHECK POWER SUPPLY OF YAW RATE Is the voltage between 10 Go to step 7. Go to step 5.
AND LATERAL G SENSOR. and 15 V?
2) Disconnect connector from yaw rate and
lateral G sensor.
4) Measure voltage between yaw rate and
lateral G sensor and chassis ground.
(R100) No. 3 — Chassis ground:
2) Disconnect connector from VDCCM. and lateral G sen-
3) Remove cover for VDCCM connector. sor and VDCCM.
TORS. yaw rate and lateral G sen- VDCCM connec-
sor connector? tor.
7 CHECK GROUND CIRCUIT OF YAW RATE Is the resistance less than Go to step 10. Go to step 8.
AND LATERAL G SENSOR. 0.5 Ω?
Measure resistance between yaw rate and
8 CHECK GROUND CIRCUIT OF VDCCM. Is the resistance less than Repair harness Go to step 9.
1) Disconnect connector from VDCCM. 0.5 Ω? between yaw rate
2) Remove cover from VDCCM connector. and lateral G sen-
<Ref. to VDC-17 VDCCM Connector Cover.> sor and VDCCM.
VDC-115
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

TORS. VDCCM connector? VDCCM connec-
tor.
10 CHECK HARNESS OF YAW RATE AND Is the resistance less than Go to step 11. Repair harness
LATERAL G SENSOR. 0.5 Ω? between yaw rate
2) Measure resistance between VDCCM and sor and VDCCM.
yaw rate and lateral G sensor.
(F87) No. 65 — (R100) No. 4:
(F87) No. 66 — (R100) No. 1:
(F87) No. 67 — (R100) No. 2:
Measure resistance between VDCCM connec- 1 MΩ? between yaw rate
tor and chassis ground. and lateral G sen-
Connector & terminal sor and VDCCM.
12 CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 0.5 Go to step 13. Repair harness
Measure voltage between VDCCM connector V? between yaw rate
and chassis ground. and lateral G sen-
1) Turn ignition switch to ON. V? between yaw rate
2) Measure voltage between VDCCM and and lateral G sen-
chassis ground. sor and VDCCM.
14 CHECK YAW RATE AND LATERAL G SEN- Is the voltage between 2.1 Go to step 15. Replace yaw rate
SOR. and 2.9 V? and lateral G sen-
1) Turn ignition switch to OFF. sor.
2) Install yaw rate and lateral G sensor to
body.
tor terminals.
(F87) No. 66 (+) — No. 64 (−):
15 CHECK YAW RATE AND LATERAL G SEN- Is the oscilloscope pattern Go to step 16. Replace VDCCM.
SOR. the same as shown in the
1) Turn ignition switch to ON. figure?
2) Check oscilloscope signal pattern between
VDCCM connector terminals. <Ref. to
VDC-15 WAVE FORM, MEASUREMENT,
(F87) No. 67 (+) — No. 64 (−):
VDC-116
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

16 CHECK YAW RATE SENSOR. Is the oscilloscope pattern Replace VDCCM. Replace yaw rate
Check oscilloscope pattern between yaw rate the same as shown in the and lateral G sen-
and lateral G sensor terminals. <Ref. to figure? sor.
VDC-15 WAVE FORM, MEASUREMENT,
(F87) No. 65 (+) — No. 64 (−):
VDC-117
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AN: TROUBLE CODE 73 ABNORMAL LATERAL G SENSOR S005522E00
DIAGNOSIS:
쐌 Faulty lateral G sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2330
VDC-118
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK INSTALLATION OF LATERAL G Is the yaw rate and lateral Go to step 2. Install yaw rate
SENSOR. G sensor fixed securely? and lateral G sen-
Check installation of lateral G sensor. sor securely.
2 CHECK INPUT VOLTAGE OF G SENSOR. Is the voltage between 10 Go to step 3. Repair harness/
2) Remove console box. between yaw rate
3) Disconnect connector from yaw rate and and lateral G sen-
lateral G sensor. sor and VDCCM.
lateral G sensor connector terminals.
(R100) No. 3 (+) — No. 6 (−):
3 CHECK YAW RATE AND LATERAL G SEN- Is the resistance between Go to step 4. Replace yaw rate
SOR. 4.3 and 4.9 kΩ? and lateral G sen-
2) Measure resistance between yaw rate and
lateral G sensor terminals.
Terminals
No. 3 — No. 5:
4 CHECK OPEN CIRCUIT IN YAW RATE AND Is the resistance between Go to step 5. Repair harness/
LATERAL G SENSOR OUTPUT HARNESS 4.3 and 4.9 kΩ? connector
AND GROUND HARNESS. between yaw rate
1) Connect connector to yaw rate and lateral and lateral G sen-
G sensor. sor and VDCCM.
nector terminals.
(F87) No. 63 — No. 70:
5 CHECK GROUND SHORT IN YAW RATE Is the resistance more than Go to step 6. Repair harness
AND LATERAL G SENSOR HARNESS. 1 MΩ? between yaw rate
Measure voltage between VDCCM connector V? between yaw rate
and chassis ground. and lateral G sen-
2) Measure voltage between VDCCM connec- and lateral G sen-
tor and chassis ground. sor and VDCCM.
VDC-119
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

8 CHECK LATERAL G SENSOR. Is the voltage between 2.3 Go to step 9. Replace yaw rate
1) Turn ignition switch to OFF. and 2.7 V when yaw rate and lateral G sen-
2) Remove yaw rate and lateral G sensor and lateral G sensor is sor. <Ref. to
from vehicle. horizontal? VDC-24 Yaw Rate
3) Connect connector to yaw rate and lateral and Lateral G
G sensor. Sensor.>
(R100) No. 5 (+) — No. 6 (−):
SOR. and 3.7 V when yaw rate and lateral G sen-
Measure voltage between yaw rate and lateral and lateral G sensor is sor. <Ref. to
G sensor connector terminals. horizontal, and is inclined VDC-24 Yaw Rate
Connector & terminal 90° to the left in front of the and Lateral G
(R100) No. 5 (+) — No. 6 (−): sensor? Sensor.>
Connector & terminal 90° to the right in front of and Lateral G
(R100) No. 5 (+) — No. 6 (−): the sensor? Sensor.>
VDCCM and yaw rate and
lateral G sensor?
sponding to the
trouble code.
VDC-120
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-121
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AO: TROUBLE CODE 74 ABNORMAL PRESSURE SENSOR S005522E08
DIAGNOSIS:
쐌 Faulty pressure sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2332
VDC-122
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK GROUND CIRCUIT OF PRESSURE Is the resistance less than Go to step 4. Go to step 2.
SENSOR. 0.5 Ω?
2) Disconnect connector (F91) from VDCH/U.
2 CHECK GROUND CIRCUIT OF VDCCM. Is the resistance less than Replace harness Go to step 3.
1) Disconnect connector from VDCCM. 0.5 Ω? between VDCH/U
2) Remove cover from VDCCM. <Ref. to and VDCCM.
chassis ground.
tor.
4 CHECK POWER SUPPLY OF PRESSURE Is the voltage between 4.75 Go to step 7. Go to step 5.
SENSOR. and 5.25 V?
nector terminals.
(F91) No. 16 (+) — No. 15 (−):
5 CHECK POWER SUPPLY OF VDCCM. Is the voltage between 4.75 Repair harness Go to step 6.
1) Turn ignition switch to OFF. and 5.25 V? between VDCH/U
2) Disconnect connector from VDCCM. and VDCCM.
3) Remove cover from VDCCM. <Ref. to
tor terminals.
(F87) No. 78 (+) — No. 76 (−):
tor.
Measure voltage between VDCH/U connector V? between VDCH/U
and chassis ground. and VDCCM.
VDC-123
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

2) Measure voltage between VDCH/U con- and VDCCM.
10 CHECK OUTPUT VOLTAGE OF PRESSURE Is the voltage between 0.53 Go to step 11. Replace VDCH/U.
SENSOR. and 0.67 V? <Ref. to VDC-13
2) Disconnect connector from VDCCM. Unit (H/U).>
7) Do not depress brake pedal.
tor terminals.
(F87) No. 77 (+) — No. 76 (−):
(F87) No. 36 (+) — No. 76 (−):
11 CHECK BRAKE PEDAL STROKE. Is the stroke less than 95 Go to step 12. Perform bleeding.
Measure the stroke between non-forced pedal mm (3.74 in)?
position and forced pedal position with 50 kg
(110 lb).
12 CHECK INPUT VOLTAGE OF PRESSURE Is the voltage between A Go to step 13. Replace VDCH/U.
SENSOR. and B more than 0.2 V?
1) Depress the brake pedal with 50 kg (110
lb).
tor terminals.
A (F87) No. 77 (+) — No. 76 (−):
B (F87) No. 36 (+) — No. 76 (−):
VDCCM and pressure sen-
sor?
sponding to the
trouble code.
VDC-124
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-125
墌 00.5.31/68j/0vdc 墍
DIAGNOSTICS CHART WITH SELECT MONITOR
VDC (DIAGNOSTICS)
15. Diagnostics Chart with Select Monitor S005504
A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE (SELECT MONITOR

COMMUNICATION FAILURE) S005504E35
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2333
VDC-126
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK IGNITION SWITCH. Is ignition switch ON? Go to step 2. Turn ignition
switch ON, and
select brake con-
trol mode using
the select monitor.
1) Start the engine. and 15 V?
2) Idle the engine.
3) Measure voltage between generator and
chassis ground.
Terminal
ground (−):
4 CHECK COMMUNICATION OF SELECT Are the name and year of Go to step 5. Repair select
MONITOR. the system displayed on monitor communi-
Using the select monitor, check whether com- the select monitor? cation cable and
munication to other system (such as engine, connector.
AT, etc.) can be executed normally.
5 CHECK INSTALLATION OF VDCCM CON- Is VDCCM connector Go to step 6. Insert VDCCM
NECTOR. inserted into VDCCM until connector into
Turn ignition switch to OFF. the clamp locks onto it? VDCCM until the
clamp locks onto
it.
6 CHECK POWER SUPPLY OF VDCCM. Is the voltage between 10 Go to step 7. Repair VDCCM
1) Disconnect connector from VDCCM. and 15 V? power supply cir-
2) Start engine. cuit.
3) Idle the engine.
7 CHECK GROUND CIRCUIT OF VDCCM. Is the resistance less than Go to step 8. Repair harness/
2) Measure resistance between VDCCM con- between VDCCM
nector and chassis ground. and chassis
Connector & terminal ground.
8 CHECK HARNESS/CONNECTOR Is the resistance less than Go to step 9. Repair harness
BETWEEN VDCCM AND DATA LINK CON- 0.5 Ω? and connector
NECTOR. between VDCCM
1) Turn ignition switch OFF. and data link con-
2) Measure resistance between VDCCM connector.
nector and data link connector.
(F87) No. 11 — (B40) No. 5:
(F87) No. 38 — (B40) No. 4:
9 CHECK POOR CONTACT IN CONNEC- Is there poor contact in Repair connector. Replace VDCCM.
TORS. connectors between <Ref. to VDC-10
VDCCM and data link con- VDC Control Mod-
nector? ule (VDCCM).>
VDC-127
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
B: TROUBLE CODE 21 FRONT RIGHT ABS SENSOR CIRCUIT OPEN OR

SHORTED BATTERY S005504C48
NOTE:
For diagnostic procedure, refer to TROUBLE CODE 27. <Ref. to VDC-128 TROUBLE CODE 27 REAR
LEFT ABS SENSOR CIRCUIT OPEN OR SHORTED BATTERY, Diagnostics Chart with Select Monitor.>
C: TROUBLE CODE 23 FRONT LEFT ABS SENSOR CIRCUIT OPEN OR
NOTE:
D: TROUBLE CODE 25 REAR RIGHT ABS SENSOR CIRCUIT OPEN OR
NOTE:
E: TROUBLE CODE 27 REAR LEFT ABS SENSOR CIRCUIT OPEN OR
DIAGNOSIS:
TROUBLE SYMPTOM:
VDC-128
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2319
VDC-129
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

tion?
0.3 — 0.8 mm (0.012 — 0.031 in) 26755AA000). If
replace worn sen-
sor or worn tone
wheel.
to VDC-32 Front
Tone Wheel.>
Rear <Ref. to
VDC-33 Rear
Tone Wheel.>
Turn ignition switch to OFF. VDCCM and ABS sensor?
and connectors
between VDCCM
and ABS sensor.
8 CHECK ABS SENSOR. Is the resistance between Go to step 9. Replace ABS sen-
1) Turn ignition switch to OFF. 1.0 and 1.5 kΩ? sor. Front <Ref. to
tor terminals. Rear <Ref. to
VDC-130
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1) Disconnect connector from VDCCM. VDC-30 Front
(−):
(−):
(−):
(−):
1) Turn ignition switch to ON. VDC-30 Front
(−):
(−):
(−):
(−):
2) Connect connector to ABS sensor. and ABS sensor.
nector terminals.
15:
19:
46:
17:
Measure voltage between VDCCM connector V? between VDCCM
and chassis ground. and ABS sensor.
Trouble code 21 / (F87) No. 14 (+) —
Trouble code 23 / (F87) No. 49 (+) —
Trouble code 25 / (F87) No. 18 (+) —
Trouble code 27 / (F87) No. 16 (+) —
VDC-131
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

2) Measure voltage between VDCCM connec- and ABS sensor.
Trouble code 21 / (F87) No. 14 (+) —
Trouble code 23 / (F87) No. 49 (+) —
Trouble code 25 / (F87) No. 18 (+) —
Trouble code 27 / (F87) No. 16 (+) —
0.3 — 0.8 mm (0.012 — 0.031 in) 26755AA000). If
replace worn sen-
sor or worn tone
wheel.
16 CHECK HUB AND TONE WHEEL RUNOUT. Is the runout less than 0.05 Go to step 17. Repair hub and
Measure hub and tone wheel runout. mm (0.0020 in)? tone wheel. Front
<Ref. to VDC-30
Front ABS Sen-
sor.> Rear <Ref.
to VDC-31 Rear
ABS Sensor.>
and connectors
between VDCCM
and ABS sensor.
VDC-132
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-133
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
F: TROUBLE CODE 22 FRONT RIGHT ABS SENSOR SIGNAL S005504C55
NOTE:
LEFT ABS SENSOR SIGNAL, Diagnostics Chart with Select Monitor.>
G: TROUBLE CODE 24 FRONT LEFT ABS SENSOR SIGNAL S005504C65
NOTE:
H: TROUBLE CODE 26 REAR RIGHT ABS SENSOR SIGNAL S005504C74
NOTE:
I: TROUBLE CODE 28 REAR LEFT ABS SENSOR SIGNAL S005504C83
DIAGNOSIS:
쐌 Faulty ABS sensor signal (noise, irregular signal)
TROUBLE SYMPTOM:
VDC-134
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2319
VDC-135
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

tion?
Turn ignition switch to OFF. VDCCM and ABS sensor?
transmitter.
harness.
1) Turn ignition switch to OFF. 0.5 Ω? ness.
Chassis ground:
Chassis ground:
NOTE:
For the trouble code 26 and 28, Go to step 6.
sponding to the
trouble code.
sor or worn tone
wheel.
able?
VDC-136
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

NOTE:
29.
Trouble code 22 / (F87) No. 14 (+) —
No. 15 (−):
Trouble code 24 / (F87) No. 49 (+) —
No. 19 (−):
Trouble code 26 / (F87) No. 18 (+) —
No. 46 (−):
Trouble code 28 / (F87) No. 16 (+) —
No. 17 (−):
Remove disc rotor or drum from hub in accor- contaminated by dirt or other foreign mat-
dance with trouble code. other foreign matter? ter.
pole piece or the tone Front <Ref. to
wheel? VDC-30 Front
ABS Sensor.> and
<Ref. to VDC-32
Front Tone
Wheel.> Rear
<Ref. to VDC-31
Rear ABS Sen-
sor.> and <Ref. to
VDC-33 Rear
Tone Wheel.>
to VDC-32 Front
Tone Wheel.>
Rear <Ref. to
VDC-33 Rear
Tone Wheel.>
15 CHECK RESISTANCE OF ABS SENSOR. Is the resistance between Go to step 16. Replace ABS sen-
1) Turn ignition switch OFF. 1.0 and 1.5 kΩ? sor. Front <Ref. to
connector terminals. Rear <Ref. to
VDC-137
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

SOR. 1 MΩ? sor. Front <Ref. to
Measure resistance between ABS sensor and VDC-30 Front
Terminal Rear <Ref. to
Front RH No. 1 — Chassis ground: VDC-31 Rear
Front LH No. 1 — Chassis ground: ABS Sensor.>
1) Connect connector to ABS sensor. between VDCCM
2) Disconnect connector from VDCCM. and ABS sensor.
3) Measure resistance at VDCCM connector
terminals.
15:
19:
46:
17:
Connector & terminal and ABS sensor.
sis ground:
sis ground:
sis ground:
sis ground:
Measure resistance between VDCCM and 0.5 Ω? ground harness.
chassis ground.
transmitter.
harness.
VDC-138
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

Chassis ground:
Chassis ground:
NOTE:
For the trouble code 26 and 28, Go to step
25.
sponding to the
trouble code.
VDC-139
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
J: TROUBLE CODE 29 ANY ONE OF FOUR ABS SENSOR SIGNAL S005504C87
DIAGNOSIS:
TROUBLE SYMPTOM:
VDC-140
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2319
VDC-141
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK IF THE WHEELS HAVE TURNED Check if the wheels have The VDC is nor- Go to step 2.
when the vehicle
is towed or
jacked-up, or
when steering
wheel is continu-
ously turned all
the way, this
trouble code may
sometimes occur.
correct?
sively?
sure.
sor or worn tone
wheel.
able?
NOTE:
29.
(F49) No. 14 (+) — No. 15 (−) (Front
RH):
(F49) No. 49 (+) — No. 19 (−) (Front
LH):
(F49) No. 18 (+) — No. 46 (−) (Rear
RH):
(F49) No. 16 (+) — No. 17 (−) (Rear LH):
VDC-142
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

Remove disc rotor from hub. contaminated by dirt or other foreign mat-
other foreign matter? ter.
sor pole piece or the tone Front <Ref. to
wheel? VDC-30 Front
ABS Sensor.> and
<Ref. to VDC-32
Front Tone
Wheel.> Rear
<Ref. to VDC-31
Rear ABS Sen-
sor.> and <Ref. to
VDC-33 Rear
Tone Wheel.>
to VDC-32 Front
Tone Wheel.>
Rear <Ref. to
VDC-33 Rear
Tone Wheel.>
sponding to the
trouble code.
VDC-143
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
K: TROUBLE CODE 31 FR HOLD VALVE MALFUNCTION (FRONT RIGHT

INLET VALVE MALFUNCTION) S005504C92
NOTE:
For diagnostic procedure, refer to TROUBLE CODE 62. <Ref. to VDC-144 TROUBLE CODE 62 NORMAL
OPENING VALVE 1 MALFUNCTION (SECONDARY CUT VALVE MALFUNCTION), Diagnostics Chart with
Select Monitor.>
L: TROUBLE CODE 33 FL HOLD VALVE MALFUNCTION (FRONT LEFT INLET
VALVE MALFUNCTION) S005504D02
NOTE:
Select Monitor.>
M: TROUBLE CODE 35 RR HOLD VALVE MALFUNCTION (REAR RIGHT
INLET VALVE MALFUNCTION) S005504D12
NOTE:
Select Monitor.>
N: TROUBLE CODE 37 RL HOLD VALVE MALFUNCTION (REAR LEFT INLET
VALVE MALFUNCTION) S005504D21
NOTE:
Select Monitor.>
O: TROUBLE CODE 61 NORMAL OPENING VALVE 2 MALFUNCTION
(PRIMARY CUT VALVE MALFUNCTION) S005504D78
NOTE:
Select Monitor.>
P: TROUBLE CODE 62 NORMAL OPENING VALVE 1 MALFUNCTION
(SECONDARY CUT VALVE MALFUNCTION) S005504D80
DIAGNOSIS:
TROUBLE SYMPTOM:
VDC-144
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2320
VDC-145
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

from VDCH/U.
nector terminals.
(VDC2) No. 2:
(VDC2) No. 2:
(VDC2) No. 2:
(VDC2) No. 2:
(VDC2) No. 2:
(VDC2) No. 2:
sis ground:
sis ground:
sis ground:
sis ground:
sis ground:
Chassis ground:
VDC-146
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

VDC-147
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

sis ground:
sis ground:
sis ground:
sis ground:
sis ground:
sis ground:
No. 2:
No. 2:
No. 2:
Trouble code 37/(F87) No. 31— (VDC2)
No. 2:
No. 2:
No. 2:
VDCCM and VDCH/U?
10 CHECK VDCCM. Is the same trouble code Repair VDCCM. Go to step 11.
sponding to the
trouble code.
VDC-148
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-149
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
Q: TROUBLE CODE 32 FR PRESSURE REDUCING VALVE MALFUNCTION

(FRONT RIGHT OUTLET VALVE MALFUNCTION) S005504C98
NOTE:
CLOSING VALVE 1 MALFUNCTION (SECONDARY SUCTION VALVE MALFUNCTION), Diagnostics Chart
with Select Monitor.>
R: TROUBLE CODE 34 FL PRESSURE REDUCING VALVE MALFUNCTION
(FRONT LEFT OUTLET VALVE MALFUNCTION) S005504D07
NOTE:
S: TROUBLE CODE 36 RR PRESSURE REDUCING VALVE MALFUNCTION
(REAR RIGHT OUTLET VALVE MALFUNCTION) S005504D16
NOTE:
T: TROUBLE CODE 38 RL PRESSURE REDUCING VALVE MALFUNCTION
(REAR LEFT OUTLET VALVE MALFUNCTION) S005504D25
NOTE:
U: TROUBLE CODE 63 NORMAL CLOSING VALVE 2 MALFUNCTION
(PRIMARY SUCTION VALVE MALFUNCTION) S005504D82
NOTE:
V: TROUBLE CODE 64 NORMAL CLOSING VALVE 1 MALFUNCTION
(SECONDARY SUCTION VALVE MALFUNCTION) S005504D84
DIAGNOSIS:
TROUBLE SYMPTOM:
VDC-150
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2320
VDC-151
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

from VDCH/U.
nector terminals.
(VDC2) No. 2:
(VDC2) No. 2:
(VDC2) No. 2:
(VDC2) No. 2:
(VDC2) No. 2:
(VDC2) No. 2:
sis ground:
sis ground:
sis ground:
sis ground:
Chassis ground:
Chassis ground:
VDC-152
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

VDC-153
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

ground:
sis ground:
sis ground:
ground:
sis ground:
ground:
No. 1:
No. 1:
No. 1:
No. 1:
No. 1:
No. 1:
VDCCM and VDCH/U?
sponding to the
trouble code.
VDC-154
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-155
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
W: TROUBLE CODE 41 ELECTRICAL CONTROL MODULE (VDC CONTROL

MODULE MALFUNCTION) S005504D32
DIAGNOSIS:
쐌 Faulty VDCCM
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2321
VDC-156
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

chassis ground.
VDCCM?
transmitter.
harness.
sponding to the
trouble code.
VDC-157
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
X: TROUBLE CODE 42 POWER SUPPLY VOLTAGE LOW S005504D34
DIAGNOSIS:
쐌 Power source voltage of the VDCCM is low.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2322
VDC-158
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1) Start engine. and 15 V?
2) Idling after warm-up.
3) Measure voltage between generator B ter-
Terminal
ground:
clamped?
3 CHECK INPUT VOLTAGE OF VDCCM. Is the voltage between 10 Go to step 4. Repair harness
1) Disconnect connector from VDCCM. and 15 V? connector
3) Measure voltage between VDCCM connec- ignition switch and
tor and chassis ground. VDCCM.
chassis ground.
VDCCM?
sponding to the
trouble code.
VDC-159
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
Y: TROUBLE CODE 43 AET COMMUNICATION LINE MALFUNCTION S005504D40
DIAGNOSIS:
쐌 AET communication line is broken or short circuited.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2323
VDC-160
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

nector and ECM.
Terminal
(F87) No. 21 — (B135) No. 6:
Terminal and ECM.
Terminal and ECM.
Terminal
and VDCCM?
sponding to the
trouble code.
1) Turn ignition switch to ON. and 15 V? connector
(−):

normally?
VDC-161
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
Z: TROUBLE CODE 43 AEB COMMUNICATION LINE MALFUNCTION S005504D38
DIAGNOSIS:
쐌 AEB communication line is broken or short circuited.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2323
VDC-162
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

nector and ECM.
Terminal
(F87) No. 43 — (B135) No. 4:
Terminal and ECM.
Terminal and ECM.
Terminal
and VDCCM?
sponding to the
trouble code.

normally?
VDC-163
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AA: TROUBLE CODE 43 AEC COMMUNICATION LINE MALFUNCTION S005504D39
DIAGNOSIS:
쐌 AEC communication line is broken or short circuited.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2323
VDC-164
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

nector and ECM.
Terminal
(F87) No. 8 — (B135) No. 11:
Terminal and ECM.
Terminal and ECM.
Terminal
and VDCCM?
sponding to the
trouble code.
(−):

normally?
VDC-165
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AB: TROUBLE CODE 44 TCM COMMUNICATION CIRCUIT S005504D44
DIAGNOSIS:
쐌 Communication with AT control faults
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2324
VDC-166
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK RESISTANCE OF HARNESS. Is the resistance 60±3 Ω? Go to step 2. Repair harness
2) Disconnect two connectors from TCM. VDCCM.
3) Measure resistance between TCM connec-
tor terminals.
(B56) No. 9 — No. 18:
TORS. TCM connectors?
3 CHECK TCM. Is the same trouble code Replace TCM. Go to step 4.

1) Turn ignition switch to OFF. as in the current diagnosis <Ref. to AT-42
2) Connect all connectors. still being output? Transmission
3) Erase the memory. Control Module
4) Perform inspection mode. (TCM).>
sponding to the
trouble code.
VDC-167
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AC: TROUBLE CODE 45 INCORRECT VDC CONTROL MODULE S005504D47
DIAGNOSIS:
TROUBLE SYMPTOM:
1 CHECK VDCCM SPECIFICATIONS. Does the VDCCM identifi- Go to step 2. Replace VDCCM.
Check the VDCCM identification mark. cation mark agree with the <Ref. to VDC-10
VDCCM identification mark vehicle specifications? VDC Control Mod-
E1 ule (VDCCM).>
2 CHECK TCM SPECIFICATIONS. Does the TCM identification Go to step 3. Replace TCM.
Check the TCM identification mark. mark agree with the vehicle <Ref. to AT-42
TCM identification mark specifications? Transmission
XD Control Module
(TCM).>
3 CHECK TCM. Is the same trouble code Go to step 4. The original TCM
1) Replace TCM. <Ref. to AT-42 Transmission as in the current diagnosis has been faulty.
Control Module (TCM).> still being output?
4 CHECK TCM. Is the same trouble code Go to step 5. Proceed with the
trouble code.
5 CHECK VDCCM. Is the same trouble code Go to step 6. The original
1) Install original TCM. as in the current diagnosis VDCCM has been
2) Replace VDCCM. <Ref. to VDC-10 VDC still being output? faulty.
Control Module (VDCCM).>
6 CHECK VDCCM. Is the same trouble code Replace TCM. Proceed with the
as in the current diagnosis <Ref. to AT-42 diagnosis corre-
still being output? Transmission sponding to the
Control Module trouble code.
(TCM).>
VDC-168
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AD: TROUBLE CODE 45 TCM MALFUNCTION SPECIFICATIONS S005504D49
DIAGNOSIS:
TROUBLE SYMPTOM:
1 CHECK AT SYSTEM. Is AT system trouble code Repair AT system. Replace VDCCM.
1) Start the engine. stored in memory?
2) Check AT system trouble code.
VDC-169
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AE: TROUBLE CODE 46 ABNORMAL VOLTAGE OF 5 V POWER SUPPLY S005504D51
DIAGNOSIS:
쐌 5 volt power supply is abnormal.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2325
VDC-170
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK GROUND SHORT OF SENSOR Is the resistance more than Go to step 3. Go to step 2.
AND HARNESS. 1 MΩ?
eral G sensor):
sure sensor):
2 CHECK GROUND SHORT OF HARNESS. Is the resistance more than Replace faulty Repair or replace
1) Disconnect connector from faulty sensors. 1 MΩ? sensors. harness connector
2) Measure resistance between VDCCM and between VDCCM
eral G sensor):
sure sensor):
3 CHECK BATTERY SHORT OF SENSOR Is the voltage less than 0.5 Go to step 4. Go to step 5.
AND HARNESS. V?
Measure voltage between VDCCM and chas-
sis ground.
(Lateral G sensor):
(Pressure sensor):
4 CHECK BATTERY SHORT OF SENSOR Is the voltage less than 0.5 Replace VDCCM. Go to step 5.
AND HARNESS. V?
(Lateral G sensor):
(Pressure sensor):
1) Turn ignition switch to OFF. V? harness connector
2) Disconnect connector from faulty sensors. between VDCCM
3) Measure voltage between VDCCM and and faulty sensor.
chassis ground.
(Lateral G sensor):
(Pressure sensor):
6 CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 0.5 Replace faulty Repair or replace
1) Turn ignition switch to ON. V? sensor. harness connector
2) Measure voltage between VDCCM and between VDCCM
(Lateral G sensor):
(Pressure sensor):
VDC-171
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AF: TROUBLE CODE 47 IMPROPER CAN COMMUNICATION S005504D53
DIAGNOSIS:
쐌 CAN communication line is broken or short circuited.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2324
VDC-172
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK HARNESS BETWEEN VDCCM, Is the resistance less than Go to step 3. Go to step 2.
STEERING ANGLE SENSOR AND TCM. 0.5 Ω?
2) Disconnect connector from VDCCM, TCM
and steering angle sensor.
3) Measure resistance between VDCCM,
TCM and steering angle sensor.
(F87) No. 83 — (B56) No. 9:
(F87) No. 81 — (B56) No. 18:
(F87) No. 83 — (B231) No. 2:
(F87) No. 81 — (B231) No. 1:
2 CHECK HARNESS BETWEEN STEERING Is the resistance less than Repair or replace Repair or replace
ANGLE SENSOR AND TCM. 0.5 Ω? harness connector harness connector
Measure resistance between TCM and steer- between VDCCM between TCM and
ing angle sensor. and steering steering angle
Connector & terminal angle sensor. sensor.
(B56) No. 9 — (B231) No. 2:
(B56) No. 18 — (B231) No. 1:
Measure resistance between VDCCM and 1 MΩ? harness connector
chassis ground. between VDCCM,
Measure voltage between VDCCM and chas- V? harness connector
sis ground. between VDCCM,
1) Turn ignition switch to ON. V? harness connector
2) Measure voltage between VDCCM and between VDCCM,
chassis ground. TCM and steering
Connector & terminal angle sensor.
6 CHECK STEERING ANGLE SENSOR. Is the resistance 120±6 Ω? Go to step 8. Go to step 7.
2) Connect connector to steering angle sen-
sor.
nector terminals.
(F87) No. 83 — No. 81:
7 CHECK POOR CONTACT IN CONNEC- Is there poor contact in Replace steering Repair or replace
TORS. steering angle sensor? angle sensor. steering angle
sensor connector.
8 CHECK VDCCM. Is the resistance 120±6 Ω? Go to step 10. Go to step 9.
sensor.
sensor connector terminals.
(B231) No. 1 — No. 2:
VDC-173
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

9 CHECK POOR CONTACT IN CONNEC- Is there poor contact in Replace VDCCM. Repair or replace
TORS. steering angle sensor? VDCCM connec-
tor.
10 CHECK TCM. Is the resistance more than Go to step 12. Go to step 11.
1) Connect connector to TCM. 1 MΩ?
sensor terminals.
(B231) No. 1 — No. 2:
11 CHECK POOR CONTACT IN CONNEC- Is there poor contact in Replace TCM. Repair or replace
TORS. steering angle sensor? TCM connector.
12 CHECK VDCCM. Are other trouble codes Go to step 13. A temporary poor
1) Connect all connectors. being output? contact.
13 CHECK TROUBLE CODE. Is the same trouble code Go to step 14. Proceed with the
trouble code.
14 CHECK AT SYSTEM TROUBLE CODE. Is the AT system trouble Replace steering Replace VDCCM.
code No. 86? angle sensor.
VDC-174
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-175
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AG: TROUBLE CODE 48 IMPROPER EAC COMMUNICATION S005504D57
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2326
VDC-176
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

ECM.
ECM.
(F87) No. 45 — (B137) No. 12:
Measure resistance between VDCCM and 1 MΩ? ground short cir-
ECM. cuit between
Connector & terminal VDCCM and
(F87) No. 45 — Chassis ground: ECM.
4 CHECK INPUT VOLTAGE FROM ECM. Is the voltage between 10 Go to step 6. Go to step 5.
4) Measure voltage between ECM and chas-
sis ground.
(−):

VDC-177
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AH: TROUBLE CODE 48 EAS COMMUNICATION LINE GROUNDING

SHORTED S005504D54
DIAGNOSIS:
쐌 EAS communication line is short circuited.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2326
VDC-178
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1) Turn ignition switch to OFF. 1 MΩ? ground short cir-
2) Disconnect connector from VDCCM and cuit between
ECM. VDCCM and
3) Measure resistance between VDCCM and ECM.
ECM.
1) Connect connector to VDCCM. and 15 V?
sis ground.
(−):

VDC-179
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AI: TROUBLE CODE 48 ERRONEOUS COMMUNICATION FROM EGI TO VDC

S005504D55
DIAGNOSIS:
쐌 EAS communication line is broken or short circuited.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2326
VDC-180
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

ECM.
ECM.
(F87) No. 75 — (B137) No. 11:
(F87) No. 45 — (B137) No. 12:
sis ground.
(−):
(−):

VDC-181
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AJ: TROUBLE CODE 49 ABNORMAL ENGINE SPEED SIGNAL S005504D58
DIAGNOSIS:
쐌 Engine speed signal line is broken or short circuited.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2327
VDC-182
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK TACHOMETER OPERATION IN Does tachometer operate Go to step 2. Repair tachom-
COMBINATION METER. normally? eter.
2 CHECK HARNESS BETWEEN VDCCM AND Is the resistance less than Go to step 3. Repair harness
ECM. 0.5 Ω? connector
ECM.
nector and ECM.
(F87) No. 9 — (B137) No. 9:
VDCCM and ECM?
sponding to the
trouble code.
VDC-183
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AK: TROUBLE CODE 51 VALVE RELAY S005504D62
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2328
VDC-184
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK RESISTANCE OF VALVE RELAY. Is the resistance between Go to step 2. Replace valve
terminals.
Terminals
No. 85 — No. 86:
No. 85 and No. 86.
terminals.
Terminals
No. 30 — No. 87:
minals.
Terminals
No. 30 — No. 87a:
nals.
terminals.
Terminals
No. 30 — No. 87:
minals.
Terminals
No. 30 — No. 87a:
minals.
Terminals
No. 86 — No. 87:
No. 86 — No. 87a:
7 CHECK POWER SUPPLY FOR VALVE Is the voltage between 10 Go to step 8. Repair harness
RELAY. and 15 V? between battery
1) Disconnect connector (F89) from relay box. and relay box
2) Turn ignition switch to ON. connector. Check
3) Measure voltage between relay box confuse No. 8.
8 CHECK OPEN CIRCUIT AND GROUND Is the voltage between 10 Go to step 9. Replace relay box
SHORT IN POWER SUPPLY CIRCUIT OF and 15 V? and check fuse
RELAY BOX. No. 8.
1) Disconnect connector (VDC1) from
VDCH/U.
4) Measure voltage of relay box.
Valve relay installing point No. 87 —
Chassis ground:
VDC-185
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

connector and valve relay installing point.
(VDC4) No. 5 — Valve relay installing
point No. 85:
point No. 86:
Measure resistance between relay box con- SBF6.
11 CHECK OPEN CIRCUIT IN CONTROL SYS- Is the resistance less than Go to step 12. Repair harness
TEM HARNESS OF VALVE RELAY. 0.5 Ω? between VDCCM
(F87) No. 47 — (F90) No. 5:
(F87) No. 27 — (F90) No. 1:
12 CHECK GROUND SHORT IN CONTROL Is the resistance more than Go to step 13. Repair harness
SYSTEM HARNESS OF VALVE RELAY. 1 MΩ? between VDCCM
nector and valve relay installing point.
point No. 30:
Measure resistance between VDCH/U con- No. 8.
15 CHECK RESISTANCE OF INLET AND CUT Is the resistance between Go to step 16. Replace VDCH/U.
SOLENOID VALVES. 8.04 and 9.04 Ω?
nector terminals.
(VDC5) No. 8 — (VDC2) No. 2:
(VDC5) No. 5 — (VDC2) No. 2:
(VDC5) No. 6 — (VDC2) No. 2:
(VDC5) No. 7 — (VDC2) No. 2:
(VDC5) No. 9 — (VDC2) No. 2:
(VDC5) No. 12 — (VDC2) No. 2:
VDC-186
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

16 CHECK RESISTANCE OF OUTLET SOLE- Is the resistance between Go to step 17. Replace VDCH/U.
NOID VALVE. 4.04 and 4.54 Ω?
nector terminals.
(VDC5) No. 4 — (VDC2) No. 2:
(VDC5) No. 1 — (VDC2) No. 2:
(VDC5) No. 2 — (VDC2) No. 2:
(VDC5) No. 3 — (VDC2) No. 2:
(VDC5) No. 10 — (VDC2) No. 2:
(VDC5) No. 11 — (VDC2) No. 2:
17 CHECK GROUND SHORT OF SOLENOID Is the resistance more than Go to step 18. Replace VDCH/U
VALVE. 1 MΩ? and check all
Measure resistance between VDCH/U con- fuses.
1) Connect connector (F91) to VDCH/U. between VDCH/U
nector and VDCH/U
(F87) No. 30 — (VDC2) No. 2:
(F87) No. 24 — (VDC2) No. 2:
(F87) No. 23 — (VDC2) No. 2:
(F87) No. 31 — (VDC2) No. 2:
(F87) No. 26 — (VDC2) No. 2:
(F87) No. 25 — (VDC2) No. 2:
Measure resistance between VDCCM connec- between VDCH/U
tor terminals. and VDCCM.
(F87) No. 3 — (VDC2) No. 2:
(F87) No. 51 — (VDC2) No. 2:
(F87) No. 50 — (VDC2) No. 2:
(F87) No. 4 — (VDC2) No. 2:
(F87) No. 2 — (VDC2) No. 2:
(F87) No. 29 — (VDC2) No. 2:
VDCCM and VDCH/U?
VDC-187
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

sponding to the
trouble code.
VDC-188
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-189
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AL: TROUBLE CODE 51 VALVE RELAY ON FAILURE S005504D63
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2328
VDC-190
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

No. 85 and No. 86.
terminals.
Terminals
No. 30 — No. 87:
minals.
Terminals
No. 30 — No. 87a:
nals.
terminals.
Terminals
No. 30 — No. 87:
minals.
Terminals
No. 30 — No. 87a:
minals.
Terminals
No. 86 — No. 87:
No. 86 — No. 87a:
1) Disconnect connector (F90) from relay box. No. 8 and SBF3.
(−):
(−):
1) Turn ignition switch to ON. No. 8 and SBF3.
(−):
(−):
VDC-191
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1) Turn ignition switch to OFF. and relay box and
2) Disconnect connector from VDCCM. check all fuses.
1) Turn ignition switch to ON. and relay box and
2) Measure voltage between VDCCM connec- check all fuses.
POINT CIRCUIT OF RELAY BOX. V? box.
1) Disconnect connector VDC1 from relay
box.
(−):
POINT CIRCUIT OF RELAY BOX. V? box.
(−):
1) Turn ignition switch to OFF. fuses.
(−):
1) Turn ignition switch to ON. fuses.
(−):
VDC-192
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1) Turn ignition switch to OFF. V? between VDCH/U
Turn ignition switch to OFF. VDCCM and VDCH/U?
sponding to the
trouble code.
VDC-193
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AM: TROUBLE CODE 52 MOTOR AND MOTOR RELAY OFF FAILURE S005504D66
DIAGNOSIS:
TROUBLE SYMPTOM:
VDC-194
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2329
VDC-195
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

terminals.
Terminals
No. 30 — No. 87:
minals.
Terminals
No. 85 — No. 30:
No. 85 — No. 87:
connector unit and chassis ground.
RELAY BOX. V? box.
and chassis ground.
(−):
RELAY BOX. V? box.
(−):
2) Disconnect connector from VDCCM. Check fuse SBF
3) Measure resistance between VDCCM con- holder.
and chassis ground.
VDC-196
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

VDCCM?
sponding to the
trouble code.
VDC-197
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AN: TROUBLE CODE 52 MOTOR AND MOTOR RELAY ON FAILURE S005504D67
DIAGNOSIS:
TROUBLE SYMPTOM:
VDC-198
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2329
VDC-199
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK RESISTANCE OF MOTOR RELAY. Is the resistance between Go to step 2. Replace motor
terminals.
Terminals
No. 85 — No. 86:
No. 85 and No. 86.
terminals.
Terminals
No. 30 — No. 87:
minals.
Terminals
No. 85 — No. 30:
No. 85 — No. 87:
3) Turn ignition switch to ON. and relay box,
4) Measure voltage between relay box con- and check fuse
nector and chassis ground. SBF holder.
chassis ground.
Relay installing point No. 87 (+) —
2) Disconnect connectors (VDC2, F90) from
relay box.
connector unit and motor relay installing por-
tion.
(VDC1) No. 1 — Motor relay installing
portion No. 30:
7 CHECK OPEN CIRCUIT IN MONITOR SYS- Is the resistance less than Go to step 8. Replace relay
TEM CIRCUIT OF RELAY BOX. 0.5 Ω? box.
nector and motor relay installing point.
point No. 30:
VDC-200
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

Measure resistance between motor relay
installing point and relay box connector.
point No. 85:
installing point and valve relay installing point.
Motor relay installing point No. 86 —
Valve relay installing point No. 30:
RELAY BOX. V? box.
and chassis ground.
(−):
RELAY BOX. V? box.
(−):
13 CHECK OPEN CIRCUIT IN RELAY CON- Is the resistance less than Go to step 14. Repair harness
TROL SYSTEM HARNESS. 0.5 Ω? connector
Measure resistance between VDCCM connec- between VDCCM
tor and relay box connector. and relay box.
(F87) No. 22 — (F90) No. 4:
(F87) No. 10 — (F90) No. 6:
tor and chassis ground. Check fuse SBF
and chassis ground. Check fuse SBF
VDC-201
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

2) Measure voltage between VDCCM connec- Check fuse SBF
tor and chassis ground. holder.
VDCCM?
sponding to the
trouble code.
VDC-202
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-203
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AO: TROUBLE CODE 52 MOTOR MALFUNCTION S005504D68
DIAGNOSIS:
쐌 Faulty motor
TROUBLE SYMPTOM:
VDC-204
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2329
VDC-205
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

No. 85 and No. 86.
terminals.
Terminals
No. 30 — No. 87:
1) Disconnect battery from motor relay termi-
nals.
terminals.
Terminals
No. 30 — No. 87:
3) Turn ignition switch to ON. and relay box,
4) Measure voltage between relay box con- and check fuse
nector and chassis ground. SBF holder.
chassis ground.
Relay installing point No. 87 (+) —
5 CHECK CONDITION OF MOTOR GROUND. Is the motor ground termi- Go to step 6. Tighten the clamp
Tightening torque: nal tightly clamped? of motor ground
32±10 N·m (3.3±1.0 kgf-m, 24±7 ft-lb) terminal.
6 CHECK VDCCM MOTOR DRIVE TERMINAL. Does the voltage drop from Go to step 7. Replace VDCCM.
1) Turn ignition switch OFF. between 10 V and 13 V to
2) Remove VDC connector cover. <Ref. to less than 1.5 V, and rise to
VDC-17 VDCCM Connector Cover.> between 10 V and 13 V
3) Connect all connectors. again when carrying out
4) Install motor relay. the check sequence?
5) Operate the ABS check sequence. <Ref. to
VDC-18 ABS Sequence Control.>
tor terminals.
(F87) No. 22 (+) — No. 1 (−):
7 CHECK MOTOR OPERATION. Can motor revolution noise Go to step 8. Replace VDCH/U.
Operate the check sequence. <Ref. to (buzz) be heard when car-
VDC-21 VDC Sequence Control.> rying out the check
sequence?
VDCCM?
VDC-206
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

sponding to the
trouble code.
VDC-207
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AP: TROUBLE CODE 71 STEERING ANGLE SENSOR OFFSET IS TOO BIG.

S005504D93
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2324
VDC-208
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

2) Stop the vehicle in a straight line. steering wheel.
sponding to the
trouble code.
VDC-209
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AQ: TROUBLE CODE 71 CHANGE RANGE OF STEERING ANGLE SENSOR

IS TOO BIG. S005504D89
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2324
VDC-210
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

sponding to the
trouble code.
VDC-211
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AR: TROUBLE CODE 71 STEERING ANGLE SENSOR MALFUNCTION S005504D92
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2324
VDC-212
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

2 CHECK OUTPUT OF STEERING ANGLE Does the steering angle Go to step 3. Replace steering
SENSOR USING SELECT MONITOR. sensor output (value) angle sensor.
1) Select “Current data display & Save” on change on the monitor dis-
the select monitor. play when the steering
2) Read steering angle sensor output on the wheel is turned in either
select monitor display. direction?
faces) sometimes
results in a
VDCCM memory
trouble code.
sponding to the
trouble code.
VDC-213
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AS: TROUBLE CODE 71 NO SIGNAL FROM STEERING ANGLE SENSOR S005504D90
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2324
VDC-214
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK POWER SUPPLY OF STEERING Is the voltage between 10 Go to step 4. Go to step 2.
ANGLE SENSOR. and 15 V?
sensor.
4) Measure voltage between steering angle
2) Disconnect connector from VDCCM. sensor and
3) Remove cover for VDCCM connector. VDCCM.
<Ref. to VDC-21 VDC Sequence Control.>
chassis ground.
TORS. yaw rate sensor connector? VDCCM connec-
tor.
4 CHECK GROUND CIRCUIT OF STEERING Is the resistance less than Go to step 5. Repair steering
ANGLE SENSOR. 0.5 Ω? angle sensor
Measure resistance between steering sensor ground harness.
and chassis ground.
5 CHECK HARNESS OF STEERING ANGLE Is the resistance 120±6 Ω? Repair harness Go to step 6.
SENSOR. between steering
1) Connect connector to steering angle sen- angle sensor and
sor. VDCCM.
nector terminals.
(F87) No. 81 — No. 83:
6 CHECK STEERING ANGLE SENSOR. Is the same trouble code Go to step 8. Go to step 7.
1) Turn ignition switch to OFF. as in the current diagnosis
2) Connect all connectors. still being output?
sponding to the
trouble code.
2) Replace steering angle sensor. still being output? VDC Control Mod-
9 CHECK ANY OTHER TROUBLE CODES Are other trouble codes Proceed with the The original steer-
APPEARANCE. being output? diagnosis corre- ing angle sensor
sponding to the has been faulty.
trouble code.
VDC-215
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AT: TROUBLE CODE 72 ABNORMAL YAW RATE SENSOR OUTPUT S005504D95
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2330
VDC-216
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

faces) sometimes
results in a
VDCCM memory
trouble code.
sensor.
3 CHECK OUTPUT OF YAW RATE AND LAT- Is the yaw rate and lateral Go to step 4. Replace yaw rate
ERAL G SENSOR USING SELECT MONI- G sensor output on monitor and lateral G sen-
TOR. display 0±5.25 deg? sor. <Ref. to
1) Drive the vehicle on a flat road. VDC-24 Yaw Rate
2) Stop the vehicle in a straight line. and Lateral G
3) Select “Current data display & Save” on Sensor.>
the select monitor.
4) Read yaw rate and lateral G sensor output
4 CHECK OUTPUT OF STEERING ANGLE Is the steering angle sen- Go to step 5. Perform centering
SENSOR USING SELECT MONITOR. sor output on monitor dis- alignment of
1) Drive the vehicle on a flat road. play 0±2.5°? steering wheel.
2) Stop the vehicle in a straight line.
the select monitor.
4) Read steering angle sensor output on the
select monitor display.
5 CHECK YAW RATE AND LATERAL G SEN- Is the same trouble code Go to step 6. Go to step 7.
SOR. as in the current diagnosis
1) Turn ignition switch to OFF. still being output?
sponding to the
trouble code.
2) Replace yaw rate and lateral G sensor. still being output? VDC Control Mod-
8 CHECK ANY OTHER TROUBLE CODES Are other trouble codes Proceed with the The original yaw
APPEARANCE. being output? diagnosis corre- rate and lateral G
sponding to the sensor has been
trouble code. faulty.
VDC-217
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AU: TROUBLE CODE 72 VOLTAGE INPUTTED TO YAW RATE SENSOR

EXCEEDS SPECIFICATION. S005504D99
DIAGNOSIS:
TROUBLE SYMPTOM:
VDC-218
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2330
VDC-219
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

lateral G sensor.
chassis ground.
sor connector? tor.
1) Turn ignition switch OFF. and lateral G sen-
2) Disconnect connector from VDCCM. sor and VDCCM.
(F87) No. 65 — (R100) No. 4:
Measure resistance between VDCCM and 1 MΩ? between yaw rate
chassis ground. and lateral G sen-
Measure voltage between VDCCM and chas- V? between yaw rate
sis ground. and lateral G sen-
7 CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 0.5 Replace yaw rate Repair harness
1) Turn ignition switch to ON. V? and lateral G sen- between yaw rate
2) Measure voltage between VDCCM and sor. <Ref. to and lateral G sen-
chassis ground. VDC-24 Yaw Rate sor and VDCCM.
Connector & terminal and Lateral G
(F87) No. 65 (+) — Chassis ground (−): Sensor.>
VDC-220
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-221
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AV: TROUBLE CODE 72 ABNORMAL YAW RATE SENSOR REFERENCE

VOLTAGE S005504D96
DIAGNOSIS:
TROUBLE SYMPTOM:
VDC-222
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2330
VDC-223
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

lateral G sensor.
chassis ground.
sor connector? tor.
(F87) No. 66 — (R100) No. 1:
8 CHECK YAW RATE AND LATERAL G SEN- Is the voltage between 2.1 Replace VDCCM. Replace yaw rate
SOR. and 2.9 V? <Ref. to VDC-10 and lateral G sen-
1) Turn ignition switch to OFF. VDC Control Mod- sor. <Ref. to
2) Install yaw rate and lateral G sensor to ule (VDCCM).> VDC-24 Yaw Rate
body. and Lateral G
3) Remove VDCCM connector cover. <Ref. to Sensor.>
tor terminals.
(F87) No. 66 (+) — No. 64 (−):
VDC-224
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-225
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AW: TROUBLE CODE 72 CHANGE RANGE OF YAW RATE SENSOR SIGNAL

IS TOO BIG. S005504D97
DIAGNOSIS:
TROUBLE SYMPTOM:
VDC-226
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2330
VDC-227
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK RUNNING FIELD. Was the vehicle driven on When driving on Go to step 2.
surfaces with holes or surfaces with
bumps at high speeds? holes or bumps at
high speeds,
VDCCM some-
times records
trouble codes in
memory.
sensor.
lateral G sensor.
chassis ground.
sor connector? tor.
6 CHECK GROUND CIRCUIT OF YAW RATE Is the resistance less than Go to step 9. Go to step 7.
AND LATERAL G SENSOR. 0.5 Ω?
Measure resistance between yaw rate and
7 CHECK GROUND CIRCUIT OF VDCCM. Is the resistance less than Repair harness Go to step 8.
1) Disconnect connector from VDCCM. 0.5 Ω? between yaw rate
2) Remove cover from VDCCM connector. and lateral G sen-
<Ref. to VDC-17 VDCCM Connector Cover.> sor and VDCCM.
chassis ground.
tor.
VDC-228
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

9 CHECK HARNESS OF YAW RATE SEN- Is the resistance less than Go to step 10. Repair harness
SOR. 0.5 Ω? between yaw rate
(F87) No. 65 — (R100) No. 4:
(F87) No. 66 — (R100) No. 1:
(F87) No. 67 — (R100) No. 2:
13 CHECK YAW RATE AND LATERAL G SEN- Is the voltage between 2.1 Replace VDCCM. Replace yaw rate
SOR. and 2.9 V? <Ref. to VDC-10 and lateral G sen-
1) Turn ignition switch to OFF. VDC Control Mod- sor. <Ref. to
2) Install yaw rate and lateral G sensor to ule (VDCCM).> VDC-24 Yaw Rate
body. and Lateral G
3) Connect all connectors. Sensor.>
(F87) No. 66 (+) — No. 64 (−):
VDC-229
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
AX: TROUBLE CODE 73 LATERAL G SENSOR OFFSET IS TOO BIG. S005504E04
NOTE:
For diagnostic procedure, refer to TROUBLE CODE 73. <Ref. VDC-230 TROUBLE CODE 73 EXCESSIVE
LATERAL G SENSOR SIGNAL, Diagnostics Chart with Select Monitor.>
AY: TROUBLE CODE 73 ABNORMAL LATERAL G SENSOR OUTPUT S005504E01
NOTE:
AZ: TROUBLE CODE 73 CHANGE RANGE OF LATERAL G SENSOR IS TOO
BIG. S005504E02
NOTE:
BA: TROUBLE CODE 73 EXCESSIVE LATERAL G SENSOR SIGNAL S005504E03
DIAGNOSIS:
TROUBLE SYMPTOM:
VDC-230
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2330
VDC-231
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

sensor.
2 CHECK OUTPUT OF LATERAL G SENSOR Is the yaw rate and lateral Go to step 3. Replace yaw rate
USING SELECT MONITOR. G sensor output on monitor and lateral G sen-
1) Stop the vehicle on a flat road. display 2.5±0.2 V? sor. <Ref. to
2) Select “Current data display & Save” on VDC-24 Yaw Rate
the select monitor. and Lateral G
3) Read yaw rate and lateral G sensor output Sensor.>
Turn ignition switch to OFF. VDCCM and yaw rate and
lateral G sensor?
sponding to the
trouble code.
VDC-232
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-233
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
BB: TROUBLE CODE 73 VOLTAGE INPUTTED TO LATERAL G SENSOR

EXCEEDS SPECIFICATION. S005504E06
DIAGNOSIS:
TROUBLE SYMPTOM:
VDC-234
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
WIRING DIAGRAM:
B4M2330
VDC-235
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK OUTPUT OF YAW RATE AND LAT- Is the yaw rate and lateral Go to step 2. Go to step 5.
ERAL G SENSOR USING SELECT MONI- G sensor output on monitor
TOR. display 2.5±0.2 V?
1) Stop the vehicle on a flat road.
the select monitor.
3) Read yaw rate and lateral G sensor output
Turn ignition switch to OFF. VDCCM and yaw rate and
lateral G sensor?
sponding to the
trouble code.
5 CHECK INPUT VOLTAGE OF YAW RATE Is the voltage between 10 Go to step 6. Repair harness/
AND LATERAL G SENSOR. and 15 V? connector
1) Turn ignition switch to OFF. between yaw rate
2) Remove console box. and lateral G sen-
3) Disconnect connector from yaw rate and sor and VDCCM.
lateral G sensor.
(R100) No. 3 (+) — No. 6 (−):
6 CHECK YAW RATE AND LATERAL G SEN- Is the resistance between Go to step 7. Replace yaw rate
SOR. 4.3 and 4.9 kΩ? and lateral G sen-
2) Measure resistance between yaw rate and
lateral G sensor terminals.
Terminals
No. 3 — No. 5:
7 CHECK OPEN CIRCUIT IN YAW RATE AND Is the resistance between Go to step 8. Repair harness/
LATERAL G SENSOR OUTPUT HARNESS 4.3 and 4.9 kΩ? connector
AND GROUND HARNESS. between yaw rate
1) Connect connector to yaw rate and lateral and lateral G sen-
G sensor. sor and VDCCM.
nector terminals.
(F87) No. 69 — No. 70:
8 CHECK GROUND SHORT IN YAW RATE Is the resistance more than Go to step 9. Repair harness
AND LATERAL G SENSOR HARNESS. 1 MΩ? between yaw rate
VDC-236
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1) Turn ignition switch to OFF. and lateral G sensor is sor. <Ref. to
2) Remove yaw rate and lateral G sensor horizontal? VDC-24 Yaw Rate
from vehicle. and Lateral G
3) Connect connector to yaw rate and lateral Sensor.>
G sensor.
(R100) No. 5 (+) — No. 6 (−):
Connector & terminal 90° to the left in front of the and Lateral G
(R100) No. 5 (+) — No. 6 (−): sensor? Sensor.>
Connector & terminal 90° to the right in front of and Lateral G
(R100) No. 5 (+) — No. 6 (−): the sensor? Sensor.>
VDCCM and yaw rate and
lateral G sensor?
sponding to the
trouble code.
VDC-237
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
BC: TROUBLE CODE 74 VOLTAGE INPUTTED TO PRESSURE SENSOR 1

EXCEEDS SPECIFICATION. (PRIMARY PRESSURE SENSOR) S005504E12
DIAGNOSIS:
쐌 Faulty primary pressure sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2332
VDC-238
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

SENSOR. 0.5 Ω?
chassis ground.
tor.
SENSOR. and 5.25 V?
nector terminals.
(F91) No. 16 (+) — No. 15 (−):
tor terminals.
(F87) No. 78 (+) — No. 76 (−):
tor.
VDC-239
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

10 CHECK INPUT VOLTAGE OF PRESSURE Is the voltage between 0.53 Go to step 11. Replace VDCH/U.
tor terminals.
(F87) No. 77 (+) — No. 76 (−):
sor?
sponding to the
trouble code.
VDC-240
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-241
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
BD: TROUBLE CODE 74 VOLTAGE INPUTTED TO PRESSURE SENSOR 2

EXCEEDS SPECIFICATION. (SECONDARY PRESSURE SENSOR) S005504E13
DIAGNOSIS:
쐌 Faulty secondary pressure sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2332
VDC-242
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

SENSOR. 0.5 Ω?
chassis ground.
tor.
SENSOR. and 5.25 V?
nector terminals.
(F91) No. 16 (+) — No. 15 (−):
tor terminals.
(F87) No. 78 (+) — No. 76 (−):
tor.
VDC-243
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

tor terminals.
(F87) No. 36 (+) — No. 76 (−):
sor?
sponding to the
trouble code.
VDC-244
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
MEMO:
VDC-245
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
BE: TROUBLE CODE 74 PRESSURE SENSOR 1 OFFSET IS TOO BIG.

(PRIMARY PRESSURE SENSOR) S005504E10
NOTE:
For diagnostic procedure, refer to TROUBLE CODE 74. <Ref. VDC-246 TROUBLE CODE 74 PRESSURE
SENSOR 2 OFFSET IS TOO BIG. (SECONDARY PRESSURE SENSOR), Diagnostics Chart with Select
Monitor.>
BF: TROUBLE CODE 74 PRESSURE SENSOR 2 OFFSET IS TOO BIG.
(SECONDARY PRESSURE SENSOR) S005504E11
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2332
VDC-246
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

1 CHECK DRIVING TECHNIC. Are the accelerator and The VDC is nor- Go to step 2.
Check the driver’s technic. brake pedals depressed mal. Erase the
simultaneously while driv- trouble code.
ing? NOTE:
Driving the vehicle
with both the
accelerator pedal
and brake pedal
depressed may
store a trouble
code in the
memory.
2 CHECK OUTPUT OF PRESSURE SENSOR Is the presssure sensor Go to step 3. Replace VDCH/U.
USING SELECT MONITOR. output on monitor display <Ref. to VDC-13
1) Select “Current data display & Save” on 0.6±0.075 V with brake Hydraulic Control
the select monitor. pedal released? Unit (H/U).>
2) Read pressure sensor output on the select
monitor display.
sponding to the
trouble code.
VDC-247
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
BG: TROUBLE CODE 74 DIFFERENTIAL PRESSURE OF PRESSURE

SENSOR IS TOO BIG. S005504E09
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M2332
VDC-248
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

tor terminals.
(F87) No. 77 (+) — No. 76 (−):
(F87) No. 36 (+) — No. 76 (−):
5 CHECK BRAKE PEDAL STROKE. Is the stroke less than 95 Go to step 6. Perform bleeding
Measure the stroke between non-forced pedal mm (3.74 in)? from brake sys-
position and forced pedal position with 50 kg tem.
(110 lb).
6 CHECK INPUT VOLTAGE OF PRESSURE Is the voltage between A Go to step 7. Replace VDCH/U.
SENSOR. and B less than 0.2 V?
1) Depress the brake pedal with 50 kg (110
lb).
tor terminals.
A (F87) No. 77 (+) — No. 76 (−):
B (F87) No. 36 (+) — No. 76 (−):
sor?
VDC-249
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)

sponding to the
trouble code.
VDC-250
墌 00.5.31/68j/0vdc 墍
VDC (DIAGNOSTICS)
Symptom Primary probable cause Secondary probable cause

Poor braking Long braking VDCH/U Faulty ABS sensor or sensor gap
effectiveness distance VDCCM Faulty steering angle sensor or improper neu-
Brake pads tral position
Air in brake line Faulty yaw rate and lateral G sensor or
Tire specifications, wear and pressures improper installation
Incorrect wiring or piping Proportioning valve
Master cylinder
Brake caliper
Disc rotor
Brake pipe
Brake booster
Wheel locks VDCH/U Faulty steering angle sensor or improper neu-
VDCCM tral position
Faulty ABS sensor or sensor gap Faulty yaw rate and lateral G sensor or
Incorrect wiring or piping improper installation
Proportioning valve
Brake caliper
Brake pipe
Brake dragging VDCH/U Faulty steering angle sensor or improper neu-
VDCCM tral position
Faulty ABS sensor or sensor gap Faulty yaw rate and lateral G sensor or
Master cylinder improper installation
Brake caliper Brake pads
Parking brake Brake pipe
Axle & wheels
Brake pedal play
Long brake Air in brake line VDCH/U
pedal stroke Brake pedal play Proportioning valve
Master cylinder
Brake caliper
Brake pads
Brake pipe
Brake booster
Vehicle pitching VDCH/U Faulty ABS sensor or sensor gap
VDCCM Faulty steering angle sensor or improper neu-
Uneven road tral position
Suspension play or fatigue (reduced Faulty yaw rate and lateral G sensor or
damping) improper installation
Incorrect wiring or piping
Unstable or VDCH/U Faulty ABS sensor or sensor gap
uneven braking VDCCM Faulty steering angle sensor or improper neu-
Faulty ABS sensor or sensor gap tral position
Brake caliper Faulty yaw rate and lateral G sensor or
Brake pads improper installation
Uneven road Master cylinder
Tire specifications, wear and pressures Disc rotor
Incorrect wiring or piping Brake pipe
Axle & wheels
Crowned road or banked road
Suspension play or fatigue (reduced damping)
VDC-251
VDC (DIAGNOSTICS)

Vibration and/or Excessive brake Uneven road VDCH/U
noise pedal vibration Incorrect wiring or piping Proportioning valve
쐌 During abrupt Brake booster
braking Suspension play or fatigue (reduced damping)
쐌 During rapid Noise from VDCH/U (mount bushing) VDCCM
acceleration VDCH/U Faulty ABS sensor or sensor gap Faulty steering angle sensor or improper neu-
쐌 During slip- Brake pipe tral position
pery road driv- Faulty yaw rate and lateral G sensor or
ing improper installation
Noise from front VDCH/U (mount bushing) Axle & wheels
of vehicle Faulty ABS sensor or sensor gap Tire specifications, wear and pressures
Master cylinder
Brake caliper
Brake pads
Disc rotor
Brake pipe
Brake booster
Suspension play or fatigue (reduced
damping)
Noise inside VDCCM
passenger com- Faulty steering angle sensor or improper neu-
partment tral position
Faulty yaw rate and lateral G sensor or
Noise from rear Faulty ABS sensor or sensor gap Axle & wheels
of vehicle Brake caliper Tire specifications, wear and pressures
Brake pads
Disc rotor
Parking brake
Brake pipe
damping)
Engine does not accelerate or VDCH/U Faulty steering angle sensor or improper neu-
engine stalls during rapid accel- VDCCM tral position
eration or on slippery roads. Faulty ABS sensor or sensor gap Faulty yaw rate and lateral G sensor or
Master cylinder improper installation
Brake caliper Brake pads
Parking brake Brake pipe
VDC-252
VDC (DIAGNOSTICS)

Poor TCS’s Deviation in VDCH/U Proportioning valve
directional either left or VDCCM Disc rotor
operation stabil- right direction Faulty ABS sensor or sensor gap Brake pipe
ity Faulty steering angle sensor or improper Axle & wheels
neutral position Suspension play or fatigue (reduced damping)
Brake caliper
Brake pads
Wheel alignment
Uneven road
Tire specifications, wear and pressures
Vehicle spin VDCH/U Proportioning valve
VDCCM Brake caliper
Faulty ABS sensor or sensor gap Brake pipe
Faulty steering angle sensor or improper
neutral position
Brake pads
Steering wheel drags during VDCH/U Brake caliper
operation. VDCCM Brake pads
Faulty ABS sensor or sensor gap Disc rotor
Faulty steering angle sensor or improper Wheel alignment
neutral position Uneven road
Faulty yaw rate and lateral G sensor or Crowned road or banked road
improper installation Suspension play or fatigue (reduced damping)
Incorrect wiring or piping connections Tire specifications, wear and pressures
Power steering system
VDC activates during ordinary VDCH/U
driving. VDCCM
Faulty ABS sensor or sensor gap
Faulty steering angle sensor or improper
neutral position
Wheel alignment
Uneven road
damping)
Power steering system
VDC-253
VDC (DIAGNOSTICS)
MEMO:
VDC-254
GENERAL DESCRIPTION
VDC
Item Standard or remarks

Front 0.3 — 0.8 mm (0.012 — 0.031 in)
ABS sensor gap
Rear 0.44 — 0.94 mm (0.0173 — 0.0370 in)
ABS sensor resistance 1.25±0.25 kΩ
ABS sensor Front LH Brown
Front RH Light blue
Marks of the harness
Rear LH Yellow
Rear RH White
Yaw rate and lateral G sensor Lateral G sensor voltage 2.5±0.2 V
VDC hydraulic control unit marks D2
VDC control module marks E1
VDC-2
墌 00.5.31/68j/4vdc 墍
GENERAL DESCRIPTION
VDC
1. ABS SENSOR S402001A0501
B4M2257B
(1) Clip (5) Housing Tightening torque: N·m (kgf-m, ft-lb)

(2) Rear ABS sensor (6) Front ABS sensor
T: 32 (3.3, 24)
(3) ABS spacer (7) Tone wheel (Front)
(4) Tone wheel (Rear)
VDC-3
墌 00.5.31/68j/4vdc 墍
GENERAL DESCRIPTION
VDC
2. YAW RATE AND LATERAL G SENSOR S402001A0507
B4M2367A
(1) Yaw rate and lateral G sensor Tightening torque: N·m (kgf-m, ft-lb)
T: 7.5 (0.76, 5.5)
VDC-4
墌 00.5.31/68j/4vdc 墍
GENERAL DESCRIPTION
VDC
3. STEERING ANGLE SENSOR S402001A0504
B4M1879A
(1) Steering angle sensor (2) Connector
VDC-5
墌 00.5.31/68j/4vdc 墍
GENERAL DESCRIPTION
VDC
4. VDC CONTROL MODULE (VDCCM) S402001A0505
B4M1880B
(1) VDC control module Tightening torque: N·m (kgf-m, ft-lb)

T: 7.5 (0.76, 5.5)
VDC-6
墌 00.5.31/68j/4vdc 墍
GENERAL DESCRIPTION
VDC
5. HYDRAULIC CONTROL UNIT (H/U) S402001A0506
B4M2461A
(1) Relay box (9) Pressure sensor Tightening torque: N·m (kgf-m, ft-lb)
(2) Motor relay (10) Ground terminal
T1: 13 (1.3, 9.4)
(3) Valve relay (11) Front-LH outlet
T2: 18 (1.8, 13.0)
(4) Cap (12) Secondary inlet
T3: 30 (3.1, 22.4)
(5) Bracket (13) Front-RH outlet
(6) Hydraulic control unit (14) Primary inlet T4: 33 (3.4, 24.6)
(7) Damper (15) Rear-LH outlet
(8) Stud bolt (16) Rear-RH outlet
VDC-7
墌 00.5.31/68j/4vdc 墍
GENERAL DESCRIPTION
VDC
쐌 Wear working clothing, including, a cap, protec-

tion.
ment.
fied points.
VDC-8
墌 00.5.31/68j/4vdc 墍
GENERAL DESCRIPTION
VDC

B2M3876
B2M3877
TOOL NAME REMARKS

Pressure gauge Used for measuring oil pressure.
VDC-9
墌 00.5.31/68j/4vdc 墍
VDC CONTROL MODULE (VDCCM)
VDC
2. VDC Control Module 4) Remove two bolts which install VDCCM onto
body side bracket.
(VDCCM) S402550
B4M1910
5) Disconnect connector from VDCCM by pulling

up the securing holder.
G6M0095
2) Remove lower cover of instrument panel and

disconnect connectors on the back side of the
cover.
B4M1912
6) Remove VDCCM.
B3M1591
3) Remove three bolts which secure the fuse box

onto body side, then move the fuse box aside.
B4M1909
VDC-10
墌 00.5.31/68j/4vdc 墍
VDC
Install in the reverse order of removal. Check the VDCCM identification mark.
CAUTION:
After completion of installation procedure, the
following two position settings must be made.
쐌 Steering angle sensor center positioning
쐌 Yaw rate and lateral G sensor 0 positioning
These procedures are necessary for VDCCM to
later recognize what position the vehicle is in.
For procedures for the above two settings,
<Ref. to VDC-12 ADJUSTMENT, VDC Control
Module (VDCCM).>.
B4M2267B
(1) Specification mark
Vehicle specifications VDCCM identification mark

Six cylinder engine E1
VDC-11
墌 00.5.31/68j/4vdc 墍
VDC
D: ADJUSTMENT S402550A01 7) If there are any abnormalities in VDC function

or steering operation found while vehicle is being
Always conduct steering angle sensor center posi- driven, conduct the procedure over again.
tioning and yaw rate and lateral G sensor 0 posi-
tioning whenever you have replaced, removed or
installed the following items.
쐌 VDCCM
쐌 Steering angle sensor
쐌 Yaw rate and lateral G sensor
쐌 Steering wheel parts (including airbag)
쐌 Suspension parts
쐌 Adjustment of wheel alignment
S402550A0101
1) Park the vehicle in a straight ahead position on

a horizontal surface.
2) Confirm the steering wheel center position. (If
the center position is not accurate, adjust wheel
alignment.)
3) Drive the vehicle approx. 10 km (6 MPH) pref-
erably on a straight road, then turn ignition switch
OFF. Then drive the vehicle approx. 10 km (6
MPH) again confirming that ABS and VDC warning
lights do not go ON while vehicle is being driven.
Also make sure there are no abnormalities of the
VDC function or steering operation.
NOTE:
If it is not possible to drive the vehicle, use
SUBARU SELECT MONITOR.
<Ref. to VDC-12 WITH SUBARU SELECT
MONITOR, ADJUSTMENT, VDC Control Module
(VDCCM).>
4) If there are any abnormalities found, conduct
the procedure over again.
2. WITH SUBARU SELECT MONITOR
S402550A0102
1) Park the vehicle in a straight ahead position on

a horizontal surface. (Engine running in gear posi-
tion of P or N)
2) Confirm the steering wheel center position. (If
the center position is not accurate, adjust wheel
alignment.)
3) Set the SUBARU SELECT MONITOR on the
vehicle and select “Set Mode Str.A.Sen.N &
Lat.Gsen.0p” in “Function Check Sequence” dis-
play menu. (Follow the instructions in the display.)
4) Select “Current Data display & Save” in {Brake
Control System} display menu and confirm if the
steering angle sensor is indicated as “0 deg”.
5) If the display does not indicate {0 deg}, conduct
the procedure over again and make sure it indi-
cates “0 deg”.
6) Drive the vehicle approx. 10 minutes and con-
firm that ABS and VDC warning lights do not go ON
while vehicle is being driven.
VDC-12
墌 00.5.31/68j/4vdc 墍
HYDRAULIC CONTROL UNIT (H/U)
VDC
3. Hydraulic Control Unit (H/U) 6) Remove nuts and bolt which secure hydraulic
S402551
unit bracket, and remove hydraulic unit from
engine compartment.
CAUTION:
1. HYDRAULIC UNIT (H/U) S402551A1801
쐌 Hydraulic unit cannot be disassembled. Do
not attempt to loosen bolts and nuts.
1) Disconnect ground cable from battery. 쐌 Do not drop or bump hydraulic unit.
쐌 Do not turn the hydraulic unit upside down
or place it on its side.
쐌 Be careful to prevent foreign particles from
getting into hydraulic unit.
쐌 When a new hydraulic unit is installed, apply
a coat of rust-preventive wax (Nippeco LT or
GB) to bracket attaching bolt after tightening.
쐌 Do not pull harness disconnecting harness
connector.
G6M0095

ment to facilitate removal of hydraulic unit.
3) Disconnect connector from hydraulic unit.
CAUTION:
Be careful not to let water or other foreign mat-
ter contact the H/U terminal.
4) Unlock cable clip. B4M1913
5) Disconnect brake pipes from hydraulic unit.
CAUTION: 2. RELAY BOX S402551A1802
Wrap brake pipes with vinyl bag to avoid spill-

ing brake fluid on vehicle body.
ment to facilitate removal of relay box.
3) Disconnect connector from relay box.
4) Unlock cable clip.
5) Remove nuts which secure relay box, and
remove relay box and connector bracket.
B4M1914
CAUTION:
Do not drop or bump relay box.
VDC-13
墌 00.5.31/68j/4vdc 墍
VDC
B: INSTALLATION S402551A11 2. RELAY BOX S402551A1102
1. HYDRAULIC UNIT (H/U) S402551A1101

1) Install relay box and connector bracket.
1) Install hydraulic unit. Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
B4M1913
B4M1914
Tightening torque: 2) Secure relay box connector to connector

18 N·m (1.8 kgf-m, 13.0 ft-lb) bracket.
2) Connect hydraulic unit ground cable to body. CAUTION:
Align connector with mating receptacle.
Tightening torque:
33 N·m (3.4 kgf-m, 25 ft-lb) 3) Connect connector to relay box.
3) Connect brake pipes to their correct hydraulic
unit connections.
4) Secure hydraulic unit connector to connector
bracket.
CAUTION:
Align connector with mating receptacle.
5) Connect connector to hydraulic unit.
B4M1917B
(1) Relay box connector

(2) Hydraulic unit connector
4) Install air intake duct.

5) Connect ground cable to battery.
B4M1917B
(1) Relay box connector

(2) Hydraulic unit connector

7) Connect ground cable to battery.
8) Bleed air from the brake system.
VDC-14
墌 00.5.31/68j/4vdc 墍
VDC
1) Check connected and fixed condition of connector.

2) Check valve relay and motor relay for discontinuity or short circuits.
Condition Terminal number Standard Diagram Terminal location
85 — 86 103±10 Ω
Turning off electricity. 30 — 87a less than 0.5 Ω
Valve relay 30 — 87 more than 1 MΩ
Turning on electricity 30 — 87a more than 1 MΩ

between 85 and 86.
(DC 12 V) 30 — 87 less than 0.5 Ω G4M0457
G4M0456
85 — 86 80±10 Ω
Turning off electricity.
30 — 87 more than 1 MΩ
Motor relay
Turning on electricity
between 85 and 86. 30 — 87 less than 0.5 Ω
(DC 12 V)
G4M0458 G4M0459
1. CHECKING THE HYDRAULIC UNIT ABS 6) When the hydraulic unit begins to work, and
OPERATION BY PRESSURE GAUGE first the FL side performs decompression, holding,
S402551A1001
and compression, and then the FR side performs
1) Lift-up vehicle and remove wheels. 7) Read values indicated on the pressure gauge
2) Disconnect the air bleeder screws from the FL and check if the fluctuation of the values between
and FR caliper bodies. decompression and compression meets the stan-
3) Connect two pressure gauges to the FL and FR dard values. Also check if any irregular brake pedal
caliper bodies. tightness is felt.
CAUTION: Front wheel Rear wheel
쐌 Pressure gauges used exclusively for brake
3,432 kPa 3,432 kPa
fluid must be used. Initial value
(35 kg/cm2, 498 psi) (35 kg/cm2, 498 psi)
쐌 Do not employ pressure gauge previously 490 kPa 490 kPa
used for transmission since the piston seal is When
(5 kg/cm2, 71 psi) (5 kg/cm2, 71 psi)
expanded which may lead to malfunction of the decompressed
or less or less
brake. 3,432 kPa 3,432 kPa
When
NOTE: (35 kg/cm2, 498 psi) (35 kg/cm2, 498 psi)
compressed
or more or more
per bodies.
9) Remove air bleeder screws from the RL and RR
caliper bodies.
10) Connect the air bleeder screws to the FL and
FR caliper bodies.
RR caliper bodies.
12) Bleed air from the pressure gauges and the FL
B4M1732
<Ref. to VDC-18 ABS Sequence Control.>
4) Bleed air from the pressure gauges. 14) When the hydraulic unit begins to work, at first
5) Perform ABS sequence control. the RR side performs decompression, holding, and
<Ref. to VDC-18 ABS Sequence Control.> compression, and then the RL side performs
VDC-15
墌 00.5.31/68j/4vdc 墍
VDC
decompression, holding, and compression. Front wheel Rear wheel

15) Read values indicated on the pressure 981 N 981 N
gauges and check if they meet the standard val- Initial value
(100 kg, 221 lb) (100 kg, 221 lb)
ues. 490 N 490 N
16) After checking, remove the pressure gauges When
(50 kg, 110 lb) (50 kg, 110 lb)
from caliper bodies. decompressed
or less or less
17) Connect the air bleeder screws to RL and RR 981 N 981 N
caliper bodies. When
(100 kg, 221 lb) (100 kg, 221 lb)
compressed
18) Bleed air from brake line. or more or more
2. CHECKING THE HYDRAULIC UNIT ABS 7) After checking, also check if any irregular brake
OPERATION WITH BRAKE TESTER S402551A1002 pedal tightness is felt.
1) Prepare for operating ABS sequence control. 3. CHECKING THE HYDRAULIC UNIT VDC
<Ref. to VDC-18 ABS Sequence Control.> OPERATION BY PRESSURE GAUGE
2) Set the front wheels or rear wheels on the brake S402551A1003
tester and set the select lever’s position at “neu-
tral”. 1) Lift-up vehicle and remove wheels.
2) Disconnect the air bleeder screws from the FL
3) Connect two pressure gauges to the FL and FR
caliper bodies.
CAUTION:
쐌 Pressure gauges used exclusively for brake
fluid must be used.
쐌 Do not employ pressure gauge previously
used for transmission since the piston seal is
expanded which may lead to malfunction of the
B4M1733B
brake.
NOTE:
B4M1730B
(1) Brake tester

B4M1732
4) Perform ABS sequence control. 4) Bleed air from the pressure gauges.
<Ref. to VDC-18 ABS Sequence Control.> 5) Perform VDC sequence control.
5) When the hydraulic unit begins to work, check <Ref. to VDC-21 VDC Sequence Control.>
the following working sequence. 6) When the hydraulic unit begins to work, and
(1) The FL wheel performs decompression, first the FL side performs decompression, holding,
holding, and compression in sequence, and and compression, and then the FR side performs
subsequently the FR wheel repeats the cycle. decompression, holding, and compression.
(2) The RR wheel performs decompression, 7) Read values indicated on the pressure gauge
holding, and compression in sequence, and and check if the fluctuation of the values between
subsequently the RL wheel repeats the cycle. decompression and compression meets the stan-
6) Read values indicated on the brake tester and dard values. Also check if any irregular brake pedal
check if the fluctuation of values, when decom- tightness is felt.
pressed and compressed, meet the standard val-
ues.
VDC-16
墌 00.5.31/68j/4vdc 墍
VDC

2,942 kPa 1,961 kPa
When
(30 kg/cm2, 427 psi) (20 kg/cm2, 284 psi)
compressed
or more or more
490 kPa 490 kPa
When
(5 kg/cm2, 71 psi) (5 kg/cm2, 71 psi)
decompressed
or less or less

per bodies.
9) Remove air bleeder screws from the RL and RR B4M1730B
caliper bodies.
10) Connect the air bleeder screws to the FL and (1) Brake tester
FR caliper bodies.
RR caliper bodies. <Ref. to VDC-18 ABS Sequence Control.>
12) Bleed air from the pressure gauges and the FL 5) When the hydraulic unit begins to work, check
and FR caliper bodies. the following working sequence.
13) Perform VDC sequence control. (1) The FL wheel performs decompression,
<Ref. to VDC-21 VDC Sequence Control.> holding, and compression in sequence, and
14) When the hydraulic unit begins to work, at first subsequently the FR wheel repeats the cycle.
the RR side performs decompression, holding, and (2) The RR wheel performs decompression,
compression, and then the RL side performs holding, and compression in sequence, and
decompression, holding, and compression. subsequently the RL wheel repeats the cycle.
15) Read values indicated on the pressure 6) Read values indicated on the brake tester and
gauges and check if they meet the standard value. check if the fluctuation of values, when decom-
16) After checking, remove the pressure gauges pressed and compressed, meet the standard val-
from caliper bodies. ues.
17) Connect the air bleeder screws to RL and RR
caliper bodies. Front wheel Rear wheel
18) Bleed air from brake line. 1,961 N 981 N
When
(200 kg, 441 lb) (100 kg, 221 lb)
compressed
4. CHECKING THE HYDRAULIC UNIT VDC or more or more
OPERATION WITH BRAKE TESTER S402551A1004 490 N 490 N
When
(50 kg, 110 lb) (50 kg, 110 lb)
decompressed
1) Prepare for operating VDC sequence control. or less or less
<Ref. to VDC-21 VDC Sequence Control.>
2) Set the front wheels or rear wheels on the brake 7) After checking, also check if any irregular brake
tester and set the select lever’s position at “neu- pedal tightness is felt.
tral”.
B4M1733B
(1) Brake tester
VDC-17
墌 00.5.31/68j/4vdc 墍
VDC
4. ABS Sequence Control S402187

2. ABS SEQUENCE CONTROL WITH
NOTE:
1) Under the ABS sequence control, after the 쐌 In the event of any trouble, the sequence con-
tion of the hydraulic unit can be checked by means the sequence control, referring to “ABS
2) ABS sequence control can be started by diag- NECTOR”.
nosis connector or select monitor. <Ref. to VDC-18 ABS SEQUENCE CONTROL
1. ABS SEQUENCE CONTROL WITH ABS Sequence Control.>
beside driver’s seat instrument panel lower cover.
mode.
5) When “Function check sequence” is selected,
‘ABS sequence control’ will start.
6) The message ‘Press Brake Pedal Firmly’ is dis-
played as follows:
(1) When using the brake tester, depress brake
B4M1767F pedal with braking force of 981 N (100 kg, 221
lb).
(1) Diagnosis connector (2) When using the pressure gauge, depress
(2) Diagnosis terminal brake pedal so as to make the pressure gauge
(3) 8 terminal indicate 3,432 kPa (35 kg/cm2, 498 psi).
(4) 5 terminal
CAUTION:
2) Set the speed of all wheels at 2.75 km/h (2 Do not depress the clutch pedal.
MPH) or less. 7) When the message “Press YES” is displayed,
3) Turn ignition switch OFF. press YES key.
4) Within 0.5 seconds after the ABS and VDC 8) Operation points will be displayed on select
warning light goes out, depress the brake pedal monitor.
and hold it immediately after ignition switch is
turned to ON.
CAUTION:
NOTE:
쐌 Engine must not operate.
5) After completion of ABS sequence control, turn
VDC-18
墌 00.5.31/68j/4vdc 墍
VDC
3. CONDITIONS FOR ABS SEQUENCE CONTROL S402187A1603
B4M1915A
NOTE:
VDC-19
墌 00.5.31/68j/4vdc 墍
VDC

ABS SEQUENCE CONTROL S402187A2201
When the following conditions develop, the ABS
sequence control stops and ABS operation is
10 km/h (6 MPH).
not used.)
set to off.
key is turned to ON, and before ABS warning light
after ABS warning light goes out. (When select
monitor is used.)
VDC-20
墌 00.5.31/68j/4vdc 墍
VDC SEQUENCE CONTROL
VDC
5. VDC Sequence Control S402195

2. VDC SEQUENCE CONTROL WITH
NOTE:
1) Under the VDC sequence control, after the 쐌 In the event of any trouble, the sequence con-
tion of the hydraulic unit can be checked by means the sequence control, referring to “VDC
2) VDC sequence control can be started by diag- NECTOR”.
nosis connector or select monitor. <Ref. to VDC-21 VDC SEQUENCE CONTROL
1. VDC SEQUENCE CONTROL WITH VDC Sequence Control.>
beside driver’s seat instrument panel lower cover.
mode.
5) Select “VDC Check Mode” in {Function check
sequence} menu to start ‘VDC sequence control’.
CAUTION:
B4M1767F
6) When the message “Press YES” is displayed,
press YES key.
(1) Diagnosis connector 7) Operation points will be displayed on select
(2) Diagnosis terminal monitor.
(3) 8 terminal
(4) 5 terminal
2) Set the speed of all wheels at 2.75 km/h (2

MPH) or less.
4) Turn ignition switch ON and start engine
immediately, confirming that ABS and VDC warn-
ing light goes ON and then OFF. After ABS and
VDC warning light goes OFF, within 0.5 seconds
depress the brake pedal once, then within 3 sec-
ond depress the brake pedal twice more and
release it.
CAUTION:
NOTE:
쐌 Engine must operate.
쐌 If the VDC sequence control does not start, do
the procedure over again.
5) After completion of VDC sequence control, turn
VDC-21
墌 00.5.31/68j/4vdc 墍
VDC
3. CONDITIONS FOR VDC SEQUENCE CONTROL S402195A1603
B4M1916A
NOTE:
VDC-22
墌 00.5.31/68j/4vdc 墍
VDC

VDC SEQUENCE CONTROL S402195A2201
When the following conditions develop, the VDC
sequence control stops and VDC operation is
10 km/h (6 MPH).
not used.)
set to off.
key is turned to ON, and before VDC warning light
after VDC warning light goes out. (When select
monitor is used.)
VDC-23
墌 00.5.31/68j/4vdc 墍
YAW RATE AND LATERAL G SENSOR
VDC
6. Yaw Rate and Lateral G B: INSTALLATION S402634A11
Sensor S402634 Install in the reverse order of removal.

NOTE:
Do not install yaw rate and lateral G sensor in the
1) Disconnect battery ground cable. wrong direction. There is an arrow on the sensor
showing which side faces the front of the vehicle.
G6M0095
B4M2370
<Ref. to EI-36 Console Box.>
3) Disconnect connector from yaw rate and lateral CAUTION:
G sensor. After completion of installation procedure, the
4) Remove yaw rate and lateral G sensor. following two position settings must be made.
CAUTION: 쐌 Yaw rate and lateral G sensor 0 positioning
Do not drop or bump yaw rate and lateral G These procedures are necessary for VDCCM to
sensor. later recognize what position the vehicle is in.
For procedures for the above two settings,
Module (VDCCM).>.
B4M2368
5) Remove bracket from body.
B4M2369
VDC-24
墌 00.5.31/68j/4vdc 墍
VDC
1. LATERAL G SENSOR SIGNAL S402634A1001

1 CHECK SUBARU SELECT MONITOR. Do you have SUBARU Go to step 5. Go to step 2.
select Monitor?
2 CHECK YAW RATE AND LATERAL G SEN- Is the voltage 2.5±0.2 V Go to step 3. Replace yaw rate
SOR. when yaw rate and lateral and lateral G sen-
1) Move the vehicle to a flat location. G sensor is horizontal? sor.
3) Connect connector to yaw rate and lateral
G sensor.
(R100) No. 5 (+) — No. 6 (−)
1) Remove yaw rate and lateral G sensor G sensor is inclined left to sor.
from vehicle. 90°?
(R100) No. 5 (+) — No. 6 (−)
NOTE:
If the yaw rate and lateral G sensor is moved,
the VDC (Yaw rate sensor) may be entered
into the memory.
Measure voltage between yaw rate and lateral G sensor is inclined right to sor.
G sensor connector terminals. 90°?
(R100) No. 5 (+) — No. 6 (−)
NOTE:
into the memory.
5 CHECK YAW RATE AND LATERAL G SEN- Is the indicated reading Go to step 6. Replace yaw rate
SOR. 2.5±0.2 V when the vehicle and lateral G sen-
1) Turn ignition switch to OFF. is in horizontal position? sor.
2) Connect select monitor connector to data
link connector.
4) Turn select monitor into {BRAKE CON-
TROL} mode.
5) Set the display in the {Current Data Display
& Save} mode.
6) Read the yaw rate and lateral G sensor
output voltage.
NOTE:
into the memory.
VDC-25
墌 00.5.31/68j/4vdc 墍
VDC

6 CHECK YAW RATE AND LATERAL G SEN- Is the indicated reading Go to step 7. Replace yaw rate
SOR. 3.5±0.2 V when yaw rate and lateral G sen-
1) Remove console box. and lateral G sensor is sor.
2) Remove yaw rate and lateral G sensor inclined left to 90°?
from vehicle. (Do not disconnect connector.)
NOTE:
into the memory.
7 CHECK YAW RATE AND LATERAL G SEN- Is the indicated reading Yaw rate and lat- Replace yaw rate
SOR. 1.5±0.2 V when yaw rate eral G sensor is and lateral G sen-
Read the select monitor display. and lateral G sensor is normal. sor.
NOTE: inclined right to 90°?
into the memory.
2. YAW RATE SENSOR SIGNAL S402634A1002

SOR USING OSCILLOSCOPE. V and 2.9 V? and lateral G sen-
1) Connect all connectors. sor is normal.
2) Set oscilloscope to TCM connector termi-
nals.
Positive probe; (R100) No. 4
Earth lead; (R100) No. 6
3) Start the engine.
4) Measure signal voltage indicated on oscil-
loscope. <Ref. to VDC-15 WAVE FORM,
MEASUREMENT, Control Module I/O Signal.>
2 CHECK YAW USING OSCILLOSCOPE. Is the voltage 5 V? Yaw rate and lat- Replace yaw rate
1) Turn ignition switch to OFF. eral G sensor is and lateral G sen-
2) Set oscilloscope to TCM connector termi- normal. sor.
nals.
Positive probe; (R100) No. 2
Earth lead; (R100) No. 6
4) Measure signal voltage indicated on oscil-
loscope. <Ref. to VDC-15 WAVE FORM,
MEASUREMENT, Control Module I/O Signal.>
VDC-26
墌 00.5.31/68j/4vdc 墍
STEERING ANGLE SENSOR
VDC
7. Steering Angle Sensor S402197

5) Remove two screws securing upper steering
column cover.
A: REMOVAL S402197A18 6) Release the lock of harness band and discon-
nect connector of steering angle sensor.
B4M1902B
G6M0095
(1) Harness connector
2) Remove airbag module. (2) Connector
<Ref. to AB-12 REMOVAL, Driver’s Airbag Mod-
ule.> 7) Remove bolts which hold roll connector and
steering angle sensor onto steering column.
WARNING:
Always refer to “Airbag System” before per-
forming airbag module service (if so equipped).
<Ref. to AB-3 CAUTION, General Description.>
3) Remove steering wheel nut, then draw out
steering wheel from shaft using steering puller.
NOTE:
Steering wheel must be removed at the straight
ahead position.
B4M1903
8) Remove roll connector and steering angle sen-

sor.
S4M0378A
(1) Steering puller
4) Remove the screw securing lower steering col-

umn cover. B4M1904
NOTE:
Do not turn steering angle sensor as it’s center
position has been recognized by VDCCM.
B4M1654
VDC-27
墌 00.5.31/68j/4vdc 墍
VDC
B: INSTALLATION S402197A11 CAUTION:

Insert roll connector guide pin into guide hole
CAUTION: on lower end of surface of steering wheel to
Ensure that front wheels are set in straight for- prevent damage. Draw out airbag system
ward direction. connector, horn connector and cruise control
1) Place steering angle sensor on steering connectors from guide hole of steering wheel
column, confirming that the sensor is positioned as lower end.
in the figure. 6) Install airbag module to steering wheel.
<Ref. to AB-13 INSTALLATION, Driver’s Airbag
Module.>
WARNING:
Always refer to “Airbag System” before per-
forming the service operation.
<Ref. to AB-3 CAUTION, General Description.>
7) Connect battery ground cable.
B4M1905
2) Conduct centering of roll connector.

<Ref. to AB-22 INSTALLATION, Roll Connector.>
3) Place roll connector over steering angle sensor
and tighten bolts which secure roll connector and
steering angle sensor.
G6M0095
CAUTION:
After completion of installation procedure, the
following two position settings must be made.
쐌 Yaw rate and lateral G sensor 0 positioning
These procedures are necessary for VDCCM to
later recognize what position the vehicle is in.
B4M1906 For procedures for the above two settings,
4) Tighten bolts which install roll connector and Module (VDCCM).>.
steering angle sensor onto steering column.
B4M1907
5) Set steering wheel to neutral and install it onto

steering shaft.
Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb)
Column cover-to-steering wheel clearance:
2 — 4 mm (0.08 — 0.16 in)
VDC-28
墌 00.5.31/68j/4vdc 墍
VDC
Refer to “VDC section” for inspection procedures

of steering angle sensor.
<Ref. to VDC-110 TROUBLE CODE 71 ABNOR-
MAL STEERING ANGLE SENSOR, Diagnostics
Chart with Diagnosis Connector.>
VDC-29
墌 00.5.31/68j/4vdc 墍
FRONT ABS SENSOR
VDC
8. Front ABS Sensor S402190
A: NOTE S402190A15
The ABS sensor installed on VDC equipped

vehicles is the same as the one on ABS equipped
vehicles; therefore, for removal, inspection and
installation please refer to “ABS” section.
<Ref. to ABS-14 Front ABS Sensor.>
VDC-30
REAR ABS SENSOR
VDC
9. Rear ABS Sensor S402185
A: NOTE S402185A15
The ABS sensor installed on VDC equipped

vehicles is the same as the one on ABS equipped
vehicles; therefore, for removal, inspection and
installation please refer to “ABS” section.
<Ref. to ABS-17 Rear ABS Sensor.>
VDC-31
FRONT TONE WHEEL
VDC
10. Front Tone Wheel S402184
A: NOTE S402184A15
As front tone wheel is integrated with front drive

shaft, refer to “DS section” for removal, installation,
and inspection procedures.
<Ref. to DS-28 Front Drive Shaft.>
VDC-32
REAR TONE WHEEL
VDC
11. Rear Tone Wheel S402182
A: NOTE S402182A15
As rear tone wheel is integrated with rear drive

shaft, refer to “DS section” for removal, installation,
and inspection procedures.
VDC-33
REAR TONE WHEEL
VDC
MEMO:
VDC-34
GENERAL DESCRIPTION
Differentials
BRIGHTON
L
MODEL
MT AT
T-type VA-type
Rear differential type T1 XK
Gear Hypoid gear
Gear ratio (Number of gear teeth) 3.900 (39/10) 4.111 (37/9)
Oil capacity 0.8 (0.8 US qt, 0.7 Imp qt)
Rear differential gear oil GL-5
GT OUTBACK-CW OUTBACK
OUTBACK
GT-LTD OUTBACK-LTD SEDAN
MODEL
MT AT MT MT AT
T-type
BK CD BK CD
Rear differential type
(with LSD) (with LSD) (with LSD) (with LSD)
Gear Hypoid gear
Gear ratio (Number of gear teeth) 4.111 (37/9) 4.444 (40/9) 4.111 (37/9) 4.111 (37/9) 4.444 (40/9)
Oil capacity 0.8 (0.8 US qt, 0.7 Imp qt)
Rear differential gear oil GL-5
쐌 Identification
When replacing a rear differential assembly, select
the correct one according to the following table.
CAUTION:
Using the different rear differential assembly
causes the drive line and tires to “drag” or emit
abnormal noise when AWD is selected.
H3M1662B
(A) Lavel location

(B) Stamp location
DI-2
墌 00.5.31/68j/3di 墍
GENERAL DESCRIPTION
Differentials
쐌 Rear differential gear oil

Recommended oil
CAUTION:
Each oil manufacturer has its base oil and addi-
tives. Thus, do not mix two or more brands.
H3M1272A
1. SERVICE DATA S303001E4901
T-type 19.6 — 28.4 (2.0 — 2.9, 4.4 — 6.4)

Front and rear bearing preload at companion New bearing
VA-type 12.7 — 32.4 (1.3 — 3.3, 2.9 — 7.3)
flange bolt hole N (kgf, lb)
Used bearing T-type 8.34 — 16.67 (0.85 — 1.7, 1.87 — 3.75)
T-type 0.10 — 0.20 (0.0039 — 0.0079)
Side gear backlash mm (in)
VA-type 0.05 — 0.15 (0.0020 — 0.0059)
Side bearing standard width mm (in) 20.00 (0.7874)
T-type 0.10 — 0.20 (0.0039 — 0.0079)
Crown gear to drive pinion backlash mm (in)
VA-type 0.10 — 0.15 (0.0039 — 0.0059)
Crown gear runout on its back surface mm (in) Less than 0.05 (0.0020)
DI-3
墌 00.5.31/68j/3di 墍
GENERAL DESCRIPTION
Differentials
2. ADJUSTING PARTS S303001E4902
쐌 VA-type
Item Part No. Length or thickness
32288AA040 52.3 mm (2.059 in)
32288AA050 52.5 mm (2.067 in)
31454AA100 52.6 mm (2.071 in)
32288AA060 52.7 mm (2.075 in)
Preload adjusting spacer 31454AA110 52.8 mm (2.079 in)
32288AA070 52.9 mm (2.083 in)
31454AA120 53.0 mm (2.087 in)
32288AA080 53.1 mm (2.091 in)
32288AA090 53.3 mm (2.098 in)
38336AA000 1.500 mm (0.0591 in)
38336AA120 1.513 mm (0.0596 in)
38336AA010 1.525 mm (0.0600 in)
38336AA130 1.538 mm (0.0606 in)
38336AA020 1.550 mm (0.0610 in)
38336AA140 1.563 mm (0.0615 in)
38336AA030 1.575 mm (0.0620 in)
38336AA150 1.588 mm (0.0625 in)
38336AA040 1.600 mm (0.0630 in)
38336AA160 1.613 mm (0.0635 in)
38336AA050 1.625 mm (0.0640 in)
Preload adjusting washer 38336AA170 1.638 mm (0.0645 in)
38336AA060 1.650 mm (0.0650 in)
38336AA180 1.663 mm (0.0655 in)
38336AA070 1.675 mm (0.0659 in)
38336AA190 1.688 mm (0.0665 in)
38336AA080 1.700 mm (0.0669 in)
38336AA200 1.713 mm (0.0674 in)
38336AA090 1.725 mm (0.0679 in)
38336AA210 1.738 mm (0.0684 in)
38336AA100 1.750 mm (0.0689 in)
38336AA220 1.763 mm (0.0694 in)
38336AA110 1.775 mm (0.0699 in)
32295AA200 0.150 mm (0.0059 in)
32295AA210 0.175 mm (0.0069 in)
32295AA220 0.200 mm (0.0079 in)
Pinion height adjusting shim
32295AA230 0.225 mm (0.0089 in)
32295AA240 0.250 mm (0.0098 in)
32295AA250 0.275 mm (0.0108 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
Side gear thrust washer 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)
DI-4
墌 00.5.31/68j/3di 墍
GENERAL DESCRIPTION
Differentials
쐌 T-type

383695201 56.2 mm (2.213 in)
383695202 56.4 mm (2.220 in)
383695203 56.6 mm (2.228 in)
Preload adjusting spacer
383695204 56.8 mm (2.236 in)
383695205 57.0 mm (2.244 in)
383695206 57.2 mm (2.252 in)
383705200 2.59 mm (0.1020 in)
383715200 2.57 mm (0.1012 in)
383725200 2.55 mm (0.1004 in)
383735200 2.53 mm (0.0996 in)
383745200 2.51 mm (0.0988 in)
383755200 2.49 mm (0.0980 in)
383765200 2.47 mm (0.0972 in)
Preload adjusting washer 383775200 2.45 mm (0.0965 in)
383785200 2.43 mm (0.0957 in)
383795200 2.41 mm (0.0949 in)
383805200 2.39 mm (0.0941 in)
383815200 2.37 mm (0.0933 in)
383825200 2.35 mm (0.0925 in)
383835200 2.33 mm (0.0917 in)
383845200 2.31 mm (0.0909 in)
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)
383445201 0.75 — 0.80 mm (0.0295 — 0.0315 in)
383445202 0.80 — 0.85 mm (0.0315 — 0.0335 in)
Side gear thrust washer
383445203 0.85 — 0.90 mm (0.0335 — 0.0354 in)
(Non-Turbo model)
383445204 0.90 — 0.95 mm (0.0354 — 0.0374 in)
383445205 0.95 — 1.0 mm (0.0374 — 0.0394 in)
DI-5
墌 00.5.31/68j/3di 墍
GENERAL DESCRIPTION
Differentials

383475201 0.20 mm (0.0079 in)
383475202 0.25 mm (0.0098 in)
Side bearing retainer shim 383475203 0.30 mm (0.0118 in)
383475204 0.40 mm (0.0157 in)
383475205 0.50 mm (0.0197 in)
DI-6
墌 00.5.31/68j/3di 墍
GENERAL DESCRIPTION
Differentials
1. REAR DIFFERENTIAL FOR T-TYPE WITHOUT LSD S303001A0501
B3M0130C
(1) Pinion crown gear set (13) Side bearing (26) Stud bolt
(2) Pinion height adjusting washer (14) O-ring (27) Oil filler plug
(3) Rear bearing (15) Side bearing retainer shim (28) Oil drain plug
(4) Bearing preload adjusting spacer (16) Side bearing retainer (29) Rear cover
(5) Bearing preload adjusting (17) Side oil seal (30) Differential case
washer (18) Side gear thrust washer
(6) Differential carrier (19) Side gear Tightening torque: N·m (kgf-m, ft-lb)
(7) Front bearing (20) Pinion mate gear T1: 10.3 (1.05, 7.6)
(8) Spacer (21) Pinion mate gear washer T2: 29.4 (3.00, 21.7)
(9) Pilot bearing (22) Pinion shaft lock pin T3: 49.0 (5.0, 36.2)
(10) Front oil seal (23) Circlip T4: 103.0 (10.50, 75.9)
(11) Companion flange (24) Pinion mate shaft T5: 181.4 (18.50, 133.8)
(12) Self-locking nut (25) Air breather cap
DI-7
墌 00.5.31/68j/3di 墍
GENERAL DESCRIPTION
Differentials
2. REAR DIFFERENTIAL FOR T-TYPE

WITH LSD S303001A0502
B3M1662A
(1) Pinion crown gear set (11) Companion flange (22) Stud bolt
(2) Pinion height adjusting shim (12) Self-locking nut (23) Oil filler plug
(3) Rear bearing (13) Side bearing (24) Oil drain plug
(4) Bearing preload adjusting spacer (14) O-ring
(5) Bearing preload adjusting (15) Side bearing retainer shim Tightening torque: N·m (kgf-m, ft-lb)
washer (16) Side bearing retainer T1: 10.3 (1.05, 7.6)
(6) Differential carrier (17) Side oil seal T2: 29.4 (3.00, 21.7)
(7) Front bearing (18) Gasket T3: 49.0 (5.00, 36.2)
(8) Collar (19) Differential case T4: 103.0 (10.50, 75.9)
(9) Pilot bearing (20) Rear cover T5: 181.4 (18.50, 133.8)
(10) Front oil seal (21) Air breather cap
DI-8
墌 00.5.31/68j/3di 墍
GENERAL DESCRIPTION
Differentials
3. REAR DIFFERENTIAL FOR VA-TYPE

S303001A0503
H3M1663A
(1) Pinion crown gear set (13) Lock plate (26) Gasket
(2) Pinion height adjusting shim (14) Side bearing (27) Oil filler plug
(3) Rear bearing (15) O-ring (28) Oil drain plug
(4) Bearing preload adjusting spacer (16) Axle shaft holder (29) Rear cover
(5) Bearing preload adjusting (17) Side oil seal
washer (18) Side gear thrust washer Tightening torque: N·m (kgf-m, ft-lb)
(6) Differential carrier (19) Side gear T1: 25 (2.5, 18.1)
(7) Front bearing (20) Pinion mate gear T2: 25 (2.5, 18.1)
(8) Collar (21) Pinion shaft lock pin T3: 34 (3.5, 25.3)
(9) Pilot bearing (22) Differential case T4: 62 (6.3, 45.6)
(10) Front oil seal (23) Pinion mate shaft T5: 188 (19.2, 139)
(11) Companion flange (24) Air breather cap
(12) Self-locking nut (25) Stud bolt
DI-9
墌 00.5.31/68j/3di 墍
GENERAL DESCRIPTION
Differentials
4. REAR DIFFERENTIAL MOUNTING

SYSTEM S303001A0504
B3M1740A
(1) Rear differential front member (6) Rear differential protector (if Tightening torque: N·m (kgf-m, ft-lb)
(2) Protector equipped)
T1: 65 (6.6, 48)
(3) Rear differential member plate
T2: 70 (7.1, 51)
(4) Rear differential ASSY
T3: 110 (11.2, 81)
(5) Sub flame
DI-10
墌 00.5.31/68j/3di 墍
GENERAL DESCRIPTION
Differentials

tion.
ment.
쐌 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.
fied points.
쐌 Apply gear oil onto sliding or revolution surfaces
sufficient amount of gear oil to avoid damage and
deformation.
쐌 Avoid damaging the mating face of the case.
DI-11
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GENERAL DESCRIPTION
Differentials

398477701 HANDLE Used for installing front and rear bearing cone.
B3M1893
398477702 DRIFT Used press-fitting the bearing cone of differen-
tial carrier (rear).
B3M1894
398217700 ATTACHEMENT Stand for rear differential carrier disassembly
SET and assembly.
B3M1895
498447120 DRIFT Used for installing front oil seal.
B3M1896
DI-12
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GENERAL DESCRIPTION
Differentials

498427200 FLANGE WRENCH Used for stopping rotaiotn of companion flange
when loosening and tightening self-lock nut.
B3M1897
398467700 DRIFT Used for removing pinion, pilot bearing and
front bearing cone.
B3M1898
399780104 WEIGHT Used for installing front bearing cone, pilot
bearing companion flange.
B3M1899
899580100 INSTALLER Used for press-fitting the front bearing cone,
pilot bearing.
B3M1900
899904100 STRAIGHT PIN Used for driving out differential pinion shaft lock
REMOVER pin.
B3M1901
DI-13
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GENERAL DESCRIPTION
Differentials

498247001 MAGENT BASE 쐌 Used for measuring backlash between side
gear and pinion, and hypoid gear..
쐌 Used with DIAL GAUGE (498247100).
B3M1902
498247100 DAIL GAUGE 쐌 Used measurng backlash between side gear
and pinion, hypoid gear.
쐌 Used with MAGNET BASE (498247001).
B3M1903
398507704 BLOCK Used for adjusting pinion height and preload.
B3M1904
398177700 INSTALLER 쐌 Used for installing rear bearing cone.
쐌 For T-type.
B3M1905
DI-14
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GENERAL DESCRIPTION
Differentials

398457700 ATTACHMENT 쐌 Used for removing side bearing retainer.
쐌 For T-type.
B3M1906
398477703 DRIFT2 쐌 Used forpress-fitting the bearing race (rear)
of differential carrier.
쐌 For T-type.
B3M1907
398437700 DRIFT 쐌 Used for installing said oil seal.
쐌 For T-type.
B3M1908
398507702 DUMMY SHAFT 쐌 Used for adjusting pinion height and preload.
쐌 For T-type.
B3M1909
DI-15
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GENERAL DESCRIPTION
Differentials

398507703 DUMMY COLLAR 쐌 Used for adjusting pinion height and preload.
쐌 For T-type.
B3M1910
398517700 REPLACER 쐌 Used for removing rear bearing cone.
쐌 For T-type.
B3M1911
398487700 DRIFT 쐌 Used for press-fitting the side bearing cone.
쐌 For T-type.
B3M1912
398507701 GAUGE 쐌 Used for adjusting pinion height.
쐌 For T-type.
B3M1913
398527700 PULLEY ASSY 쐌 Used for removing oil seal and side bearing
cup.
쐌 For T-type.
B3M1914
DI-16
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GENERAL DESCRIPTION
Differentials

398527700 PULLER SET 쐌 Used for extracking side bearing cone.
(1) BOLT (899521412)
(2) PULLER (399527702)
(3) HOLDER (399527703)
(4) ADAPTER (398497701)
(5) BOLT (899520107)
(6) NUT (021008000)
쐌 For T-type.
B3M1915A
398227700 WEIGHT 쐌 Used for installing side bearing.
쐌 For T-type.
B3M1916
28099PA090 OIL SEAL PROTEC- 쐌 Used for installing rear drive shaft into rear
TOR differential.
쐌 For protecting oil seal.
쐌 For T-type.
B3M1917
398237700 GAUGE 쐌 Used for installing side bearing.
쐌 For T-type.
B3M1918
28099PA100 DRIVE SHAFT 쐌 Used for removing rear drive shaft from rear
REMOVER differential.
쐌 For T-type.
B3M1919
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GENERAL DESCRIPTION
Differentials

498175500 INSTALLER 쐌 Used for installing rear bearing cone.
쐌 For VA-type.
B3M1920
499785500 WRENCH ASSY 쐌 Used for removing and installing side oil seal
holder.
쐌 For VA-type.
B3M1921
498447100 DRIFT 쐌 Used for installing oil seal.
쐌 For VA-type.
B3M1922
399520105 SEAT 쐌 Used for removing side bearing cone.
쐌 Used with PULLER SET (899524100).
쐌 For VA-type.
B3M1923
DI-18
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GENERAL DESCRIPTION
Differentials

498485400 DRIFT 쐌 UUsed for installing side bearing cone.
쐌 For VA-type.
B3M1924
498505501 GAUGE 쐌 Used for adjusting pinion height.
쐌 For VA-type.
B3M1925
498447110 BEARING OUTER 쐌 Used for press-fitting the bearing race (front)
RACE DRIFT of differential carrier.
쐌 For VA-type.
B3M1926
498447150 DUMMY SHAFT 쐌 Used for adjusting pinion height and Pre-
load.
쐌 For VA-type.
B3M1927
DI-19
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GENERAL DESCRIPTION
Differentials

32285AA000 DUMMY COLLAR 쐌 Used for adjusting pinion height and Pre-
load.
쐌 For VA-type.
B3M1928
499705404 SEAT 쐌 Used for removing side bearing race.
쐌 Used with PULLEY ASSY (499705401).
쐌 For VA-type.
B3M1929
499705401 PULLEY ASSY 쐌 Used for removing side bearing race.
쐌 Used with SEAT (499705404).
쐌 For VA-type.
B3M1930
899874100 INSTALLER 쐌 Used for installing companion flange.
쐌 For VA-type.
B3M1931
899524100 DIFFERENTIAL 쐌 Used for removing side bearing cone of dif-
BEARING PULLER ferential.
SET 쐌 For VA-type.
(1) Puller
(2) Cap
B3M1932A
DI-20
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GENERAL DESCRIPTION
Differentials
TOOL NAME REMERKS

Transmission jack Used for assembly/disassembly of rear differential.
Puller Used for removal of side bearing retainer. (T-type)
Thickness gauge Used for measuring clearance.
Tire lever Used for removal of rear drive shaft. (VA-type)
DI-21
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DIFFERENTIAL GEAR OIL
Differentials
2. Differential Gear Oil S303150

6) Install filler plug.
CAUTION:
Apply fluid packing to oil drain plug.
1) Disconnect ground terminal from battery. Fluid packing:
2) Jack-up vehicle and support it with sturdy THREE BOND 1105 or equivalent
racks.
Tightening torque:
3) Remove the oil drain plug and filler plug, and
T-type;
drain the gear oil.
49.0 N·m (5.0 kgf-m, 36.2 ft-lb)
CAUTION: VA-type;
Be careful not to burn your hands, because 33 N·m (3.4 kgf-m, 24.6 ft-lb)
gear oil becomes extremely hot after running.
B3M1627A
(A) Filler plug

(B) Drain plug
4) Tighten oil drain plug.

CAUTION:
Apply fluid packing to oil drain plug.
Fluid packing:
THREE BOND 1105 or equivalent
Tightening torque:
49.0 N·m (5.0 kgf-m, 36.2 ft-lb)
5) Fill differential carrier with gear oil to the upper
plug level.
CAUTION:
Carefully refill oil while watching the level.
Excess or insufficient oil must be avoided.
Oil capacity:
0.8 (0.8 US qt, 0.7 Imp qt)
B3M1627A
DI-22
FRONT DIFFERENTIAL
Differentials
3. Front Differential S303152
A: NOTE S303152A15
1. AT MODEL S303152A1501
Refer to AUTOMATIC TRANSMISSION in sepa-

rate publication “AUTOMATIC TRANSMISSION for
Front Differential.
2. MT MODEL S303152A1502
For front differential of manual transmission, refer

to “MT” section.
DI-23
REAR DIFFERENTIAL FOR T-TYPE
Differentials
4. Rear Differential for T-type 12) Loosen self-locking nuts connecting rear dif-
S303145
ferential to rear crossmember.
1) Disconnect ground terminal from battery.

2) Move select lever or gear shift lever to “N”.
3) Loosen wheel nuts.
4) Release the parking brake.
5) Jack-up vehicle and support it with sturdy
racks.
6) Remove wheels.
7) Remove rear exhaust pipe and muffler.
B3M1613
8) Remove heat shield cover.
13) Remove DOJ of rear drive shaft from rear dif-
ferential using ST.
ST 28099PA100 DRIVE SHAFT REMOVER
B3M1605
9) Remove propeller shaft.

<Ref. to DS-13 REMOVAL, Propeller Shaft.>
B3M1628B
CAUTION:
When removing propeller shaft, pay attention (A) Bolt
not to damage the sliding surfaces of rear drive
14) Remove protector nut.
shaft (extension) spline, oil seal and sleeve
yoke.
NOTE:
쐌 Prepare an oil can and cap since the transmis-
sion oil flows out from the extension at removing
propeller shaft.
쐌 Insert the cap into the extension to prevent
transmission oil from flowing out immediately after
removing the propeller shaft.
10) Remove rear differential protector. (if
B3M1642
equipped)
11) Prepare a transmission jack and a band. 15) Remove differential member.
B3M1610
B3M1611
DI-24
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Differentials
16) Support rear differential with transmission 22) Pull out axle shaft from rear differential.
jack. NOTE:
If axle shaft is difficult to remove from rear
differential, use ST to remove it.
ST 28099PA100 DRIVE SHAFT REMOVER
B3M1629
17) Remove differential member.

18) Fix rear differential at band.
CAUTION: B3M1616
Be sure to secure the rear differential on the 23) Take down transmission jack.
transmission jack. 24) Secure rear drive shaft to lateral link use wire.
19) Remove self-locking nuts connecting rear dif-
ferential to crossmember.
20) Remove rear differential stud bolt from rear
crossmember bushing.
NOTE:
Carefully adjust angle and position of transmission
jack and jack stand as required during stud bolt
removal.
B3M1617
25) Remove protector and plate from rear differ-

ential.
B3M1614
21) After removing rear differential stud bolt from

rear crossmember, lower transmission jack stand.
Do not allow rear drive shaft to strike lateral link
bolt.
B3M1618A
(A) Protector
(B) Riar differential member plate
B3M1615
DI-25
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Differentials
B: INSTALLATION S303145A11 5) Remove ST from rear differential.

ST 28099PA090 OIL SEAL PROTECTOR
1) Install protector and plate to rear differential. 6) Completely insert axle shaft into rear differential
by pressing rear differential.
B3M1618A
(A) Protector B3M1623
(B) Rear differental member plate

7) Adjust transmission jack as required so rear dif-
2) Set rear differential to transmission jack. ferential stud bolt is properly inserted into rear
NOTE:
Secure rear differential to transmission jack using
a band.
3) Install ST to rear differential.
B3M1624
8) After rear differential stud bolt has been

inserted into rear crossmember bushing, raise
transmission jack to make jack rear differential
B3M1635A
level.
4) Insert the spline shaft until the spline portion is

inside the side oil seal.
B3M1625
B3M1636
DI-26
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Differentials
9) Temporarily tighten rear crossmember self- 13) Tighten protector nut.

locking nuts. Tightening torque:
64 N·m (6.5 kgf-m, 47.0 ft-lb)
B3M1613
B3M1642
10) Remove band from rear differential. Raise rear
differential just enough to move transmission jack 14) Take down transmission jack.
away from it. 15) Install propeller shaft.
11) Install differential member. <Ref. to DS-14 INSTALLATION, Propeller Shaft.>
Tightening torque: 16) Install heat shield cover.
17) Install rear exhaust pipe and muffler.
T1: 65 N·m (6.6 kgf-m, 48 ft-lb)
18) After installing rear differential carrier on
T2: 110 N·m (11.2 kgf-m, 81 ft-lb)
vehicle, remove filler plug and replenish gear oil up
to upper level mark.
Oil capacity:
0.8 (0.8 US qt, 0.7 Imp qt)
B3M1639C
12) Tighten self-locking nut.

Tightening torque:
S3M0536A
70 N·m (7.1 kgf-m, 51 ft-lb)
(A) Filler plug
(B) Drain plug
19) Tighten filler plug.

CAUTION:
Apply fluid packing to plug.
Fluid packing:
Tightening torque:
B3M1613
49.0 N·m (5.0 kgf-m, 36.2 ft-lb)
20) Install rear differential protector. (if equipped)
To detect real cause of trouble, inspect the follow-

ing items before disassembling.
DI-27
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Differentials
쐌 Tooth contact of crown gear and pinion, and 5) Make right and left side bearing retainers in
backlash order to identify them at reassembly. Remove side
쐌 Runout of crown gear at its back surface bearing retainer attaching bolts, set ST to differen-
쐌 Turning resistance of drive pinion tial case, and extract right and left side bearing
1) Set ST on vise and install the differential retainers with a puller.
assembly to ST. CAUTION:
ST 398217700 ATTACHMENT Each shim, which is installed to adjust the side
bearing preload, should be kept together with
its mating retainer.
ST 398457700 ATTACHMENT
G3M1031
2) Drain gear oil by removing plug.

3) Remove the air breather cap.
NOTE: S3M0532A
Do not attempt to replace the air breather cap 6) Pull out differential case assembly from differ-
unless necessary. ential carrier.
CAUTION:
Be careful not to hit the teeth against the case.
S3M0530A
(A) Air breather cap

(B) Rear cover S3M0533
4) Remove rear cover by loosening retaining 7) When replacing side bearing, pull bearing cup
bolts. from side bearing retainer using ST.
S3M0531A
S3M0534A
(A) Rear cover
(B) Differential carrier
DI-28
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Differentials
8) Extract bearing cone with ST. 10) Drive out pinion shaft lock pin from crown gear
CAUTION: side. (Without LSD)
Do not attempt to disassemble the parts unless NOTE:
necessary. The lock pin is staked at the pin hole end on the
NOTE: differential carrier; do not drive it out forcibly before
쐌 Set puller so that its claws catch the edge of the unstaking it.
bearing cone. ST 899904100 STRAIGHT PIN REMOVER
쐌 Never mix up the right and left hand bearing
races and cones.
ST 399527700 PULLER SET
B3M0133
11) Draw out pinion mate shaft and remove pinion

G3M0068
mate gears, side gears and thrust washers. (With-
out LSD)
9) Remove crown gear by loosening crown gear NOTE:
bolts. The gears as well as thrust washers should be
CAUTION: marked or kept separated left and right, and front
Further disassembling is not allowed. and rear.
S3M0509 S3M0510A
(A) Side gear

(B) Pinion mate gear
(C) Thrust washer
(D) Differential case
(E) Pinion mate shaft
DI-29
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Differentials
12) Hold companion flange with ST and remove 15) Remove rear bearing cone from drive pinion
drive pinion nut. by supporting cone with ST.
ST 498427200 FLANGE WRENCH 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 front oil seal from differential carrier

using ST.
S3M0511
14) Press the end of drive pinion shaft and extract

it together with rear bearing cone, preload adjust-
ing spacer and washer.
NOTE:
Hold the drive pinion so as not to drop it. S3M0513
ST 398467700 DRIFT 17) Remove pilot bearing together with front bear-
ing cone using ST.
ST 398467700 DRIFT
G3M0074
S3M0514A
(A) Pinion bearing

(B) Front bearing
(C) Rear bearing cup
DI-30
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Differentials
18) When replacing bearings, tap front bearing 2) Adjusting preload for front and rear bearings
cup and rear bearing cup in this order out of case Adjust the bearing preload with spacer and washer
by using a brass bar. between front and rear bearings. Pinion height
adjusting washer are not affected by this adjust-
ment. The adjustment must be carried out without
oil seal inserted.
(1) Press rear bearing race into differential car-
rier with ST1 and ST2.
ST1 398477701 HANDLE
ST2 398477703 DRIFT 2
S3M0515A
(A) 2 cutouts along diagonal lines

(B) Tap alternately with brass bar.
1) Precautions for assembling

쐌 Assemble in the reverse order of disassembling.
G3M1037
쐌 Check and adjust each part during assembly.
쐌 Keep the shims and washers in order, so that (2) Insert ST1 into carrier with pinion height
they are not misinstalled. adjusting washer and rear bearing cone fitted
쐌 Thoroughly clean the surfaces on which the onto it.
shims, washers and bearings are to be installed.
쐌 Apply gear oil when installing the bearings and CAUTION:
thrust washers. 쐌 Re-use the used washer if not deformed.
쐌 Be careful not to mix up the right and left hand 쐌 Use a new rear bearing cone.
races of the bearings. (3) Then install preload adjusting spacer and
쐌 Replace the oil seal with new one at every dis- washer, front bearing cone, ST2, companion
assembly. Apply chassis grease between the lips flange, and washer and drive pinion nut.
when installing the oil seal.
ST1 398507702 DUMMY SHAFT
ST2 398507703 DUMMY COLLAR
G3M0079
S3M0516A
(A) Pinion height adjusting shim

(B) Preload adjusting spacer
(C) Preload adjusting washer
DI-31
墌 00.5.31/68j/3di 墍
Differentials
(4) Turn ST1 with hand to make it seated, and Part No. Thickness mm (in)
tighten drive pinion nut while measuring the pre- 383705200 2.59 (0.1020)
load with spring balance. Select preload adjust- 383715200 2.57 (0.1012)
ing washer and spacer so that the specified pre-
383725200 2.55 (0.1004)
load is obtained when nut is tightened to the
383735200 2.53 (0.0996)
specified torque.
383745200 2.51 (0.0988)
CAUTION: 383755200 2.49 (0.0980)
Use a new lock nut. Preload adjusting 383765200 2.47 (0.0972)
NOTE: washer 383775200 2.45 (0.0965)
쐌 Be careful not to give excessive preload. 383785200 2.43 (0.0957)
쐌 When tightening the drive pinion nut, lock ST1 383795200 2.41 (0.0949)
with ST2 as shown in the figure. 383805200 2.39 (0.0941)
383815200 2.37 (0.0933)
ST1 398507704 BLOCK
ST2 398507702 DUMMY SHAFT 383825200 2.35 (0.0925)
383835200 2.33 (0.0917)
Tightening torque: 383845200 2.31 (0.0909)
181 N·m (18.5 kgf-m, 134 ft-lb) Part No. Length mm (in)
383695201 56.2 (2.213)
383695202 56.4 (2.220)
Preload adjusting
383695203 56.6 (2.228)
spacer
383695204 56.8 (2.236)
383695205 57.0 (2.244)
383695206 57.2 (2.252)
3) Adjusting drive pinion height

Adjust drive pinion height with shim installed
between rear bearing cone and the back of pinion
G3M1038 gear.
(1) Install ST1, ST2 and ST3, as shown in the
Front and rear bearing preload figure, and apply the specified preload on the
For new bearing: bearings.
19.6 — 28.4 N (2.0 — 2.9 kg, 4.4 — 6.4 lb)
at companion flange bolt hole Front and rear bearing preload
For used bearing: For new bearing:
8.34 — 16.67 N (0.85 — 1.7 kg, 1.87 — 3.75 lb) 19.6 — 28.4 N (2.0 — 2.9 kg, 4.4 — 6.4 lb)
at companion flange bolt hole at companion flange bolt hole
For used bearing:
8.34 — 16.67 N (0.85 — 1.7 kg, 1.87 — 3.75 lb)
at companion flange bolt hole
Adjusting preload for front and rear bearings

NOTE:
At this time, install a pinion height adjusting shim
which is temporarily selected or the same as that
used before. Measure and record the thickness.
ST2 398507701 DIFFERENTIAL CARRIER
S3M0518A
GAUGE
ST3 398507703 DUMMY COLLAR
DI-32
墌 00.5.31/68j/3di 墍
Differentials
(Example of calculation)
To = 2.20 + 1.20 = 3.40 mm
N = 0.23 mm H = + 1,
T = 3.40 + 0.23 − 0.01 − 0.20 = 3.42
Result: Thickness = 3.42 mm
Therefore use the shim 383605200.
383495200 3.09 (0.1217)
S3M0518B 383505200 3.12 (0.1228)
(A) Pinion height adjusting shim 383515200 3.15 (0.1240)
383525200 3.18 (0.1252)
(2) Measure the clearance N between the end 383535200 3.21 (0.1264)
of ST2 and the end surface of ST1 by using a 383545200 3.24 (0.1276)
thickness gauge. 383555200 3.27 (0.1287)
NOTE: 383565200 3.30 (0.1299)
Make sure there is no clearance between the case 383575200 3.33 (0.1311)
and ST2. 383585200 3.36 (0.1323)
383595200 3.39 (0.1335)
383605200 3.42 (0.1346)
383615200 3.45 (0.1358)
GAUGE
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)
4) Install the selected pinion height adjusting shim

on drive pinion, and press the rear bearing cone
into position with ST.
H3M1309B
(3) Obtain the thickness of pinion height adjust-
ing 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 Thickness of shim temporarily
inserted mm (in) S3M0519A
To Thickness of pinion height adjusting

shim mm (in)
N Reading of thickness gauge mm (in)
H Figure marked on drive pinion head
Memo:
DI-33
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Differentials
5) Insert drive pinion into differential carrier, install 8) Fit a new oil seal with ST.
the previously selected bearing preload adjusting NOTE:
spacer and washer. 쐌 Press-fit until end of oil seal is 1 mm (0.04 in)
inward from end of carrier.
쐌 Apply grease between the oil seal lips.
ST 498447120 OIL SEAL INSTALLER
B3M0560B
(A) Drive pinion

(B) Bearing adjusting spacer
(C) Washer G3M0087
(D) Differential carrier
9) Press-fit companion flange with ST1 and ST2.
6) Press-fit front bearing cone into case with ST1,
ST2 and ST3. CAUTION:
ST1 398507703 DUMMY COLLAR Be careful not to damage bearing.
ST2 399780104 WEIGHT ST1 899874100 INSTALLER
ST3 899580100 INSTALLER ST2 399780104 WEIGHT
G3M0085 S3M0521A
7) Insert spacer, then press-fit pilot bearing with 10) Install self-locking nut. Then tighten it with ST.
ST1 and ST2. ST 498427200 FLANGE WRENCH
ST1 399780104 WEIGHT
Tightening torque:
181 N·m (18.5 kgf-m, 134 ft-lb)
S3M0520A
G3M1052
DI-34
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Differentials
11) Assembling differential case (2) Adjust the backlash as specified by select-
Install side gears and pinion mate gears, with their ing side gear thrust washer.
thrust washers and pinion mate shaft, into differen-
tial case. (Without LSD) Side gear thrust washer
CAUTION: 383445201 0.75 — 0.80 (0.0295 — 0.0315)
쐌 Apply gear oil on both sides of the washer 383445202 0.80 — 0.85 (0.0315 — 0.0335)
and on the side gear shaft before installing.
383445203 0.85 — 0.90 (0.0335 — 0.0354)
쐌 Insert the pinion mate shaft into the differen-
383445204 0.90 — 0.95 (0.0354 — 0.0374)
tial case by aligning the lock pin holes.
383445205 0.95 — 1.00 (0.0374 — 0.0394)
(3) Check the condition of rotation after apply-

ing oil to the gear tooth surfaces and thrust sur-
faces.
(4) After inserting pinion shaft lock pin into dif-
ferential case, stake the both sides of the hole
to prevent pin from falling off.
12) Install crown gear on differential case.
CAUTION:
Before installing bolts, apply Lock Tite to bolt
threads.
Lock Tite:
NOTE:
Tighten diagonally while tapping the bolt heads.
Tightening torque:
103 N·m (10.5 kgf-m, 76 ft-lb)
G3M0089
(1) Measure the side gear backlash.

Side gear back clearance:
0.10 — 0.20 mm (0.0039 — 0.0079 in)
S3M0509
13) Press side bearing cone onto differential case

with ST.
ST 398487700 DRIFT
B3M1933
G3M0091
DI-35
墌 00.5.31/68j/3di 墍
Differentials
14) Adjusting side bearing retainer shims (5) Tighten side bearing retainer bolts.
(1) The driven gear backlash and side bearing CAUTION:
preload can be determined by the side bearing Before tightening the two side bearing retainer
retainer shim thickness. bolts, apply Lock Tite to bolt threads.
(2) Install the differential case assembly into
differential carrier in the reverse order of disas- Lock Tite:
sembly. THREE BOND 1105 or equivalent
Tightening torque:
10.3 N·m (1.05 kgf-m, 7.6 ft-lb)
S3M0533
(3) Install side retainer shims and O-rings to the

S3M0173
left and right retainers from which they were
removed. (6) Measure the crown gear-to-drive pinion
NOTE: backlash. Set magnet base on differential car-
쐌 Replace broken or cracked O-ring with new one. rier. Align contact point of dial gauge with tooth
쐌 Replace broken or corroded side retainer shim face of crown gear, and move crown gear while
with new one of same thickness. holding drive pinion still. Read value indicated
on dial gauge.
Side bearing retainer shim
Backlash:
0.10 — 0.20 mm (0.0039 — 0.0079 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)
(4) Align arrow marked on differential carrier

with that marked on side retainer during instal-
lation.
CAUTION:
Be careful that side bearing outer race is not G3M1047
damaged by bearing roller.
(7) At the same time, measure the turning
resistance of drive pinion. Compared with the
resistance when differential case is not
installed, if the increase of the resistance is not
within the specified range, readjust side bearing
retainer shims.
Turning resistance increase:
2.9 — 10.8 N (0.3 — 1.1 kgf, 0.7 — 2.4 lb)
S3M0172B
(A) Arrow mark
DI-36
墌 00.5.31/68j/3di 墍
Differentials
15) Re-check crown gear-to-pinion backlash. 18) If proper tooth contact is not obtained, once
Backlash: again adjust the drive pinion height changing RH
0.10 — 0.20 mm (0.0039 — 0.0079 in) and LH side bearing retainer shims and the hypoid
gear backlash.
(1) Drive pinion height
GAUGE
G3M1047
16) Check the crown gear runout on its back

surface, and make sure pinion and crown gear
rotate smoothly.
Limit of runout: H3M1309B
Less than 0.05 mm (0.0020 in)
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:
S3M0525 0.10 — 0.20 mm (0.0039 — 0.0079 in)
17) Checking and adjusting tooth contact of crown
gear
(1) Apply an even coat of red lead on both
sides of three or four teeth on the crown gear.
Check the contact pattern after rotating crown
gear several revolutions back and forth until a
definite contact pattern appears on the crown
gear.
(2) When the contact pattern is incorrect, read-
just according to the instructions given in
“TOOTH CONTACT PATTERN”. G3M1047
NOTE:
Be sure to wipe off red lead completely after
adjustment is completed.
DI-37
墌 00.5.31/68j/3di 墍
Differentials
TOOTH CONTACT PATTERN

Condition Contact pattern Adjustment
Correct tooth contact
Tooth contact pattern slightly shifted
towards toe under no load rotation.
(When loaded, contact pattern moves
—
toward heel.)
G3M0098A
Backlash is too large. tooth ends. adjusting shim in order to bring drive pin-
ion closer to crown gear center.
G3M0098B
G3M0098F
Flank contact This may cause noise and stepped wear Reduce thickness of drive pinion height
Backlash is too small. on surfaces. adjusting shim in order to move drive
G3M0098C
G3M0098G
Toe contact This may cause chipping at toe ends. Adjust as for flank contact.
G3M0098D G3M0098G
Heel contact This may cause chipping at heel ends. Adjust as for face contact.
G3M0098E G3M0098F
: Adjusting direction of drive pinion

: Adjusting direction of crown gear
DI-38
墌 00.5.31/68j/3di 墍
Differentials
19) Install rear cover and tighten bolts to specified 1. SIDE GEAR BACKLASH S303145A1001
torque.
Using a dial gauge, check the backlash of the side
CAUTION: gear.
Securely connect ground terminal of rear dif-
Side gear backlash:
ferential temperature sensor.
0.1 — 0.2 mm (0.004 — 0.008 in)
Tightening torque:
If side gear backlash is not within the specification,
29 N·m (3.0 kgf-m, 21.7 ft-lb)
adjust clearance as specified by selecting side
gear thrust washer.
G3M1050
B3M1934
Wash all the disassembled parts clean, and exam- 2. CROWN GEAR BACKLASH S303145A1002
ine them for wear, damage, or other defects. Using a dial gauge, check the backlash of the
Repair or replace defective parts as necessary. crown gear.
1) Crown gear and drive pinion
Crown gear backlash:
쐌 If abnormal tooth contact is evident, find out the
0.1 — 0.2 mm (0.004 — 0.008 in)
cause and adjust to give correct tooth contact at
assembly. Replace the gear if excessively worn or If crown gear backlash is not within the
incapable of adjustment. specification, adjust the side bearing preload or
쐌 If crack, score, or seizure is evident, replace as repair if necessary.
a set. Slight damage of tooth can be corrected by
oil stone or the like.
2) Side gear and pinion mate gear
쐌 Replace if crack, score, or other defects are evi-
dent on tooth surface.
쐌 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
G3M1047
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-39
墌 00.5.31/68j/3di 墍
Differentials
3. CROWN GEAR RUNOUT S303145A1003 3. TOOTH CONTACT BETWEEN CROWN

Using a dial gauge, check the crown gear runout. GEAR AND DRIVE PINION A303145A0103
Crown gear runout: Adjust the tooth contact between crown gear and
drive pinion gear.
<Ref. to DI-31 ASSEMBLY, Differential for T-type.>
If the crown gear runout exceeds 0.05 mm (0.0020
in), replace the crown gear. 4. TOTAL PRELOAD A303145A0104
Adjust side bearing shim.

S3M0525
4. TOOTH CONTACT BETWEEN CROWN

GEAR AND DRIVE PINION S303145A1004
Inspect tooth contact between crown gear and
driven pinion. <Ref. to DI-31 ASSEMBLY, Differen-
tial for T-type.>
5. TOTAL PRELOAD S303145A1005
Using a gauge, check the turning resistance

increase.
Total preload:
2.9 — 10.8 N (0.3 — 1.1 kg, 0.7 — 2.4 lb)
If the increase of the resistance is not within the
specification, adjust the side bearing retainer
shims.
B3M1935
F: ADJUSTMENT S303145A01
1. SIDE GEAR BACKLASH A303145A0101
Adjust side gear backlash.

2. CROWN GEAR BACKLASH A303145A0102
Adjust crown gear backlash.

DI-40
墌 00.5.31/68j/3di 墍
REAR DIFFERENTIAL FOR VA-TYPE
Differentials
5. Rear Differential for VA-type 12) Loosen self-locking nuts connecting rear dif-
S303151
ferential to rear crossmember.

3) Loosen wheel nuts.
racks.
6) Remove wheels.
7) Remove center exhaust pipes.
B3M1613
9) Remove heat shield cover. 13) Remove DOJ of rear drive shaft from rear dif-
ferential.
B3M1605
B3M1646B
10) Remove propeller shaft.
<Ref. to DS-13 REMOVAL, Propeller Shaft.> (A) Tire lever
CAUTION:
14) Remove protector nut.
When removing propeller shaft, pay attention
not to damage the sliding surfaces of rear drive
shaft (extension) spline, oil seal and sleeve
yoke.
NOTE:
쐌 Prepare an oil can and cap since the transmis-
sion oil flows out from the extension at removing
propeller shaft.
쐌 Insert the cap into the extension to prevent
transmission oil from flowing out immediately after
removing the propeller shaft. B3M1642
11) Prepare a transmission jack and a band. 15) Remove nuts which secure differential mem-
ber.
B3M1610
B3M1611
DI-41
墌 00.5.31/68j/3di 墍
Differentials
16) Support rear differential with transmission 22) Pull out axle shaft from rear differential.
jack. NOTE:
If axle shaft is difficult to remove from rear
differential, use a tire lever to remove it.
B3M1629
17) Remove differential member.

B3M1616
18) Fix rear differential at band.
19) Remove self-locking nuts connecting rear dif- 23) Take down transmission jack.
ferential to rear crossmember. 24) Secure rear drive shaft to lateral link using
20) Remove rear differential stud bolt from rear wire.
NOTE:
Carefully adjust angle and position of transmission
jack and jack stand as required during stud bolt
removal.
B3M1617
25) Remove protector and plate from rear differ-

ential.
B3M1614
21) After removing rear differential stud bolt from

rear crossmember, lower transmission jack stand.
Do not allow rear drive shaft to strike lateral link
bolt.
B3M1618A
(A) Protector
(B) Rear differential member plate
B3M1615
DI-42
墌 00.5.31/68j/3di 墍
Differentials
B: INSTALLATION S303151A11 5) Remove ST from rear differential.

1) Insert protector and plate to rear differential. 6) Completely insert axle shaft into rear differential
by pressing rear differential.
B3M1618A
(A) Protector B3M1623
(B) Rear differential member plate

7) Adjust transmission jack as required so rear dif-
2) Set rear differential to transmission jack. ferential stud bolt is properly inserted into rear
NOTE:
Secure rear differential to transmission jack using
a band.
3) Install ST to rear differential.
B3M1624
8) After rear differential stud bolt has been

inserted into rear crossmember bushing, raise
transmission jack to make jack rear differential
G3M0256
level.
4) Insert the spline shaft until the spline portion is

inside the side oil seal.
B3M1625
B3M1622A
DI-43
墌 00.5.31/68j/3di 墍
Differentials
9) Temporarily tighten rear crossmember self- 13) Tighten protector nut.

locking nuts. Tightening torque:
64 N·m (6.5 kgf-m, 47.0 ft-lb)
B3M1613
10) Remove band from rear differential. Raise rear B3M1642
differential just enough to move transmission jack 14) Take down transmission jack.
away from it. 15) Install propeller shaft.
11) Install differential member. <Ref. to DS-14 INSTALLATION, Propeller Shaft.>
Tightening torque: 16) Install heat shield cover.
T1: 65 N·m (6.6 kgf-m, 48 ft-lb) 17) Install rear exhaust pipe and muffler.
T2: 110 N·m (11.2 kgf-m, 81 ft-lb)
To detect real cause of trouble, inspect the follow-

ing items before disassembling.
쐌 Tooth contact of crown gear and pinion, and
backlash
쐌 Runout of crown gear at its back surface
쐌 Turning resistance of drive pinion
1) Set ST on vise and install the differential
assembly to ST.
ST 398217700 ATTACHMENT
B3M1639C
12) Tighten self-locking nut.

Tightening torque:
70 N·m (7.1 kgf-m, 51 ft-lb)
G3M0060
2) Drain gear oil by removing plug.
B3M1613
DI-44
墌 00.5.31/68j/3di 墍
Differentials
3) Remove rear cover by loosening retaining 6) Remove right and left holders with ST.
bolts. ST 399780111 WRENCH
S3M0506 G3M0064
4) Replace air breather cap. 7) Pull out differential assembly from differential
NOTE: case.
Do not attempt to replace the air breather cap CAUTION:
unless necessary. Be careful not to hit the teeth against the case.
S3M0507A G3M0065
(A) Air breather cap 8) Remove bearing race from right and left holders
(B) Rear cover with ST1 and ST2.
ST1 499705401 BEARING OUTER RACE
5) Remove right and left lock plates.
PULLER ASSY
ST2 499705404 OUTER RACE PULLER
SEAT
G3M0063
S3M0508A
(A) Bearing race

(B) Holder
DI-45
墌 00.5.31/68j/3di 墍
Differentials
9) Remove oil seal from right and left holders with 12) Drive out pinion shaft lock pin from crown gear
screwdriver. side.
CAUTION: NOTE:
Perform this operation only when changing oil The lock pin is staked at the pin hole end on the
seal. differential case; do not drive it out forcibly before
unstaking it.
ST 899904100 STRAIGHT PIN REMOVER
B3M0132
10) Extract bearing cone with ST1 and ST2.

B3M0133
CAUTION:
Do not attempt to disassemble the parts unless 13) Draw out pinion mate shaft and remove pinion
necessary. mate gears, side gears and thrust washers.
NOTE: NOTE:
쐌 Set Puller so that its claws catch the edge of the The gears as well as thrust washers should be
bearing cone. marked or kept separated left and right, and front
쐌 Never mix up the right and left hand bearing and rear.
races and cones.
ST2 399520105 SEAT
S3M0510A
(A) Side gear

(B) Pinion mate gear
H3M1970A (C) Thrust washer
(D) Differential case
11) Remove crown gear by loosening crown gear (E) Pinion mate shaft
bolts.
S3M0509
DI-46
墌 00.5.31/68j/3di 墍
Differentials
14) Hold companion flange with ST and remove 17) Remove rear bearing cone from drive pinion
self-locking nut. by supporting cone with ST.
ST 498427200 FLANGE WRENCH 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 front oil seal from differential carrier

using ST.
S3M0511A
(A) Companion
(B) Puller
16) Press the end of drive pinion shaft and extract

it together with rear bearing cone, preload adjust-
S3M0513A
ing spacer and washer.
NOTE: (A) Differential carrier
Hold the drive pinion so as not to drop it. (B) Front oil seal
ST 398467700 DRIFT 19) Remove pilot bearing together with front bear-
ing cone using ST.
ST 398467700 DRIFT
G3M0074
S3M0514A
(A) Pilot bearing

(B) Front bearing
(C) Rear bearing cup
DI-47
墌 00.5.31/68j/3di 墍
Differentials
20) When replacing bearings, tap front bearing (1) Press rear bearing race into differential car-
cup and rear bearing cup in this order out of case rier with ST1 and ST2.
by using a brass bar. ST1 398477701 HANDLE
ST2 398477702 DRIFT
(2) Press front bearing race into differential car-
rier with ST1 and ST2.
ST1 398477701 HANDLE
ST2 498447110 DRIFT
S3M0515A
(A) 2 cutouts along diagonal lines

(B) Tap alternately with brass bar.
G3M0080
1) Precautions for assembling
쐌 Assemble in the reverse order of disassembling. (3) Insert front bearing cone.
쐌 Check and adjust each part during assembly. CAUTION:
쐌 Keep the shims and washers in order, so that Use a new front bearing cone.
they are not misinstalled.
쐌 Thoroughly clean the surfaces on which the (4) Insert ST1 into case with pinion height
shims, washers and bearings are to be installed. adjusting shim and rear bearing cone fitted onto
쐌 Apply gear oil when installing the bearings and it.
thrust washers. CAUTION:
쐌 Be careful not to mix up the right and left hand 쐌 Re-use the used washer if not deformed.
races of the bearings. 쐌 Use a new rear bearing cone.
쐌 Replace the oil seal with new one at every dis- (5) Then install preload adjusting spacer and
assembly. Apply chassis grease between the lips washer, front bearing cone, ST2, companion
when installing the oil seal. flange, and washer and self-locking nut.
ST2 32285AA000 DUMMY COLLAR
G3M0079
2) Adjust preload for front and rear bearings. S3M0516A

Adjust the bearing preload with spacer and washer
between front and rear bearings. Pinion height (A) Pinion height adjujusting shim
adjusting washer are not affected by this adjust- (B) Preload adjusting spacer
ment. The adjustment must be carried out without (C) Preload adjusting washer
oil seal inserted. (6) Turn ST1 with hand to make it seated, and
tighten drive pinion nut while measuring the pre-
load with spring balance. Select preload adjust-
ing washer and spacer so that the specified pre-
load is obtained when nut is tightened to the
specified torque.
DI-48
墌 00.5.31/68j/3di 墍
Differentials
CAUTION: Part No. Thickness mm (in)

Use a new self-locking nut. 38336AA000 1.500 (0.0591)
NOTE: 38336AA120 1.513 (0.0596)
쐌 Be careful not to give excessive preload. 38336AA010 1.525 (0.0600)
쐌 When tightening the drive pinion nut, lock ST1 38336AA130 1.538 (0.0606)
with ST2 as shown in the figure. 38336AA020 1.550 (0.0610)
ST1 398507704 BLOCK 38336AA140 1.563 (0.0615)
ST2 498447150 DUMMY SHAFT 38336AA030 1.575 (0.0620)
38336AA150 1.588 (0.0625)
Tightening torque:
38336AA040 1.600 (0.0630)
188 N·m (19.2 kgf-m, 139 ft-lb)
38336AA160 1.613 (0.0635)
Preload adjusting 38336AA050 1.625 (0.0640)
washer 38336AA170 1.638 (0.0645)
38336AA060 1.650 (0.0650)
38336AA180 1.663 (0.0655)
38336AA070 1.675 (0.0659)
38336AA190 1.688 (0.0665)
38336AA080 1.700 (0.0669)
38336AA200 1.713 (0.0674)
38336AA090 1.725 (0.0679)
G3M1038 38336AA210 1.738 (0.0684)
38336AA100 1.750 (0.0689)
38336AA220 1.763 (0.0694)
Front and rear bearing preload
38336AA110 1.775 (0.0699)
For new bearing:
12.7 — 32.4 N (1.3 — 3.3 kg, 2.9 — 7.3 lb) Part No. Length mm (in)
at companion flange bolt hole 32288AA040 52.3 (2.059)
32288AA050 52.5 (2.067)
31454AA100 52.6 (2.071)
Preload adjusting 32288AA060 52.7 (2.075)
spacer 31454AA110 52.8 (2.079)
32288AA070 52.9 (2.083)
31454AA120 53.0 (2.087)
32288AA080 53.1 (2.091)
32288AA090 53.3 (2.098)
S3M0517
DI-49
墌 00.5.31/68j/3di 墍
Differentials
3) Adjusting drive pinion height (3) Obtain the thickness of pinion height adjust-
Adjust drive pinion height with shim installed ing washer to be inserted from the following
between rear bearing cone and the back of pinion formula, and replace the temporarily installed
gear. shim with this one.
(1) Install ST1, ST2 and ST3, as shown in the
figure, and apply the specified preload on the NOTE:
bearings Use 1 to 3 shims as required for adjustment.
T = To + N − 0.05 (mm)
Front and rear bearing preload where
For new bearing: T = Thickness of pinion height adjusting shim
12.7 — 32.4 N (1.3 — 3.3 kg, 2.9 — 7.3 lb)
(mm)
at companion flange bolt hole
To = Thickness of shim originally installed
Adjusting preload for front and rear bearings (mm)
NOTE: N = Reading of thickness gauge (mm)
At this time, install an original pinion height adjust- H = Figure marked on drive pinion head
ing shim. (Example of calculation)
ST1 498447150 DUMMY SHAFT To = 0.15 mm
ST2 32285AA000 DUMMY COLLAR N = 0.1 mm
ST3 498505501 DIFFERENTIAL CARRIER T = 0.15 + 0.1 − 0.05 = 0.2 mm
GAUGE Result: Thickness = 0.2 mm
Therefore use the 32295AA220.
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
4) Install the selected pinion height adjusting shim
(A) Pinion height adjusting shim on drive pinion, and press the rear bearing cone
into position with ST.
(2) Measure the clearance N between the end ST 498175500 INSTALLER
of ST3 and the end surface of ST1 by using a
thickness gauge.
NOTE:
Make sure there is no clearance between the case
and ST3.
GAUGE
S3M0519A
H3M1309B
DI-50
墌 00.5.31/68j/3di 墍
Differentials
5) Insert drive pinion into differential carrier, install 8) Fit a new oil seal with ST.
the previously selected bearing preload adjusting NOTE:
spacer and washer. 쐌 Press-fit until end of oil seal is 1 mm (0.04 in)
inward from end of carrier.
쐌 Apply grease between the oil seal lips.
H3M1666A
(A) Drive pinion

(B) Bearing preload adjusting spacer
(C) Bearing preload adjusting washer G3M0087
(D) Differential carrier
9) Press-fit companion flange with ST1 and ST2.
6) Press-fit front bearing cone into carrier with
ST1, ST2 and ST3. CAUTION:
ST1 32285AA000 DUMMY COLLAR Be careful not to damage bearing.
ST2 399780104 WEIGHT ST1 899874100 INSTALLER
ST3 899580100 INSTALLER ST2 399780104 WEIGHT
G3M0085 S3M0521A
7) Insert spacer, then press-fit pilot bearing with 10) Install self-locking nut. Then tighten it with ST.
ST1 and ST2. ST 398427200 FLANGE WRENCH
ST1 399780104 WEIGHT
Tightening torque:
188 N·m (19.2 kgf-m, 139 ft-lb)
S3M0520A
G3M0721
DI-51
墌 00.5.31/68j/3di 墍
Differentials
11) Assembling differential case (2) Adjust the side gear backlash as specified
Install side gears and pinion mate gears, with their by selecting side gear thrust washer.
thrust washers and pinion mate shaft, into differen-
tial case. Side gear thrust washer
NOTE: 803135011 0.925 — 0.950 (0.0364 — 0.0374)
쐌 Apply gear oil on both sides of the washer and 803135012 0.950 — 0.975 (0.0374 — 0.0384)
on the side gear shaft before installing.
803135013 0.975 — 1.000 (0.0384 — 0.0394)
쐌 Insert the pinion mate shaft into the differential
803135014 1.000 — 1.025 (0.0394 — 0.0404)
case by aligning the lock pin holes.
803135015 1.025 — 1.050 (0.0404 — 0.0413)
(3) Check the condition of rotation after apply-

ing oil to the gear tooth surfaces and thrust sur-
faces.
(4) After driving in pinion shaft lock pin, stake
the both sides of the hole to prevent pin from
falling off.
(5) Install crown gear on differential case.
CAUTION:
Before installing bolts, apply Lock Tite to bolt
threads.
Lock Tite
NOTE:
Tighten diagonally while tapping the bolt heads.
Tightening torque:
62 N·m (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 side bearing cone onto differential case

with ST.
ST 498485400 DRIFT
B3M1933
G3M0091
13) Assemble holders.
DI-52
墌 00.5.31/68j/3di 墍
Differentials
(1) Install oil seal into right and left holders. (1) Turn drive pinion with ST for better fitting of
ST 498447100 AXLE SHAFT OIL SEAL differential side bearing.
INSTALLER ST 498427200 FLANGE WRENCH
S3M0522A G3M0094
(2) Install bearing race into right and left hold- (2) Screw in side (left-side) holder until light
ers. contact is made with ST.
ST 398477702 BEARING OUTER RACE ST 399780111 WRENCH
DRIFT
G3M0064
G3M0093
(3) Back off side (left-side) holder approxi-
(3) Install the differential case assembly into mately 1 1/2 teeth of holder, and tighten left-side
differential carrier in the reverse order of disas- holder by approximately 2 teeth (approximately
sembly. 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 lock plate.
NOTE:
Turn over lock plate to displace holder 1/2 tooth.
G3M0065
14) Perform adjustment of backlash of pinion

crown gear set and adjustment of preload of differ-
ential side bearing.
G3M0063
DI-53
墌 00.5.31/68j/3di 墍
Differentials
(5) Measure the crown gear-to-drive pinion 16) Tighten bolt of lock plate to specified torque.
backlash. Set magnet base on differential car- Tightening torque:
rier. Align contact point of dial gauge with tooth 25 N·m (2.5 kgf-m, 18.1 ft-lb)
face of crown gear, and move crown gear while
holding drive pinion still. Read value indicated
on dial gauge.
NOTE:
If measured backlash is not within specified range,
repeat procedures for pinion crown gear set back-
lash adjustment and differential side bearing pre-
load adjustment.
Backlash:
0.10 — 0.15 mm (0.0039 — 0.0059 in)
G3M0063
17) Re-check crown gear-to-pinion backlash.

Backlash:
0.10 — 0.15 mm (0.0039 — 0.0059 in)
S3M0523
15) Draw a matching mark on both differential car-

rier and holder. Remove holder one side at a time.
Replace in the original position after inserting an
O-ring and applying grease to threaded portion. S3M0523
18) Check the crown gear runout on its back

surface, and make sure pinion and crown gear
rotate smoothly.
Limit of runout:
0.05 mm (0.0020 in)
S3M0524A
(A) Matching mark

(B) Holder
S3M0525
19) Checking and adjusting tooth contact of crown

gear.
(1) Apply an even coat of red lead on both
sides of three or four teeth on the crown gear.
Check the contact pattern after rotating crown
gear several revolutions back and forth until a
definite contact pattern appears on the crown
gear.
DI-54
墌 00.5.31/68j/3di 墍
Differentials
(2) When the contact pattern is incorrect, read- (3) Hypoid gear backlash
just according to the instructions given in
Backlash:
“TOOTH CONTACT PATTERN”.
0.10 — 0.15 mm (0.0039 — 0.0059 in)
NOTE:
Be sure to wipe off red lead completely after
adjustment is completed.
20) If proper tooth contact is not obtained, once
again adjust the drive pinion height and the differ-
ential side bearing preload (already mentioned)
and the hypoid gear backlash.
(1) Drive pinion height
ST2 498505501 DIFFERENTIAL GAUGE
S3M0523
H3M1309B
T = To + N − 0.05 (mm)
where
T = Thickness of pinion height adjusting shim
(mm)
To = Thickness of shim originally installed
(mm)
N = Reading of thickness gauge (mm)
(2) Differential side bearing preload
Screw in side (left-side) holder until light contact
is made with ST.
Back off side (left-side) holder approximately 1
1/2 teeth of holder, and tighten left-side holder
by approximately 2 teeth (approximately 1 1/2 +
1/2 teeth).
[Back off amount of side (left-side) holder + 1/2
tooth.]
This + 1/2 tooth gives preload.
ST 399780111 WRENCH
G3M0064
DI-55
墌 00.5.31/68j/3di 墍
Differentials
TOOTH CONTACT PATTERN

Condition Contact pattern Adjustment
Correct tooth contact
Tooth contact pattern slightly shifted
towards toe under no load rotation.
(When loaded, contact pattern moves
—
toward heel.)
G3M0098A
Backlash is too large. tooth ends. adjusting washer in order to bring drive
pinion closer to crown gear center.
G3M0098B
G3M0098F
Flank contact This may cause noise and stepped wear Reduce thickness of drive pinion height
Backlash is too small. on surfaces. adjusting washer in order to move drive
G3M0098C
G3M0098G
Toe contact Contact area is small. Adjust as for flank contact.
This may cause chipping at toe ends.
G3M0098G
G3M0098D
Heel contact Contact area is small. Adjust as for face contact.
This may cause chipping at heel ends.
G3M0098F
G3M0098E
: Adjusting direction of drive pinion

: Adjusting direction of crown gear
DI-56
墌 00.5.31/68j/3di 墍
Differentials
21) Install rear cover and tighten bolts to specified 1. SIDE GEAR BACKLASH S303151A1001
torque.
Using a dial gauge, check the backlash of the side
Tightening torque: gear.
25 N·m (2.5 kgf-m, 18.1 ft-lb)
Side gear backlash:
0.05 — 0.15 mm (0.0020 — 0.0059 in)
If side gear backlash is not within the specification,
adjust clearance as specified by selecting side
gear trust washer.
S3M0526A
(A) Rear cover
Wash all the disassembled parts clean, and exam- B3M1934

ine them for wear, damage, or other defects.
Repair or replace defective parts as necessary. 2. CROWN GEAR BACKLASH S303151A1002
1) Crown gear and drive pinion
쐌 If abnormal tooth contact is evident, find out the Using a dial gauge, check the backlash of the
cause and adjust to give correct tooth contact at crown gear.
assembly. Replace the gear if excessively worn or Crown gear backlash:
incapable of adjustment. 0.10 — 0.15 mm (0.0039 — 0.0059 in)
쐌 If crack, score, or seizure is evident, replace as
If crown gear backlash is not within the
a set. Slight damage of tooth can be corrected by
specification, adjust the side bearing preload or
oil stone or the like.
repair if necessary.
2) Side gear and pinion mate gear
쐌 Replace if crack, score, or other defects are evi-
dent on tooth surface.
쐌 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
G3M1047
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-57
墌 00.5.31/68j/3di 墍
Differentials
3. CROWN GEAR RUNOUT S303151A1003
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.
S3M0525

GEAR AND DRIVE PINION S303151A1004
Inspect tooth contact between crown gear and
drive pinion.
<Ref. to DI-48 ASSEMBLY Rear Differential for VA-
type.>
1. SIDE GEAR BACKLASH A303151A0101
Adjust side gear backlash.

type.>
2. CROWN GEAR BACKLASH A303151A0102
Adjust crown gear backlash.

type.>
GEAR AND DRIVE PINION A303151A0103
Adjust the tooth contact between crown gear and
drive pinion gear.
type.>
DI-58
墌 00.5.31/68j/3di 墍
REAR DIFFERENTIAL FRONT OIL SEAL
Differentials
6. Rear Differential Front Oil 10) Remove self-locking nut while holding com-
panion flange with ST.
Seal S303139
ST 498427200 FLANGE WRENCH

4) Remove rear differential protector. (if equipped)
5) Remove oil drain plug, and drain gear oil.
B3M1608A
11) Remove nut of protector.
B3M1627A
(A) Filler plug

(B) Drain plug
6) Install oil drain plug.

Tightening torque: B3M1642
T-type;
49 N·m (5.0 kgf-m, 36.2 ft-lb) 12) Remove tank cover.
VA-type;
33 N·m (3.4 kgf-m, 24.6 ft-lb)
7) Jack-up rear wheels and support the vehicle
body with sturdy racks.
9) Remove propeller shaft from body. <Ref. to
DS-16 REMOVAL, Propeller Shaft.>
B3M1643
13) Extract companion flange using ST.

ST 399703602 PULLEY ASSY
B3M1606
B3M1644B
DI-59
墌 00.5.31/68j/3di 墍
REAR DIFFERENTIAL FRONT OIL SEAL
Differentials
14) Remove oil seal using ST.

B3M1609B
15) Fit a new oil seal using ST.

B3M1645A
16) Install companion flange.

NOTE:
Use a plastic hammer to install companion flange.
17) Tighten self-locking nut within the specified
torque range so that the turning resistance of com-
panion flange becomes the same as that before
replacing oil seal.
ST 498427200 FLANGE WRENCH
CAUTION:
Use a new self-locking nut.
Tightening torque:
181.4 N·m (18.50 kgf-m, 133.8 ft-lb)
B3M1608A
18) Reassembling procedure hereafter is the

reverse of the disassembling.
DI-60
墌 00.5.31/68j/3di 墍
REAR DIFFERENTIAL MEMBER
Differentials
7. Rear Differential Member S303135

2) Jack-up the vehicle.
3) Using a transmission jack, support rear
differential, and remove rear differential member.
B3M1639B
(A) Rear differential member
1) Install rear differential member.

Tightening torque:
T1: 65 N·m (6.6 kgf-m, 48 ft-lb)
T2: 110 N·m (11.2 kgf-m, 81 ft-lb)
B3M1639C
1) Check rear differential member for damage,

bend, or corrosion.
If damage, bend, or corrosion is excessive, replace
rear differential member.
2) Check bushings of rear differential member for
cracking, hardening, or damage.
If cracking, hardening, or damage is excessive,
replace rear differential member.
DI-61
墌 00.5.31/68j/3di 墍
Differentials
Symptom or trouble Possible cause Remedy

1. Oil leakage (1) Worn, scratched, or incorrectly Repair or replace.
seated front or side oil seal. Scored,
battered, or excessively worn sliding sur-
face of companion flange.
(2) Clogged or damaged air breather. Clean, repair or replace.
(3) Loose bolts on differential spindle or Tighten bolts to specified torque.
side retainer, or incorrectly fitted O-ring. Replace O-ring.
(4) Loose rear cover attaching bolts or Tighten bolts to specified torque.
damaged gasket. Replace gasket and apply liquid packing.
(5) Loose oil filler or drain plug. Retighten and apply liquid packing.
(6) Wear, damage or incorrectly fitting for Repair or replace.
spindle, side retainer and oil seal.
2. Seizure (1) Insufficient backlash for hypoid gear. Readjust or replace.
NOTE:
Seized or damaged parts should be (2) Excessive preload for side, rear, or Readjust or replace.
replaced, and also other parts should be front bearing.
thoroughly checked for any defect and
should be repaired or replaced as (3) Insufficient or improper oil used. Replace seized part and fill with speci-
required. fied oil to specified level.
3. Damage (1) Improper backlash for hypoid gear. Replace.
NOTE: (2) Insufficient or excessive preload for Readjust or replace.
Damaged parts should be replaced, and side, rear, or front bearing.
also other parts should be thoroughly
checked for any defect and should be (3) Excessive backlash for differential Replace gear or thrust washer.
repaired or replaced as required. gear.
(4) Loose bolts and nuts such as crown Retighten.
gear bolt.
(5) Damage due to overloading. Replace.
4. Noises when starting or shifting (1) Excessive backlash for hypoid gear. Readjust.
gears (2) Excessive backlash for differential Replace gear or thrust washer.
NOTE: gear.
Noises may be caused by differential
assembly, universal joint, wheel bearing, (3) Insufficient preload for front or rear Readjust.
etc. Find out what is actually making bearing.
noise before disassembly. (4) Loose drive pinion nut. Tighten to specified torque.
(5) Loose bolts and nuts such as side Tighten to specified torque.
bearing retainer attaching bolt.
5. Noises when cornering (1) Damaged differential gear. Replace.
(2) Excessive wear or damage of thrust Replace.
washer.
(3) Broken pinion mate shaft. Replace.
(4) Seized or damaged side bearing. Replace.
6. Gear noises (1) Improper tooth contact of hypoid Readjust or replace hypoid gear set.
NOTE: gear.
Since noises from engine, muffler, (2) Improper backlash for hypoid gear. Readjust.
transmission, propeller shaft, wheel
bearings, tires, and body are sometimes (3) Scored or chipped teeth of hypoid Replace hypoid gear set.
mistaken for noises from differential gear.
assembly, be careful in checking them. (4) Seized hypoid gear. Replace hypoid gear set.
Inspection methods to locate noises (5) Improper preload for front or rear Readjust.
include coasting, accelerating, cruising, bearings.
and jacking-up all four wheels. Perform
these inspections according to condition (6) Seized, scored, or chipped front or Replace.
of trouble. When listening to noises, shift rear bearing.
gears into four wheel drive and fourth (7) Seized, scored, or chipped side bear- Replace.
speed position, trying to pick up only dif- ing.
ferential noise. (8) Vibrating differential carrier. Replace.
DI-62
GENERAL DESCRIPTION
Drive Shaft System
1. PROPELLER SHAFT S301001E4901
Propeller shaft type DOJ type

AT 629 (24.76)
Front propeller shaft Joint-to-joint length: L1 mm (in)
MT 688 (27.09)
Rear propeller shaft Joint-to-joint length: L2 mm (in) 773 (30.43)
D1 63.5 (2.500)
Outside diameter of tube: mm (in)
D2 57.0 (2.244)
B3M1674A
DS-2
墌 00.5.31/68j/3ds 墍
GENERAL DESCRIPTION
Drive Shaft System
2. FRONT DRIVE SHAFT ASSEMBLY S301001E4902
SHAFT
Type of drive shaft assembly
Shaft diameter
BJ87+SFJ82 26 mm (1.02 in)
B4M2218E
(A) BJ87+SFJ82 (B) Measuring point
DS-3
墌 00.5.31/68j/3ds 墍
GENERAL DESCRIPTION
Drive Shaft System
3. REAR DRIVE SHAFT ASSEMBLY S301001E4903
SHAFT
Type of axle shaft assembly
No. of identification, protrusion on shaft
82AC-RH, 82AC-LH 2 (Two)
79AC-RH, 79AC-LH 1 (One)
79AC None
B4M1972B
(A) 82AC-RH (D) 79AC-LH (G) Identification protrusion

(B) 82AC-LH (E) 79AC
(C) 79AC-RH (F) Indication mark of RH
DS-4
墌 00.5.31/68j/3ds 墍
GENERAL DESCRIPTION
Drive Shaft System
1. PROPELLER SHAFT S301001A0501
B4M2470A
(1) Propeller shaft Tightening torque: N·m (kgf-m, ft-lb)

(2) Rear differential
T1: 31 (3.2, 23.1)
(3) Bush
T2: 52 (5.3, 38.3)
DS-5
墌 00.5.31/68j/3ds 墍
GENERAL DESCRIPTION
Drive Shaft System
2. FRONT AXEL S301001A0502
B4M2471A
(1) Baffle plate (SFJ) (11) BJ ASSY (21) Axle nut (3.0 model: Olive
(2) Spring pin (12) Tone wheel color)
(3) Outer race (SFJ) (13) Baffle plate (22) Axle nut (2.5 model: Gold
(4) Snap ring (14) Oil seal (IN) color)
(5) Trunnion (15) Snap ring
(6) Free ring (16) Bearing Tightening torque: N·m (kgf-m, ft-lb)
(7) Circlip (17) Housing T1: 186 (19, 137)
(8) Boot band (18) Oil seal (OUT) T2: 216 (22, 159)
(9) Boot band (19) Hub bolt
(10) Boot (BJ) (20) Hub
DS-6
墌 00.5.31/68j/3ds 墍
GENERAL DESCRIPTION
Drive Shaft System
3. REAR AXLE S301001A0503
B4M2240A
(1) Baffle plate (DOJ) (8) Boot band (15) Hub

(2) Outer race (DOJ) (9) Boot (DOJ) (16) Axle nut (Olive color)
(3) Snap ring (10) Boot (BJ)
(4) Inner race (11) BJ ASSY Tightening torque: N·m (kgf-m, ft-lb)
(5) Ball (12) Tone wheel T1: 66 (6.7, 48.5)
(6) Cage (13) Hub unit bearing T2: 235 (24, 174)
(7) Circlip (14) Hub bolt
DS-7
墌 00.5.31/68j/3ds 墍
GENERAL DESCRIPTION
Drive Shaft System

tion.
ment.
fied points.
deformation.
DS-8
墌 00.5.31/68j/3ds 墍
GENERAL DESCRIPTION
Drive Shaft System

922431000 AXLE SHAFT 쐌 Used for installing axle shaft into housing.
INSTALLER 쐌 Used with ADAPTER (927390000).
B4M2386
925091000 BAND TIGHTENING 쐌 Used for tightening boot band.
TOOL (A) Jig for band
(B) Ratchet wrench
B4M2387A
926470000 AXLE SHAFT Used for removing axle shaft.
PULLER
B4M2388
927060000 HUB REMOVER 쐌 Used for removing front hub.
쐌 Used with HUB STAND (927080000).
B4M2389
DS-9
墌 00.5.31/68j/3ds 墍
GENERAL DESCRIPTION
Drive Shaft System

927080000 HUB STAND Used for disassembling and assembling hub
bolt in hub.
B4M2390
927100000 BEARING PULLER 쐌 Used for disassembling and assembling front
housing bearing.
쐌 Used with HOUSING STAND (927400000).
B4M2391
927140000 AXLE SHAFT Same as plate 2 included in AXLE SHAFT
PULLER PLATE PULLER (926470000).
B4M2392
927390000 ADAPTER Used as an adapter for AXLE SHAFT
INSTALLER (922431000).
B4M2393
927400000 HOUSING STAND 쐌 Used for disassembling and assemblig front
housing bearing.
쐌 Used with BEARING PULLER (927100000).
B4M2394
DS-10
墌 00.5.31/68j/3ds 墍
GENERAL DESCRIPTION
Drive Shaft System

927410000 OIL SEAL 쐌 Used for installing oil seal into front housing.
INSTALLER 쐌 Used with HOUSING STAND (927400000).
B4M2395
398507703 DUMMY COLLAR Used for removing hub ASSY from hub unit.
B4M2396
399520105 SEAT Used for removing inner race fom hub ASSY.
B4M2397
28499AE000 BEARING Used for installing hub unit into hub ASSY.
SPACHER
B4M2398
927120000 HUB INSTALLER Used for installing hub.
B4M2399
DS-11
墌 00.5.31/68j/3ds 墍
GENERAL DESCRIPTION
Drive Shaft System

927450000 HUB INSTALLER 쐌 Used for installing hub unit into hub ASSY.
쐌 Used with BEARING SPACER (28499AE000)
and HUB STAND (927080000).
B4M2400
28099PA090 OIL SEAL PROTEC- 쐌 Used for installing rear drive shaft into rear
TOR differential.
쐌 For potecting oil seal.
B4M2401
28099PA100 DRIVE SHAFT Used for removing rear drive shaft from rear
REMOVER differential.
B4M2402
28099AC000 BOOT BAND PLI- Used for tightening front BJ boot band.
ERS
B4M2403
TOOL NAME REMERKS

Puller Used for removing ball joint from knuckle arm.
Dial gauge Used for inspecting propeller shaft run-out.
Snap ring pliers Used for installing and removing snap ring.
DS-12
墌 00.5.31/68j/3ds 墍
PROPELLER SHAFT
Drive Shaft System
2. Propeller Shaft S301160

8) Remove the four bolts which hold propeller
shaft to rear differential.
NOTE:
NOTE: 쐌 Put matching mark on affected parts before
쐌 Before removing propeller shaft, wrap metal removal.
parts with a cloth or rubber material. 쐌 Remove all but one bolt.
쐌 In case of DOJ type, before removing propeller
shaft, wrap metal parts (installed at the rubber boot
of center DOJ) with a cloth or rubber material, as
shown in the figure. Rubber boot may be damaged
due to interference with adjacent metal parts while
bending the DOJ during removal.
B3M1587C
(A) Matching mark
9) Remove the two bolts which hold center bear-

ing to vehicle body.
S3M0030

racks.
7) Remove heat shield cover. B3M1606
10) Remove propeller shaft from transmission.

CAUTION:
Be sure not to damage oil seals and the fric-
tional surface of sleeve yoke.
NOTE:
쐌 Be sure to use an empty oil can to catch oil
flowing out when removing propeller shaft.
쐌 Be sure to plug the opening in transmission after
B3M1605
removal of propeller shaft.
B3M1607
DS-13
墌 00.5.31/68j/3ds 墍
PROPELLER SHAFT
Drive Shaft System
11) Install the extension cap to transmission. 5) Install rear exhaust pipe and muffler.
NOTE:
If extension cap is not available, place vinyl bag
C: INSPECTRION S301160A10
over opening and fasten with string to prevent gear NOTE:

oil or ATF from leaking. Do not disassemble propeller shaft. Check the fol-
lowing 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 non-
smooth operation
5) Oil seals for abnormal wear or damage
6) Center bearing for breakage
Check the following points with propeller shaft
S3M0498A installed in vehicle.
(A) Extension cap 1. JOINTS AND CONNECTIONS S301160A1001

1) Insert sleeve yoke into transmission and attach 3) Check for any looseness of yoke flange con-
center bearing to body. necting bolts and center bearing retaining bolts.
Tightening torque: 2. SPLINES AND BEARING LOCATIONS
52 N·m (5.3 kgf-m, 38.3 ft-lb) S301160A1002

4) Turn propeller shaft by hand to see if abnormal
free play exists at splines. Also move yokes to see
if abnormal free play exists at spiders and bear-
ings.
B3M1606
2) Align matching marks and connect flange yoke

and rear differential.
Tightening torque:
31 N·m (3.2 kgf-m, 23.1 ft-lb)
B3M1602
B3M1587C
(A) Matching mark
3) Install heat shield cover.

4) Install center exhaust pipes.
DS-14
墌 00.5.31/68j/3ds 墍
PROPELLER SHAFT
Drive Shaft System
3. RUNOUT OF PROPELLER SHAFT

S301160A1003

4) Turn rear wheels by hand to check for “runout”
of propeller shaft.
NOTE:
Measure runout with a dial gauge at the center of
front and rear propeller shaft tubes.
Runout:
Limit 0.6 mm (0.024 in)
B3M1603A
(A) Propeller shaft

(B) Dial gauge
4. CENTER BEARING FREE PLAY S301160A1004
1) Remove front and center exhaust pipes.

4) While holding propeller shaft near center bear-
ing with your hand, move it up and down, and left
and right to check for any abnormal bearing free
play.
B3M1604
DS-15
墌 00.5.31/68j/3ds 墍
FRONT AXLE
Drive Shaft System
3. Front Axle S301148

8) Remove cotter pin and castle nut which secure
tie-rod end to housing knuckle arm.

2) Jack-up vehicle, support it with safety stands,
and remove front wheels.
3) Unlock axle nut.
B4M2214A
(A) Cotter pin

(B) Castle nut
(C) Tie-rod
G4M0214 9) Using a puller, remove tie-rod ball joint from

knuckle arm.
4) Remove axle nut using a socket wrench.
CAUTION:
Be sure to loose and retighten axle nut after
removing wheel from vehicle. Failure to follow
this rule may damage wheel bearings.
5) Remove stabilizer link.
B4M2215
10) Remove ABS sensor assembly and harness in

advance.
G4M0215
6) Remove disc brake caliper from housing, and

suspend it from strut using a wire.
7) Remove disc rotor from hub.
If disc rotor seizes up within hub, drive disc rotor
out by installing an 8-mm bolt in screw hole on the
rotor. B4M2209
B4M1678
DS-16
墌 00.5.31/68j/3ds 墍
FRONT AXLE
Drive Shaft System
11) Remove bolt which secures sensor harness to 15) After scribing an alignment mark on camber
strut. adjusting bolt head, remove bolts which connect
housing and strut, and disconnect housing from
strut.
B4M1442
12) Remove transverse link ball joint from hous- B4M1970

ing.
1) Install transverse link ball joint to housing.

Tightening torque:
49 N·m (5.0 kgf-m, 36 ft-lb)
2) While aligning alignment mark on camber
adjusting bolt head, connect housing and strut.
CAUTION:
B4M2216
Tightening torque:
13) Remove SFJ from transmission spindle. 177 N·m (18.0 kgf-m, 130 ft-lb)
14) Remove front drive shaft assembly from hub.
If it is hard to remove, use STs. 3) Install ABS sensor on housing.
ST1 926470000 AXLE SHAFT PULLER Tightening torque:
ST2 927140000 PLATE 32 N·m (3.3 kgf-m, 23.9 ft-lb)
CAUTION: 4) Install ABS sensor harness on strut.
쐌 Be careful not to damage oil seal lip and tone 5) Install disc rotor on hub.
wheel when removing front drive shaft. 6) Install disc brake caliper on housing.
쐌 When replacing front drive shaft, also
Tightening torque:
replace inner oil seal.
78 N·m (8 kgf-m, 57.9 ft-lb)
7) Install front drive shaft. <Ref. to DS-28
INSTALLATION, Front Drive Shaft.>
8) Connect stabilizer link.
S4M0108A
DS-17
墌 00.5.31/68j/3ds 墍
FRONT AXLE
Drive Shaft System
9) Connect tie-rod end ball joint and knuckle arm C: DISASSEMBLY S301148A06
with a castle nut, and insert cotter pin into tie-rod

end. 1) Using ST1, support housing and hub securely.
2) Attach ST2 to housing and drive hub out.
Tightening torque: ST1 927060000 HUB REMOVER
27.0 N·m (2.75 kgf-m, 19.9 ft-lb) ST2 927080000 HUB STAND
B4M2214A
(A) Cotter pin

(B) Castle nut
(C) Tie-rod
10) While depressing brake pedal, tighten axle nut

and lock it securely.
Tightening torque:
2.5 MODEL
186 N·m (19 kgf-m, 137 ft-lb)
3.0 MODEL
G4M0223
216 N·m (22 kgf-m, 159 ft-lb)
CAUTION: If inner bearing race remains in the hub, remove it
쐌 Use a new axle nut (3.0 model: Olive color, with a suitable tool (commercially available).
2.5 model: Gold color).
CAUTION:
쐌 Always tighten axle nut before installing
쐌 Be careful not to scratch polished area of
wheel on vehicle. If wheel is installed and
hub.
comes in contact with ground when axle nut is
쐌 Be sure to install inner race on the side of
loose, wheel bearings may be damaged.
outer race from which it was removed.
쐌 Be sure to tighten axle nut to specified
torque. Do not overtighten it as this may dam-
age wheel bearing.
11) After tightening axle nut, lock it securely.
G4M0224
G4M0238
12) Install wheel and tighten wheel nuts to speci-

fied torque.
Tightening torque:
88 N·m (9 kgf-m, 65 ft-lb)
DS-18
墌 00.5.31/68j/3ds 墍
FRONT AXLE
Drive Shaft System
3) Remove disc cover from housing. 8) Using ST and a hydraulic press, drive hub bolts
out.
ST 927080000 HUB STAND
CAUTION:
Be careful not to hammer hub bolts. This may
deform hub.
G4M0225
4) Using a standard screwdriver, remove outer

and inner oil seals.
CAUTION:
Do not use old oil seals. G4M0228
5) Using flat bladed screwdriver, remove snap
ring.
1) Attach hub to ST securely.

H4M1001
6) Using ST1, support housing securely.

7) Using ST2, press inner race to drive out outer G4M0230
bearing.
ST1 927400000 HOUSING STAND 2) Using a hydraulic press, press new hub bolts
ST2 927100000 BEARING REMOVER into place.
CAUTION: CAUTION:
쐌 Do not remove outer race unless it is faulty. Be sure to press hub bolts until their seating
쐌 Discard outer race after removal. surfaces contact the hub.
쐌 Do not replace inner or outer race sepa- NOTE:
rately; always replace as a unit. 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-19
墌 00.5.31/68j/3ds 墍
FRONT AXLE
Drive Shaft System
4) Using ST1 and ST2, press a new bearing into 7) Invert ST and housing.
place. ST 927400000 HOUSING STAND
ST1 927400000 HOUSING STAND 8) Using ST1 and ST2, press outer oil seal until it
ST2 927100000 BEARING REMOVER contacts the bottom of housing.
CAUTION: ST1 927410000 OIL SEAL INSTALLER
쐌 Always press outer race when installing ST2 927400000 HOUSING STAND
bearing.
쐌 Be careful not to remove plastic lock from
inner race when installing bearing.
쐌 Charge bearing with new grease when outer
race is not removed.
Specified grease:
SHELL 6459N
G4M0233
9) Apply sufficient grease to oil seal lip.

Specified grease
SHELL 6459N
CAUTION:
쐌 If specified grease is not available, remove
G4M0232
bearing grease and apply Auto Rex A instead.
쐌 Do not mix different types of grease.
5) Using pliers, install snap ring in its groove. 10) Install disc cover to housing the three bolts.
CAUTION: Tightening torque:
Make sure to install it firmly to groove. 18 N·m (1.8 kgf-m, 13.0 ft-lb)
11) Attach hub to ST1 securely.
12) Clean dust or foreign particles from the pol-
ished surface of hub.
13) Using ST2, press bearing into hub by driving
inner race.
ST1 927080000 HUB STAND
ST2 927120000 HUB INSTALLER
G4M0226
6) Using ST1 and ST2, press inner oil seal until it

contacts circlip.
ST1 927410000 OIL SEAL INSTALLER
ST2 927400000 HOUSING STAND
G4M0235
G4M0234
DS-20
墌 00.5.31/68j/3ds 墍
FRONT AXLE
Drive Shaft System
Check the removed parts for wear and damage. If

defective, replace with new ones.
CAUTION:
쐌 If bearing is faulty, replace it as the bearing
set.
쐌 Be sure to replace oil seal at every overhaul.
H4M1002C
(A) Replace as a seat.
DS-21
墌 00.5.31/68j/3ds 墍
HUB UNIT BEARING
Drive Shaft System
4. Hub Unit Bearing S301155

9) Remove four bolts from rear arm.
1. DISC BRAKE S301155A1801

2) Jack-up vehicle, and remove rear wheel cap
and wheels.
CAUTION:
Be sure to loosen and retighten axle nut after
B4M1682
3) Unlock axle nut. 10) Remove hub unit bearing.
4) Remove axle nut using a socket wrench. CAUTION:
5) Return parking brake lever. Be careful not to damage tone wheel.
6) Remove ABS sensor.
B4M1689
B4M1679
If it is hard to remove, use STs.
7) Remove brake caliper from back plate and sus- ST1 926470000 AXLE SHAFT PULLER
pend it from stabilizer using a piece of wire. ST2 927140000 PLATE
B4M1680
B4M1685A
8) Remove disc rotor from hub.

NOTE: 2. DRUM BRAKE S301155A1802
쐌 Before removing disc rotor, mark the matching 1) Disconnect ground cable from battery.
surface of hub and disc rotor so as not to be con- 2) Jack-up vehicle, and remove rear wheel cap
fused when installing. and wheels.
쐌 If disc rotor seizes up within hub, drive it out by CAUTION:
installing an 8 mm bolt into disc rotor bolt hole. Be sure to loosen and retighten axle nut after
3) Unlock axle nut.
5) Return parking brake lever.
6) Remove brake drum from hub.
DS-22
墌 00.5.31/68j/3ds 墍
HUB UNIT BEARING
Drive Shaft System
7) If it is difficult to remove brake drum, turn 10) Remove hub unit bearing.
adjusting screw using a slot-type screwdriver until If it is hard to remove, use STs.
brake shoe separates from the drum. ST1 926470000 AXLE SHAFT PULLER
ST2 927140000 PLATE
CAUTION:
Be careful not to damage tone wheel.
B4M1766A
NOTE:
If brake drum is difficult to remove, drive it out by B4M1685A
1. DISC BRAKE S301155A1101
1) Align hub unit bearing with back plate at mount-

ing holes and install hub unit assembly and back
plate. Temporarily tighten axle nuts.
CAUTION:
Be careful not to damage tone wheel.
B4M1707
8) Remove ABS sensor.
B4M1711
2) Tighten four bolts to back plate.

B4M1708
9) Remove four bolts from rear arm.
B4M1682
3) Remove axle nut.

B4M1682
DS-23
墌 00.5.31/68j/3ds 墍
HUB UNIT BEARING
Drive Shaft System
4) Using ST1 and ST2, pull axle shaft into place. CAUTION:
ST1 922431000 AXLE SHAFT INSTALLER 쐌 Use a new axle nut for rear use only (Olive
ST2 927390000 ADAPTER color).
age wheel bearing.
B4M1690A
5) Temporarily tighten axle nuts.

6) Install disc rotor on hub.
7) Install disc brake caliper on back plate.
Tightening torque:
52 N·m (5.3 kgf-m, 38.3 ft-lb)
B4M1691
11) Install wheel and tighten wheel nuts to speci-

fied torque.
Tightening torque:
88 N·m (9 kgf-m, 65 ft-lb)
2. DRUM BRAKE S301155A1102
1) Align hub unit bearing with back plate at mount-

ing holes and install hub unit assembly and back
B4M1710 plate. Temporarily tighten axle nuts.
8) Install rear ABS sensor and brake cable CAUTION:

bracket. Be careful not to damage tone wheel.
B4M1711
B4M1679
9) Adjust parking brake lever stroke by turning

adjuster. <Ref. to PB-6 ADJUSTMENT, Parking
Brake Lever.>
10) Move brake lever back to apply brakes. While
depressing brake pedal, tighten axle nut using a
socket wrench. Lock axle nut after tightening.
Tightening torque:
235 N·m (24 kgf-m, 174 ft-lb)
DS-24
墌 00.5.31/68j/3ds 墍
HUB UNIT BEARING
Drive Shaft System
2) Tighten four bolts to back plate. CAUTION:

쐌 Use a new axle nut for rear use only (Olive
color).
age wheel bearing.
9) Install wheel and tighten wheel nuts to specified
B4M1682
torque.
3) Remove axle nut. Tightening torque:
4) Using ST1 and ST2, pull axle shaft into place. 88 N·m (9 kgf-m, 65 ft-lb)
ST1 922431000 AXLE SHAFT INSTALLER
ST2 927390000 ADAPTER C: DISASSEMBLY S301155A06
5) Temporarily tighten axle nuts. 1) Using ST, remove hub unit from hub assembly.
CAUTION:
Securely set hub assembly so that it does not
lean.
ST 398507703 DUMMY COLLAR
B4M1690A
6) Install rear ABS sensor.

Tightening torque:
32 N·m (3.3 kgf-m, 23.9 ft-lb)
B4M1708
B4M1686A
7) Install brake drum on rear housing assembly.
8) Move brake lever back to apply brakes. While
depressing brake pedal, tighten axle nut using a
socket wrench. Lock axle nut after tightening.
Tightening torque:
235 N·m (24 kgf-m, 174 ft-lb)
DS-25
墌 00.5.31/68j/3ds 墍
HUB UNIT BEARING
Drive Shaft System
2) Using ST and a puller (common hand tool), D: ASSEMBLY S301155A02
remove bearing inner race.

ST1 399520105 SEAT 1) Using ST, press new hub bolt into place.
ST2 927080000 HUB STAND CAUTION:
CAUTION: 쐌 Ensure hub bolt closely contacts hub.
쐌 Do not remove hub unit bearing unless dam- 쐌 Use a 12 mm (0.47 in) hole in the ST to pre-
aged. vent hub bolt from tilting during installation.
쐌 Do not re-use hub unit bearing after removal. ST 927080000 HUB STAND
G4M0230
2) Using ST1, ST2 and ST3, press hub unit bear-

ing into hub.
ST1 927080000 HUB STAND
ST2 927450000 HUB INSTALLER
ST3 28499AE000 SPACER
B4M1687A
3) Using ST, press hub bolt out.

CAUTION:
Be careful not to hammer hub bolts. This may
deform hub.
B4M1688A
G4M0228
CAUTION:
쐌 Always press inner race when installing hub
unit bearing.
쐌 Use a new hub unit bearing.
DS-26
墌 00.5.31/68j/3ds 墍
HUB UNIT BEARING
Drive Shaft System
Check the removed parts for wear and damage. If

defective, replace with new ones.
CAUTION:
If a bearing is faulty, replace it as a hub unit
bearing.
DS-27
墌 00.5.31/68j/3ds 墍
FRONT DRIVE SHAFT
Drive Shaft System
5. Front Drive Shaft S301153 B: INSTALLATION S301153A11
1) Insert BJ into hub splines.
1) Disconnect ground cable from battery. CAUTION:
2) Jack-up vehicle, support it with safety stands Be careful not to damage inner oil seal lip and
(rigid rocks), and remove front wheel cap and tone wheel.
wheels. 2) Using ST1 and ST2, pull drive shaft into place.
3) Unlock axle nut. ST1 922431000 AXLE SHAFT INSTALLER
4) Depress brake pedal and remove axle nut ST2 927390000 ADAPTER
using a socket wrench.
CAUTION:
CAUTION: Do not hammer drive shaft when installing it.
Be sure to loosen and retighten axle nut after
5) Remove stabilizer link from transverse link.
6) Disconnect transverse link from housing.
7) Remove spring pin which secures transmission
spindle to SFJ.
CAUTION:
Use a new spring pin.
G4M0291
3) Tighten axle nut temporarily.

4) Install SFJ on transmission spindle and drive
spring pin into place.
CAUTION:
Always use a new spring pin.
G4M0279
8) Remove front drive shaft assembly. If it is hard

to remove, use ST1 and ST2.
ST1 926470000 AXLE SHAFT PULLER
ST2 927140000 PLATE
CAUTION:
쐌 Be careful not to damage oil seal lip and tone
wheel when removing front drive shaft. G4M0279
쐌 When front drive shaft is to be replaced, also
replace inner oil seal. 5) Connect transverse link to housing.
Tightening torque (self-locking nut):
49 N·m (5.0 kgf-m, 36 ft-lb)
CAUTION:
6) Install stabilizer bracket.
to the specified torque.
Tightening torque:
S4M0108A 2.5 MODEL
186 N·m (19 kgf-m, 137 ft-lb)
3.0 MODEL
216 N·m (22 kgf-m, 159 ft-lb)
DS-28
墌 00.5.31/68j/3ds 墍
FRONT DRIVE SHAFT
Drive Shaft System
CAUTION: 5) Wipe off grease.

쐌 Use a new axle nut (3.0 model: Olive color, CAUTION:
2.5 model: Gold color). The grease is a special grease. Do not confuse
쐌 Always tighten axle nut before installing with other greases.
comes in contact with ground when axle nut is 6) Place alignment mark on free ring and trunnion.
age wheel bearing.
1) Place alignment marks on shaft and outer race.
B4M0774
2) Remove SFJ boot band and boot. B4M0777

CAUTION:
Be careful not to damage boot. 7) Remove free ring from trunnion.
CAUTION:
Be careful with the free ring position.
8) Place alignment mark on trunnion and shaft.
B4M0775
3) Remove circlip from SFJ outer race using

screwdriver.
B4M0778
B4M0776
4) Remove SFJ outer race from shaft assembly.
DS-29
墌 00.5.31/68j/3ds 墍
FRONT DRIVE SHAFT
Drive Shaft System
9) Remove snap ring and trunnion. 13) Cut and remove the boot.
CAUTION:
The boot must be replaced with a new one
whenever it is removed.
B4M0779
CAUTION:
Be sure to wrap shaft splines with vinyl tape to B4M0690
prevent boot from scratches.
10) Remove SFJ boot. 14) Thus, disassembly of axle is completed, but
11) Place drive shaft in a vise between wooden BJ cannot be disassembled.
blocks.
CAUTION:
Do not place drive shaft directly in the vise; use CAUTION:
wooden block. Use specified grease.
12) Raise boot band claws by means of screw- BJ side:

driver and hammer. NTG2218 (Part No. 28093AA000)
SFJ side:
SSG6003 (Part No. 28093TA000)
1) Place BJ boot and small boot band on BJ side
of shaft.
CAUTION:
Be sure to wrap shaft splines with vinyl tape to
2) Place drive shaft in a vise.
CAUTION:
Do not place drive shaft directly in the vise; use
wooden blocks.
3) Apply a coat of specified grease [60 to 70 g
(2.12 to 2.47 oz)] to BJ.
4) Apply an even coat of specified grease [20 to
30 g (0.71 to 1.06 oz)] to the entire inner surface
of boot. Also apply grease to shaft.
NOTE:
The inside of the larger end of BJ boot and the boot
groove shall be cleaned so as to be free from
B4M2220B
grease and other substances.
(A) Boot band claws
DS-30
墌 00.5.31/68j/3ds 墍
FRONT DRIVE SHAFT
Drive Shaft System
5) Install boot projecting portion to BJ groove. Tightening torque:

Large boot band
157 N·m (16.0 kgf-m, 116 ft-lb) or more
Small boot band
133 N·m (13.6 kgf-m, 98 ft-lb) or more
9) Place SFJ boot at the center of shaft.
10) Align alignment marks and install trunnion on
shaft.
B4M2217B
(A) BJ
(B) Lorge boot band
(C) Boot
6) Set large boot band in place.

7) Install boot projecting portion to shaft groove.
B4M0778
11) Install 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 free ring
B4M1297C
and trunnion.
14) Align alignment marks on free ring and trun-
(A) Boot nion and install free ring.
(B) Small boot band
CAUTION:
(C) Shaft
Be careful with the free ring position.
8) Tighten boot bands using ST, torque wrench
and socket flex handle.
ST 28099AC000 BOOT BAND PLIER
B4M0693C
(A) Large boot band

(B) Boot
(C) Torque wrench
(D) Socket flex handle
(E) BJ
B4M0777
DS-31
墌 00.5.31/68j/3ds 墍
FRONT DRIVE SHAFT
Drive Shaft System
15) Align alignment marks on shaft and outer 22) Tap on the clip with the punch provided at the
race, and install outer race. end of ST.
ST 925091000 BAND TIGHTENING TOOL
CAUTION:
Tap to an extent that the boot underneath is not
damaged.
B4M0774
16) Install circlip in the groove on SFJ outer race.

CAUTION:
Pull the shaft lightly and assure that the circlip G4M0290
is completely fitted in the groove.
23) Cut off band with an allowance of about 10
17) Apply an even coat of the specified grease 30 mm (0.39 in) left from the clip and bend this allow-
to 40 g (1.06 to 1.41 oz) to the entire inner surface ance over the clip.
of boot.
CAUTION:
18) Install SFJ boot taking care not to twist it. Be careful so that the end of the band is in
CAUTION: close contact with clip.
쐌 The inside of the larger end of SFJ boot and 24) Fix up boot on BJ in the same manner.
the boot groove shall be cleaned so as to be
free from grease and other substances. NOTE:
쐌 When installing SFJ boot, position outer Extend and retract SFJ to provide equal grease
race of SFJ at center of its travel. coating.
19) Put a band through the clip and wind twice in E: INSPECTION S301153A10
alignment with band groove of boot. Check the removed parts for damage, wear, corro-
CAUTION: sion etc. If faulty, repair or replace.
Use a new band. 1) DOJ (Double Offset Joint)
Check seizure, corrosion, damage, wear and
20) Pinch the end of band with pliers. Hold the clip excessive play.
and tighten securely. 2) SFJ (Shudder-less Freering tripod Joint)
NOTE: Check seizure, corrosion, damage and excessive
When tightening boot, exercise care so that the air play.
within the boot is appropriate. 3) Shaft
Check excessive bending, twisting, damage and
21) Tighten band by using ST. wear.
ST 925091000 BAND TIGHTENING TOOL 4) BJ (Bell Joint)
NOTE: Check seizure, corrosion, damage and excessive
Tighten band until it cannot be moved by hand. play.
5) Boot
Check for wear, warping, breakage or scratches.
6) Grease
Check for discoloration or fluidity.
G4M0289
DS-32
墌 00.5.31/68j/3ds 墍
REAR DRIVE SHAFT
Drive Shaft System
6. Rear Drive Shaft S301156 B: INSTALLATION S301156A11
1) Insert BJ into rear hub splines.
1) Disconnect ground cable from battery. CAUTION:
2) Lift-up vehicle, and remove rear wheel cap and Be careful not to damage tone wheel.
wheels. 2) Using ST1 and ST2, pull drive shaft into place.
CAUTION: ST1 922431000 AXLE SHAFT INSTALLER
Be sure to loosen and retighten axle nut after ST2 927390000 ADAPTER
removing wheel from vehicle. Failure to follow CAUTION:
this rule may damage wheel bearings. Do not hammer drive shaft when installing it.
3) Unlock axle nut.
5) Remove rear differential assembly.
with T-type
<Ref. to DI-24 REMOVAL, Rear Differential for
T-type.>
with VA-type
<Ref. to DI-41 REMOVAL, Rear Differential for VA-
type.>
6) Remove axle nut and drive shaft. If it is hard to
remove, use ST1 and ST2. B4M1690A
ST1 926470000 AXLE SHAFT PULLER
ST2 927140000 PLATE 3) Tighten axle nut temporarily.
CAUTION: 4) Install rear differential.
Be careful not to damage tone wheel when with T-type
removing rear drive shaft. <Ref. to DI-26 INSTALLATION, Rear Differential
for T-type.>
with VA-type
<Ref. to DI-43 INSTALLATION, Rear Differential
for VA-type.>
using a socket wrench.
Tightening torque:
235 N·m (24 kgf-m, 174 ft-lb)
CAUTION:
B4M1685A
쐌 Use a new axle nut for rear use only (Olive
color).
age wheel bearing.
DS-33
墌 00.5.31/68j/3ds 墍
REAR DRIVE SHAFT
Drive Shaft System
C: DISASSEMBLY S301156A06 6) Take out DOJ outer race from shaft assembly.
7) Wipe off grease and take out balls.
1) Straighten bent claw of larger end of DOJ boot.
2) Loosen band by means of screwdriver or pliers CAUTION:
with care of not damaging boot. The grease is a special grease (grease for con-
stant velocity joint). Do not confuse with other
greases.
NOTE:
Disassemble exercising care not to lose balls (6
pcs).
G4M0281
3) Remove boot band on the small end of DOJ

boot in the same manner.
4) Remove the larger end of DOJ boot from DOJ
outer race.
B4M0227E
5) Pry and remove round circlip located at the
neck of DOJ outer race with a screwdriver. (A) Outer race
(B) Grease
8) To remove the cage from the inner race, turn

the cage by a half pitch to the track groove of the
inner race and shift the cage.
9) Remove snap ring, which fixes inner race to
shaft, by using pliers.
10) Take out DOJ inner race.
11) Take off DOJ cage from shaft and remove DOJ
boot.
G4M0282 CAUTION:
12) Remove BJ boot in the same procedure as
DOJ boot.
13) Thus, disassembly of axle is completed, but
BJ is unable to be disassembled.
CAUTION:
Use specified grease.
BJ side:
Molylex No. 2 (Part No. 723223010)
DOJ side:
VU-3A702 (Yellow) (Part No. 23223GA050)
1) Install BJ boot in specified position, and fill it
with 60 to 70 g (2.12 to 2.47 oz) of specified
grease.
2) Place DOJ boot at the center of shaft.
CAUTION:
DS-34
墌 00.5.31/68j/3ds 墍
REAR DRIVE SHAFT
Drive Shaft System
3) Insert DOJ cage onto shaft. 6) Fill 80 to 90 g (2.82 to 3.17 oz) of specified
NOTE: grease into the interior of DOJ outer race.
Insert the cage with the cut-out portion facing the 7) Apply a coat of specified grease to the cage
shaft end, since the cage has an orientation. 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 DOJ inner race on shaft and fit snap ring B4M0227E
with pliers.
(A) Outer race
NOTE:
(B) Grease
Confirm that the snap ring is completely fitted in the
shaft groove. 10) Install circlip in the groove on DOJ outer race.
NOTE:
쐌 Assure that the balls, cage and inner race are
completely fitted in the outer race of DOJ.
쐌 Exercise care not to place the matched position
of circlip in the ball groove of outer race.
쐌 Pull the shaft lightly and assure that the circlip is
completely fitted in the groove.
G4M0285
5) Install cage, which was previously fitted, to

inner race fixed upon shaft.
NOTE:
Fit the cage with the protruded part aligned with the
track on the inner race and then turn by a half
pitch.
G4M0282
11) Apply an even coat of the specified grease [20

to 30 g (0.71 to 1.06 oz)] to the entire inner surface
of boot. Also apply grease to shaft.
12) Install DOJ boot taking care not to twist it.
NOTE:
쐌 The inside of the larger end of DOJ boot and the
boot groove shall be cleaned so as to be free from
grease and other substances.
B4M0228E
쐌 When installing DOJ boot, position outer race of
DOJ at center of its travel.
(A) Inner race
13) Put a band through the clip and wind twice in
(B) Cage
alignment with band groove of boot.
DS-35
墌 00.5.31/68j/3ds 墍
REAR DRIVE SHAFT
Drive Shaft System
CAUTION: E: INSPECTION S301156A10
Use a new band.

Check the removed parts for damage, wear, corro-
14) Pinch the end of band with pliers. Hold the clip sion etc. If faulty, repair or replace.
and tighten securely. 1) DOJ (Double Offset Joint)
NOTE: Check seizure, corrosion, damage, wear and
When tightening boot, exercise care so that the air excessive play.
within the boot is appropriate. 2) SFJ (Shudder-less Freering tripod Joint)
Check seizure, corrosion, damage and excessive
15) Tighten band by using ST. play.
ST 925091000 BAND TIGHTENING TOOL 3) Shaft
NOTE: Check excessive bending, twisting, damage and
Tighten band until it cannot be moved by hand. wear.
4) BJ (Bell Joint)
Check seizure, corrosion, damage and excessive
play.
5) Boot
Check for wear, warping, breakage or scratches.
6) Grease
Check for discoloration or fluidity.
G4M0289
16) Tap on the clip with the punch provided at the

end of ST.
ST 925091000 BAND TIGHTENING TOOL
CAUTION:
Tap to an extent that the boot underneath is not
damaged.
G4M0290
17) Cut off band with an allowance of about 10

mm (0.39 in) left from the clip and bend this allow-
ance over the clip.
CAUTION:
Be careful so that the end of the band is in
close contact with clip.
18) Fix up boot on BJ in the same manner.
NOTE:
Extend and retract DOJ to provide equal grease
coating.
DS-36
墌 00.5.31/68j/3ds 墍
Drive Shaft System
NOTE:
Vibration while cruising may be caused by an unbalanced tire, improper tire inflation pressure, improper
wheel alignment, etc.
Symptom Possible cause Remedy
1. Vibration of propeller shaft (1) Worn or damaged universal joint. Replace.
NOTE: (2) Unbalanced propeller shaft due to Replace.
Vibration is caused by propeller shaft bend or dent.
during operation and is transferred to (3) Loose installation of propeller shaft. Retighten.
vehicle body. Generally vibration
(4) Worn or damaged center bearing and Replace.
increase in proportion to vehicle speed.
damaged center mounting rubber.
2. Tapping when starting and noise (1) Worn or damaged universal joint. Replace.
while cruising, caused by propeller (2) Worn spline of sleeve yoke. Replace.
shaft. (3) Loose installation of propeller shaft. Retighten.
(4) Loose installation of joint. Replace.
(5) Worn or damaged center bearing and Replace.
damaged center mounting rubber.
DS-37
Drive Shaft System
MEMO:
DS-38
GENERAL DESCRIPTION
Transfer Case
A: NOTE S302001A15
For removal, installation and inspection work, refer

to “AUTOMATIC TRANSMISSION” (a separate
publication: Pub. No. G0853ZE) or “MT” section.
TC-2
TRANSFER CASE AND EXTENSION FOR MT
Transfer Case
2. Transfer Case and Extension

for MT S302138
A: NOTE S302138A15

TC-3
墌 00.5.31/68j/3tc 墍
TRANSFER CLUTCH AND EXTENSION FOR AT
Transfer Case
3. Transfer Clutch and

Extension for AT S302142
A: NOTE S302142A15

publication: Pub. No. G0853ZE).
TC-4
OIL SEAL
Transfer Case
4. Oil Seal S302143
A: NOTE S302143A15

TC-5
TRANSFER DRIVE GEAR (MT)
Transfer Case
5. Transfer Drive Gear (MT) S302146
A: NOTE S302146A15

TC-6
墌 00.5.31/68j/3tc 墍
TRANSFER DRIVEN GEAR (MT)
Transfer Case
6. Transfer Driven Gear (MT) S302141
A: NOTE S302141A15

TC-7
墌 00.5.31/68j/3tc 墍
REDUCTION DRIVE GEAR WITHOUT VTD
Transfer Case
7. Reduction Drive Gear

without VTD S302144
A: NOTE S302144A15

publication: Pub. No. G0853ZE)
TC-8
REDUCTION DRIVE GEAR WITH VTD
Transfer Case
8. Reduction Drive Gear with

VTD S302136
A: NOTE S302136A15

TC-9
REDUCTION DRIVEN GEAR WITHOUT VTD
Transfer Case
9. Reduction Driven Gear

without VTD S302147
A: NOTE S302147A15

TC-10
REDUCTION DRIVEN GEAR WITH VTD
Transfer Case
10. Reduction Driven Gear with

VTD S302157
A: NOTE S302157A15

TC-11
CENTER DIFFERENTIAL
Transfer Case
11. Center Differential S302158
A: NOTE S302158A15

TC-12
TRANSFER CLUTCH PRESSURE TEST
Transfer Case
12. Transfer Clutch Pressure

Test S302159
A: NOTE S302159A15

TC-13
Transfer Case
13. Transfer Duty Solenoid and

Valve Body S302161
A: NOTE S302161A15

TC-14
Transfer Case
MEMO:
TC-15
Transfer Case
TC-16
Engine (DIAGNOSTICS)
1. Basic Diagnostic Procedure

S008501
1. ENGINE S008501E4501

1 CHECK ENGINE START FAILURE. Does the engine start? Go to step 2. Inspection using
1) Ask the customer when and how the “Diagnostics for
trouble occurred using the interview check list. Engine Start Fail-
<Ref. to EN(H4)-4 CHECK, Check List for ure”. <Ref. to
Interview.> EN(H4)-77 Diag-
2) Start the engine. nostics for Engine
Starting Failure.>
2 CHECK ILLUMINATION OF CHECK ENGINE Does CHECK ENGINE Go to step 3. Inspection using
MALFUNCTION INDICATOR LAMP (MIL). malfunction indicator lamp “General Diagnos-
illuminate? tics Table”. <Ref.
to EN(H4)-562
INSPECTION,
General Diagnos-
tic Table.>
3 CHECK INDICATION OF DTC ON DISPLAY. Does the Subaru Select Go to step 4. Repair the related
1) Turn ignition switch to OFF. Monitor or OBD-II general parts.
2) Connect the Subaru Select Monitor or the scan tool indicate DTC? NOTE:
OBD-II general scan tool to data link connec- If DTC is not
tor. shown on display
3) Turn ignition switch to ON and the Subaru although the MIL
Select Monitor or OBD-II general scan tool illuminates, per-
switch to ON. form diagnostics
4) Read DTC on the Subaru Select Monitor or of MIL (CHECK
OBD-II general scan tool. ENGINE malfunc-
tion indicator
lamp) circuit or
combination
meter. <Ref. to
EN(H4)-66 Engine
Malfunction Indi-
cator Lamp
(MIL).>
4 PERFORM THE DIAGNOSIS. Does the Subaru Select Inspect using Complete the
1) Inspect using “Diagnostics Procedure with Monitor or OBD-II general “Diagnostics Pro- diagnosis.
Diagnostic Trouble Code (DTC)”. scan tool indicate DTC? cedure with Diag-
NOTE: nostic Trouble
쐌 MT vehicles: <Ref. to EN(H4)-106 Diagnos- Code (DTC)”.
tic Procedure with Diagnostic Trouble Code NOTE:
(DTC) for MT Vehicles.> 쐌 MT vehicles:
쐌 AT vehicles: <Ref. to EN(H4)-310 Diagnos- <Ref. to EN(H4)-
tic Procedure with Diagnostic Trouble Code 106 Diagnostic
(DTC) for AT Vehicles.> Procedure with
NOTE: Diagnostic
Carry out the basic check, only when DTC Trouble Code
about automatic transmission is shown on (DTC) for MT
display. <Ref. to EN(H4)-59 Read Diagnostic Vehicles.>
Trouble Code.> 쐌 AT vehicles:
2) Repair the trouble cause. <Ref. to EN(H4)-
3) Perform the clear memory mode. <Ref. to 310 Diagnostic
EN(H4)-63 Clear Memory Mode.> Procedure with
4) Perform the inspection mode. <Ref. to Diagnostic
EN(H4)-60 Inspection Mode.> Trouble Code
(DTC) for AT
Vehicles.>
EN(H4)-2
2. AUTOMATIC TRANSMISSION S008501E4502
When trouble code about automatic transmission

is shown on display, carry out the following basic
check. After that, carry out the replacement or
repair work.
1) ATF level check <Ref. to AT-9 Automatic Trans-
mission Fluid.>
2) Differential gear oil level check <Ref. to AT-10
Differential Gear Oil.>
3) ATF leak check <Ref. to AT-9 Automatic Trans-
mission Fluid.>
4) Differential gear oil leak check <Ref. to AT-10
Differential Gear Oil.>
5) Stall test <Ref. to AT-12 Stall Test.>
6) Line pressure test <Ref. to AT-15 Line Pressure
Test.>
7) Transfer clutch pressure test <Ref. to AT-17
Transfer Clutch Pressure Test.>
8) Time lag test <Ref. to AT-14 Time Lag Test.>
9) Road test <Ref. to AT-11 Road Test.>
10) Shift characteristics <Ref. to AT-17 Transfer
Clutch Pressure Test.>
EN(H4)-3

Check the following items when problem has
occurred.
A: CHECK S008502A04
NOTE:
1. CHECK LIST NO. 1 S008502A0401 Use copies of this page for interviewing customers.
Customer’s name Engine no.

Date of sale Fuel brand
Date of repair Odometer reading km
Vin no. miles
Weather 쏔 Fine
쏔 Cloudy
쏔 Rainy
쏔 Snowy
쏔 Various/Others:
Outdoor temperature °F (°C)
쏔 Hot
쏔 Warm
쏔 Cool
쏔 Cold
Place 쏔 Highway
쏔 Suburbs
쏔 Inner city
쏔 Uphill
쏔 Downhill
쏔 Rough road
쏔 Others:
Engine temperature 쏔 Cold
쏔 Warming-up
쏔 After warming-up
쏔 Any temperature
쏔 Others:
Engine speed rpm
Vehicle speed MPH
Driving conditions 쏔 Not affected
쏔 At starting
쏔 While idling
쏔 At racing
쏔 While accelerating
쏔 While cruising
쏔 While decelerating
쏔 While turning (RH/LH)
Headlight 쏔 ON/쏔 OFF Rear defogger 쏔 ON/쏔 OFF
Blower 쏔 ON/쏔 OFF Radio 쏔 ON/쏔 OFF
A/C compressor 쏔 ON/쏔 OFF CD/Cassette 쏔 ON/쏔 OFF
Cooling fan 쏔 ON/쏔 OFF Car phone 쏔 ON/쏔 OFF
Front wiper 쏔 ON/쏔 OFF CB 쏔 ON/쏔 OFF
Rear wiper 쏔 ON/쏔 OFF
EN(H4)-4
2. CHECK LIST NO. 2 S008502A0402 NOTE:

Use copies of this page for interviewing customers.
Check the following items about the vehicle’s state
when MIL turns on.
a) Other warning lights or indicators turn on. 쏔 Yes/쏔 No

쏔 Low fuel warning light
쏔 Charge indicator light
쏔 AT diagnostics indicator light
쏔 ABS warning light
쏔 VDC warning light
쏔 Engine oil pressure warning light
b) Fuel level
쐌 Lack of gasoline: 쏔 Yes/쏔 No
쐌 Indicator position of fuel gauge:
c) Intentional connecting or disconnecting of harness connectors or spark plug cords: 쏔 Yes/쏔 No
쐌 What:
d) Intentional connecting or disconnecting of hoses: 쏔 Yes/쏔 No
쐌 What:
e) Installing of parts other than genuine parts: 쏔 Yes/쏔 No
쐌 What:
쐌 Where:
f) Occurrence of noise: 쏔 Yes/쏔 No
쐌 From where:
쐌 What kind:
g) Occurrence of smell: 쏔 Yes/쏔 No
쐌 From where:
쐌 What kind:
h) Intrusion of water into engine compartment or passenger compartment: 쏔 Yes/쏔 No
i) Troubles occurred
쏔 Engine does not start.
쏔 Engine stalls during idling.
쏔 Engine stalls while driving.
쏔 Engine speed decreases.
쏔 Engine speed does not decrease.
쏔 Rough idling
쏔 Poor acceleration
쏔 Back fire
쏔 After fire
쏔 No shift
쏔 Excessive shift shock
EN(H4)-5
GENERAL DESCRIPTION

8) Use ECM mounting stud bolts at the body head
grounding point when measuring voltage and
A: CAUTION S008001A03 resistance inside the passenger compartment.
1) Airbag system wiring harness is routed near the
engine control module (ECM), main relay and fuel
pump relay.
CAUTION:
cal test equipment on these circuit.
ing harness when servicing the engine control
module (ECM), transmission control module H2M1154A
(TCM), main relay and fuel pump relay.
9) Use engine grounding terminal or engine
2) Never connect the battery in reverse polarity.
proper as the grounding point to the body when
쐌 The ECM will be destroyed instantly.
measuring voltage and resistance in the engine
쐌 The fuel injector and other part will be damaged
compartment.
in just a few minutes more.
3) Do not disconnect the battery terminals while
the engine is running.
쐌 A large counter electromotive force will be gen-
erated in the alternator, and this voltage may dam-
age electronic parts such as ECM, etc.
4) Before disconnecting the connectors of each
sensor and the ECM, be sure to turn OFF the igni-
tion switch.
5) Poor contact has been identified as a primary
cause of this problem. To measure the voltage
B2M2779
and/or resistance of individual sensors or all elec-
trical control modules at the harness side 10) Use TCM mounting stud bolts at the body
connector, use a tapered pin with a diameter of head grounding point when measuring voltage and
less than 0.64 mm (0.025 in). Do not insert the pin resistance inside the passenger compartment.
more than 5 mm (0.20 in) into the part.
6) Before removing ECM from the located
position, disconnect two cables on battery.
쐌 Otherwise, the ECM may be damaged.
CAUTION:
When replacing ECM, be careful not to use the
wrong spec. ECM to avoid any damage on fuel
injection system.
7) The connectors to each sensor in the engine
compartment and the harness connectors on the B3M1666E
engine side and body side are all designed to be
waterproof. However, it is still necessary to take 11) Every MFI-related part is a precision part. Do
care not to allow water to get into the connectors not drop them.
when washing the vehicle, or when servicing the 12) Observe the following cautions when installing
vehicle on a rainy day. a radio in MFI equipped models.
CAUTION:
쐌 The antenna must be kept as far apart as
possible from the control unit.
(The ECM is located under the steering column,
inside of the instrument panel lower trim
panel.)
EN(H4)-6
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GENERAL DESCRIPTION
쐌 The antenna feeder must be placed as far 2. ENGINE GROUNDING S008001A1002
apart as possible from the ECM and MFI har-

ness. Make sure the engine grounding terminal is prop-
쐌 Carefully adjust the antenna for correct erly connected to the engine.
matching.
쐌 When mounting a large power type radio,
pay special attention to the three items above
mentioned.
쐌 Incorrect installation of the radio may affect
the operation of the ECM.
13) Before disconnecting the fuel hose, discon-
nect the fuel pump connector and crank the engine
for more than five seconds to release pressure in
the fuel system. If engine starts during this
B2M2779
operation, run it until it stops.
14) Problems in the electronic-controlled auto-
matic transmission may be caused by failure of the C: NOTE S008001A15
engine, the electronic control system, the transmis-
sion proper, or by a combination of these. These 1. DESCRIPTION S008001A1501
three causes must be distinguished clearly when

쐌 The on-board diagnostics (OBD) system detects
performing diagnostics.
and indicates a fault in various inputs and outputs
15) Diagnostics should be conducted by rotating
with simple, easy operations and proceeding to of the complex electronic control. CHECK ENGINE
complicated, difficult operations. The most impor- malfunction indicator lamp (MIL) in the combina-
tant thing in diagnostics is to understand the cus- tion meter indicates occurrence of a fault or
tomer’s complaint, and distinguish between the trouble.
three causes. 쐌 Further, against such a failure or sensors as
16) In AT vehicles, do not continue the stall for may disable the drive, the fail-safe function is pro-
more than five seconds at a time (from closed vided to ensure the minimal driveability.
throttle, fully open throttle to stall engine speed). 쐌 The OBD system incorporated with the vehicles
17) On ABS vehicle, when performing driving test within this engine family complies with Section
in jacked-up or lifted-up position, sometimes the 1968.1, California Code of Regulations (OBD-II
warning light may be lit, but this is not a malfunc- regulation). The OBD system monitors the compo-
tion of the system. The reason for this is the speed nents and the system malfunction listed in Engine
difference between the front and rear wheels. After Section which affects on emissions.
diagnosis of engine control system, perform the 쐌 When the system decides that a malfunction
ABS memory clearance procedure of self-diagno- occurs, MIL illuminates. At the same time of the
sis system. MIL illumination or blinking, a diagnostic trouble
code (DTC) and a freeze frame engine conditions
are stored into on-board computer.
쐌 The OBD system stores freeze frame engine
Before performing diagnostics, check the following condition data (engine load, engine coolant
items which might affect engine problems: temperature, fuel trim, engine speed and vehicle
speed, etc.) into on-board computer when it
1. BATTERY S008001A1001
detects a malfunction first.
1) Measure battery voltage and specific gravity of 쐌 If the OBD system detects the various malfunc-
electrolyte. tions including the fault of fuel trim or misfire, the
Standard voltage: 12 V OBD system first stores freeze frame engine con-
ditions about the fuel trim or misfire.
Specific gravity: Above 1.260 쐌 When the malfunction does not occur again for
2) Check the condition of the main and other three consecutive driving cycles, MIL is turned off,
fuses, and harnesses and connectors. Also check but DTC remains at on-board computer.
for proper grounding. 쐌 The OBD-II system is capable of communication
with a general scan tool (OBD-II general scan tool)
formed by ISO 9141 CARB.
쐌 The OBD-II diagnostics procedure is different
from the usual diagnostics procedure. When
troubleshooting OBD-II vehicles, connect Subaru
EN(H4)-7
墌 00.5.31/68j/0en4 墍
GENERAL DESCRIPTION
Select Monitor or the OBD-II general scan tool to 쐌 Reduced emission of harmful exhaust gases.
the vehicle. 쐌 Reduced in fuel consumption.
쐌 Increased engine output.
2. ENGINE AND EMISSION CONTROL 쐌 Superior acceleration and deceleration.
SYSTEM S008001A1502 쐌 Superior startability and warm-up perfor-
쐌 The Multipoint Fuel Injection (MFI) system is a mance in cold weather since compensation is
system that supplies the optimum air-fuel mixture made for coolant and intake air temperature.
to the engine for all the various operating condi-
tions through the use of the latest electronic tech- 3. AUTOMATIC TRANSMISSION AND
nology. ELECTRONIC-HYDRAULIC CONTROL
With this system fuel, which is pressurized at a SYSTEM S008001A1503
constant pressure, is injected into the intake air
The electronic-hydraulic control system consists of
passage of the cylinder head. The injection quan-
tity of fuel is controlled by an intermittent injection various sensors and switches, a transmission con-
system where the electro-magnetic injection valve trol module (TCM) and the hydraulic controller
(fuel injector) opens only for a short period of time, including solenoid valves. The system controls the
depending on the quantity of air required for one transmission proper including shift control, lock-up
cycle of operation. In actual operation, the injection control, overrunning clutch control, line pressure
quantity is determined by the duration of an elec- control and shift timing control. It also controls the
tric pulse applied to the fuel injector and this per- AWD transfer clutch. In other words, the system
mits simple, yet highly precise metering of the fuel. detects various operating conditions from various
쐌 Further, all the operating conditions of the input signals and sends output signals to shift sole-
engine are converted into electric signals, and this noids 1, 2 and low clutch timing solenoid and 2-4
results in additional features of the system, such as brake timing solenoid, line pressure duty solenoid,
large improved adaptability, easier addition of com- lock-up duty solenoid, transfer duty solenoid and
pensating element, etc. 2-4 brake duty solenoid (a total of eight solenoids).
The MFI system also has the following features:

24082AA150 CARTRIDGE Troubleshooting for electrical
systems.
B2M3876
22771AA030 SELECT MONITOR KIT Troubleshooting for electrical
systems.
쐌 English: 22771AA030
(Without printer)
쐌 German: 22771AA070
(Without printer)
쐌 French: 22771AA080
(Without printer)
쐌 Spanish: 22771AA090
(Without printer)
B2M3877
EN(H4)-8
墌 00.5.31/68j/0en4 墍
GENERAL DESCRIPTION
MEMO:
EN(H4)-9
墌 00.5.31/68j/0en4 墍
4. Electrical Components
Location S008507
1. ENGINE (MT VEHICLES) S008507A1303
쐌 MODULE S008507A130301
B2M3717A
(1) Engine control module (ECM) (3) Test mode connector

(2) Data link connector (for Subaru (4) CHECK ENGINE malfunction
Select Monitor and OBD-II gen- indicator lamp (MIL)
eral scan tool)
EN(H4)-10
B3M1575A B2M2960E
B2M2238D B2M3701A
EN(H4)-11
쐌 SENSOR S008507A130302
B2M3441A
(1) Engine coolant temperature sen- (3) Throttle position sensor (6) Camshaft position sensor
sor (4) Intake manifold pressure sensor (7) Crankshaft position sensor
(2) Intake air temperature sensor (5) Knock sensor
EN(H4)-12
S2M1248A B2M2250A
B2M2251A B2M3702A
B2M2241A B2M2242A
B2M0213J
EN(H4)-13
B2M3703A
(1) Front oxygen (A/F) sensor (3) Front catalytic converter

(2) Rear oxygen sensor (4) Rear catalytic converter
B2M2253A OBD0019I
OBD0524G OBD0525G
EN(H4)-14
B2M3717B
(1) Fuel level sensor (3) Fuel tank pressure sensor

(2) Fuel temperature sensor (4) Fuel sub level sensor
B2M3704A B2M3705A
B2M3820A B2M3706A
EN(H4)-15
쐌 SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM

PARTS S008507A130303
B2M3441B
(1) Purge control solenoid valve (2) Ignition coil & ignitor ASSY (3) Idle air control solenoid valve
EN(H4)-16
B2M2254A B2M2255A
B2M2256B
EN(H4)-17
B2M3717C
(1) Pressure control solenoid valve (3) Drain valve

(2) Canister (4) Drain filter
B2M3708A B2M1809A
B2M1810A B2M1811A
EN(H4)-18
MEMO:
EN(H4)-19
B2M3717D
(1) Fuel pump (3) Fuel pump relay (5) Radiator sub fan relay
(2) Main relay (4) Radiator main fan relay (6) Starter
EN(H4)-20
B2M3704B B2M3709A
B2M3710A B2M3711A
B2M2247D
EN(H4)-21
2. ENGINE (AT VEHICLES) S008507A1304
쐌 MODULE S008507A130401
B2M3717A
(1) Engine control module (ECM) (3) Test mode connector

(2) Data link connector (for Subaru (4) CHECK ENGINE malfunction
Select Monitor and OBD-II gen- indicator lamp (MIL)
eral scan tool)
B3M1575A B2M2960E
B2M2238D B2M3701A
EN(H4)-22
MEMO:
EN(H4)-23
쐌 SENSOR S008507A130402
B2M3427A
(1) Atmospheric pressure sensor (3) Engine coolant temperature sen- (5) Knock sensor
(2) Intake air temperature and pressor (6) Camshaft position sensor
sure sensor (4) Throttle position sensor (7) Crankshaft position sensor
EN(H4)-24
B2M3713A B2M3714A
S2M1248B B2M2240A
B2M2241A B2M2242A
B2M0213J
EN(H4)-25
B2M3703A
(1) Front oxygen (A/F) sensor (3) Front catalytic converter

(2) Rear oxygen sensor (4) Rear catalytic converter
S2M0264A OBD0019I
OBD0524G OBD0525G
EN(H4)-26
B2M3717B
(1) Fuel level sensor (3) Fuel tank pressure sensor

(2) Fuel temperature sensor (4) Fuel sub level sensor
B2M3704A B2M3705A
B2M3820A B2M3706A
EN(H4)-27
쐌 SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM

PARTS S008507A130403
B2M3427B
(1) Air assist injector solenoid valve (3) Purge control solenoid valve
(2) Idle air control solenoid valve (4) Ignition coil & ignitor ASSY
EN(H4)-28
B2M3715A H2M3259A
H2M3258B B2M3720A
EN(H4)-29
B2M3717C
(1) Pressure control solenoid valve (3) Drain valve

(2) Canister (4) Drain filter
B2M3708A B2M1809A
B2M1810A B2M1811A
EN(H4)-30
MEMO:
EN(H4)-31
B2M3717J
(1) Inhibitor switch (4) Fuel pump relay (7) Starter

(2) Fuel pump (5) Radiator main fan relay
(3) Main relay (6) Radiator sub fan relay
EN(H4)-32
B2M2246A B2M3704C
B2M3709B B2M3710B
B2M3711B B2M2247E
EN(H4)-33
3. TRANSMISSION S008507A1302
쐌 MODULE S008507A130201
B2M3717K
(1) Transmission Control Module (2) AT diagnostic indicator light (for

(TCM) (for AT vehicles) AT vehicles)
B3M1666D B2M3701B
EN(H4)-34
쐌 SENSOR S008507A130202
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(H4)-35
쐌 SOLENOID VALVE AND SWITCH (AT VEHICLES) S008507A130203
B3M1670C B2M2246B
B2M2263A B2M2264A
(1) Dropping resistor

(2) Inhibitor switch
(3) Shift solenoid valve 1
(4) Shift solenoid valve 2
(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
쐌 SOLENOID VALVE AND SWITCH (MT VEHICLES) S008507A130204
B2M2265A
(1) Neutral position switch
EN(H4)-36
MEMO:
EN(H4)-37
ENGINE CONTROL MODULE (ECM) I/O SIGNAL
5. Engine Control Module (ECM) I/O Signal S008526
1. MT VEHICLES S008526A0801
B2M2267A
Signal (V)
Connec- Termi-
Content Ignition SW ON Note
tor No. nal No. Engine ON (Idling)
(Engine OFF)
Crankshaft Signal (+) B135 1 0 −7 — +7 Sensor output waveform
position Signal (−) B135 8 0 0 —
sensor Shield B135 10 0 0 —
Camshaft Signal (+) B135 2 0 −7 — +7 Sensor output waveform
Fully closed: 0.2 — 1.0
Signal B136 17 —
Fully opened: 4.2 — 4.7
Throttle
Power sup-
position B136 15 5 5 —
ply
sensor
GND (sen-
B136 16 0 0 —
sor)
Signal B136 18 0 0 — 0.9 —
Rear oxy- Shield B136 24 0 0 —
gen sensor GND sen-
B136 16 0 0 —
sor
Front oxy- Signal 1 B134 22 0.5 — 13 0.5 — 14 Waveform
gen (A/F) Signal 2 B134 23 0.5 — 13 0.5 — 14 Waveform
sensor Power sup-
heater B136 3 10 — 13 13 — 14 —
ply monitor
Rear oxy- Signal B134 21 0.5 — 13 0.5 — 14 Waveform
gen sensor Power sup-
heater B136 3 10 — 13 13 — 14 —
ply monitor
Engine Signal B136 14 1.0 — 1.4 1.0 — 1.4 After warm-up the engine.
coolant
tempera- GND (sen-
B136 16 0 0 After warm-up the engine.
ture sensor sor)
EN(H4)-38
墌 00.5.31/68j/0en4 墍
Signal (V)
Connec- Termi-
(Engine OFF)
“5” and “0” are repeatedly dis-
Vehicle speed signal B135 24 0 or 5 0 or 5
played when vehicle is driven.
Starter switch B135 28 0 0 Cranking: 8 — 14
ON: 10 — 13 ON: 13 — 14
A/C switch B135 27 —
OFF: 0 OFF: 0
Ignition switch B135 7 10 — 13 13 — 14 —
On MT vehicle; switch is ON
ON: 12±0.5
Neutral position switch B135 26 when gear is in neutral posi-
OFF: 0
tion.
Test mode connector B135 14 5 5 When connected: 0
Knock sen- Signal B136 4 2.5 2.5 —
sor Shield B136 25 0 0 —
Back-up power supply B136 9 10 — 13 13 — 14 Ignition switch “OFF”: 10 — 13
Control unit power sup- B136 1 10 — 13 13 — 14 —
ply B136 2 10 — 13 13 — 14 —
Sensor power supply B136 15 5 5 —
Line end check 1 B135 20 0 0 —
Ignition #1, #2 B134 25 0 1 — 3.4 Waveform
control #3, #4 B134 26 0 1 — 3.4 Waveform
#1 B134 4 10 — 13 1 — 14 Waveform
Fuel injec- #2 B134 13 10 — 13 1 — 14 Waveform
tor #3 B134 14 10 — 13 1 — 14 Waveform
#4 B134 15 10 — 13 1 — 14 Waveform
Signal B134 5 — 1 — 13 Waveform
Idle air
Power sup-
control B136 2 10 — 13 13 — 14 —
ply
solenoid
valve GND
B134 8 0 0 —
(power)
ON: 0.5, or less
Fuel pump relay control B134 16 0.5, or less —
OFF: 10 — 13
ON: 0.5, or less ON: 0.5, or less
A/C relay control B134 17 —
OFF: 10 — 13 OFF: 13 — 14
Radiator fan relay 1 con- ON: 0.5, or less ON: 0.5, or less
B134 3 —
trol OFF: 10 — 13 OFF: 13 — 14
B134 12 With A/C vehicles only
trol OFF: 10 — 13 OFF: 13 — 14
Self-shutoff control B135 19 10 — 13 13 — 14 —
Malfunction indicator Light “ON”: 1, or less
B134 11 — —
lamp Light “OFF”: 10 — 14
Engine speed output B134 30 — 0 — 13, or more Waveform
Purge control solenoid ON: 1, or less ON: 1, or less
B134 2 —
valve OFF: 10 — 13 OFF: 13 — 14
Signal B136 5 3.4 — 3.6 1.2 — 1.8 —
Intake
Power sup-
manifold B136 15 5 5 —
ply
pressure
sensor GND (sen-
B136 16 0 0 —
sor)
Ambient temperature: 25°C
Fuel temperature sensor B136 26 2.5 — 3.8 2.5 — 3.8
(75°F)
Fuel level sensor B136 27 0.12 — 4.75 0.12 — 4.75 —
EN(H4)-39
墌 00.5.31/68j/0en4 墍
Signal (V)
Connec- Termi-
(Engine OFF)
The value obtained after the
Signal B136 12 2.3 — 2.7 2.3 — 2.7 fuel filler cap was removed
Fuel tank once and recapped.
pressure Power sup-
B136 15 5 5 —
sensor ply
GND (sen-
B136 16 0 0 —
sor)
Fuel tank pressure con- ON: 1, or less ON: 1, or less
B134 1 —
trol solenoid valve OFF: 10 — 13 OFF: 13 — 14
ON: 1, or less ON: 1, or less
Drain valve B134 10 —
OFF: 10 — 13 OFF: 13 — 14
ON: 0 ON: 0
Small light switch B135 18 —
OFF: 10 — 13 OFF: 13 — 14
ON: 0 ON: 0
Blower fan switch B135 5 —
OFF: 10 — 13 OFF: 13 — 14
ON: 0 ON: 0
Rear defogger switch B135 6 —
OFF: 10 — 13 OFF: 13 — 14
Front oxygen (A/F) sen-
B136 7 3.7 — 3.9 3.7 — 3.9 —
sor signal 1
B136 20 2.6 — 4.4 3.4 — 3.6 —
sor signal 2
SSM/GST communica- Less than 1 ←→ More Less than 1 ←→ More
B135 3 —
tion line than 4 than 4
Intake air temperature Intake air temperature: 25°C
B136 13 3.0 — 3.4 3.0 — 3.4
sensor (75°F)
GND (sensors) B136 16 0 0 —
GND (injectors) B134 7 0 0 —
GND (ignition system) B134 27 0 0 —
GND (power supply) B134 8 0 0 —
B136 21 0 0 —
GND (control systems)
B136 22 0 0 —
GND (oxygen sensor
B134 35 0 0 —
heater 1)
GND (oxygen sensor
B134 34 0 0 —
heater 2)
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MEMO:
EN(H4)-41
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2. AT VEHICLES S008526A0802
B2M2267A
Signal (V)
Connec- Termi-
(Engine OFF)
Crankshaft Signal (+) B135 1 0 −7 — +7 Sensor output waveform
Camshaft Signal (+) B135 2 0 −7 — +7 Sensor output waveform
Fully closed: 0.2 — 1.0
Signal B136 17 —
Fully opened: 4.2 — 4.7
Throttle
Power sup-
position B136 15 5 5 —
ply
sensor
GND (sen-
B136 16 0 0 —
sor)
Signal B136 18 0 0 — 0.9 —
Rear oxy- Shield B136 24 0 0 —
gen sensor GND (sen-
B136 16 0 0 —
sor)
Front oxy-
Signal 1 B134 22 0 — 1.0 0 — 1.0 —
gen (A/F)
sensor
Signal 2 B134 23 0 — 1.0 0 — 1.0 —
heater
Rear oxygen sensor
B134 21 0 — 1.0 0 — 1.0 —
heater signal
Engine Signal B136 14 1.0 — 1.4 1.0 — 1.4 After warm-up the engine.
coolant
tempera- GND (sen-
B136 16 0 0 After warm-up the engine.
ture sensor sor)
“5” and “0” are repeatedly dis-
Vehicle speed signal B135 24 0 or 5 0 or 5
played when vehicle is driven.
Starter switch B135 28 0 0 Cranking: 8 — 14
ON: 10 — 13 ON: 13 — 14
A/C switch B135 27 —
OFF: 0 OFF: 0
Ignition switch B135 7 10 — 13 13 — 14 —
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Signal (V)
Connec- Termi-
(Engine OFF)
ON: 0 Switch is ON when shift is in
Neutral position switch B135 26
OFF: 12±0.5 “N” or “P” position.
Test mode connector B135 14 5 5 When connected: 0
Knock sen- Signal B136 4 2.8 2.8 —
sor Shield B136 25 0 0 —
Back-up power supply B136 9 10 — 13 13 — 14 Ignition switch “OFF”: 10 — 13
Control unit power sup- B136 1 10 — 13 13 — 14 —
ply B136 2 10 — 13 13 — 14 —
Sensor power supply B136 15 5 5 —
Ignition #1, #2 B134 25 0 1 — 3.4 Waveform
control #3, #4 B134 26 0 1 — 3.4 Waveform
#1 B134 4 10 — 13 1 — 14 Waveform
Fuel injec- #2 B134 13 10 — 13 1 — 14 Waveform
tor #3 B134 14 10 — 13 1 — 14 Waveform
#4 B134 15 10 — 13 1 — 14 Waveform
Signal 1 B134 5 — 1 — 13 Waveform
Idle air Signal 2 B134 6 — 1 — 13 Waveform
control Signal 3 B134 19 — 1 — 13 Waveform
solenoid Signal 4 B134 20 — 1 — 13 Waveform
valve Power sup-
B136 2 10 — 13 13 — 14 —
ply
ON: 0.5, or less
Fuel pump relay control B134 16 0.5, or less —
OFF: 10 — 13
ON: 0.5, or less ON: 0.5, or less
A/C relay control B134 17 —
OFF: 10 — 13 OFF: 13 — 14
B134 3 —
trol OFF: 10 — 13 OFF: 13 — 14
B134 2 With A/C vehicles only
trol OFF: 10 — 13 OFF: 13 — 14
Self-shutoff control B135 19 10 — 13 13 — 14 —
Malfunction indicator Light “ON”: 1, or less
B134 11 — —
lamp Light “OFF”: 10 — 14
Engine speed output B134 30 — 0 — 13, or more Waveform
Torque control 1 signal B135 16 5 5 —
Torque control 2 signal B135 17 5 5 —
Torque control cut signal B134 31 8 8 —
Purge control solenoid ON: 1, or less ON: 1, or less
B134 2 —
valve OFF: 10 — 13 OFF: 13 — 14
Signal B136 29 3.9 — 4.1 2.0 — 2.3
Atmo-
Power sup-
spheric B136 15 5 5
ply —
pressure
sensor GND (sen-
B136 16 0 0
sor)
Ambient temperature: 25°C
Fuel temperature sensor B136 26 2.5 — 3.8 2.5 — 3.8
(75°F)
Fuel level sensor B136 27 0.12 — 4.75 0.12 — 4.75 —
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Signal (V)
Connec- Termi-
(Engine OFF)
The value obtained after the
Signal B136 12 2.3 — 2.7 2.3 — 2.7 fuel filler cap was removed
Fuel tank once and recapped.
pressure Power sup-
B136 15 5 5 —
sensor ply
GND (sen-
B136 16 0 0 —
sor)
Fuel tank pressure con- ON: 1, or less ON: 1, or less
B134 1 —
trol solenoid valve OFF: 10 — 13 OFF: 13 — 14
ON: 1, or less ON: 1, or less
Drain valve B134 10 —
OFF: 10 — 13 OFF: 13 — 14
Less than 1 ←→ More Less than 1 ←→ More
AT diagnosis input signal B135 4 Waveform
than 4 than 4
ON: 0 ON: 0
Small light switch B136 3 —
OFF: 10 — 13 OFF: 13 — 14
ON: 0 ON: 0
Blower fan switch B136 30 —
OFF: 10 — 13 OFF: 13 — 14
ON: 0 ON: 0
Rear defogger switch B135 21 —
OFF: 10 — 13 OFF: 13 — 14
B136 19 2.8 — 3.2 2.8 — 3.2 —
sor signal 1
B136 6 2.4 — 2.7 2.4 — 2.7 —
sor signal 2
B136 7 0.2 — 4.9 0.2 — 4.9 —
sor signal 3
B136 20 0.2 — 4.9 0.2 — 4.9 —
sor signal 4
Pressure sensor B136 5 2.4 — 4.8 0.4 — 1.8 —
Intake air temperature
B136 13 2.3 — 2.5 1.4 — 1.6 —
sensor
SSM/GST communica- Less than 1 ←→ More Less than 1 ←→ More
B135 3 —
tion line than 4 than 4
GND (sensors) B136 16 0 0 —
GND (injectors) B134 7 0 0 —
GND (ignition system) B134 27 0 0 —
GND (power supply) B134 8 0 0 —
B136 21 0 0 —
GND (control systems)
B136 22 0 0 —
GND (oxygen sensor
B134 35 0 0 —
heater 1)
GND (oxygen sensor
B134 34 0 0 —
heater 2)
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ENGINE CONDITION DATA
6. Engine Condition Data S008530
A: ELECTRICAL SPECIFICATION
S008530A08
Content Specified data

1.6 — 2.9 (%): Idling
Engine load
6.4 — 12.8 (%): 2,500 rpm racing
Measuring condition:
쐌 After warm-up the engine.
쐌 Gear position is in “N” or “P” position.
쐌 A/C is turned OFF.
쐌 All accessory switches are turned OFF.
EN(H4)-45
TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL
7. Transmission Control Module (TCM) I/O Signal S008506
B2M2269A
NOTE:
Check with ignition switch ON.
Connector Terminal
Content Measuring conditions Voltage (V)
No. No.
Back-up power supply B55 6 Ignition switch OFF 10 — 16
B54 23
Ignition power supply Ignition switch ON (with engine OFF) 10 — 16
B54 24
Selector lever in “P” range Less than 1
“P” range
B55 23 Selector lever in any other than “P”
switch More than 8
range
Selector lever in “N” range Less than 1
“N” range
B55 22 Selector lever in any other than “N”
switch More than 8
range
Selector lever in “R” range Less than 1
“R” range
B55 17 Selector lever in any other than “R”
switch More than 9.5
range
Inhibitor switch
Selector lever in “D” range Less than 1
“D” range
B55 8 Selector lever in any other than “D”
switch More than 9.5
range
“3” range Selector lever in “3” range Less than 1
B55 18
switch Selector lever in any other than “3” range More than 9.5
B54 10
B54 1
Brake pedal depressed More than 10.5
Brake switch B55 24
Brake pedal released Less than 1
ABS switch ON Less than 1
ABS signal B54 19
ABS switch OFF More than 6.5
EN(H4)-46
Resistance to
Connector Terminal
Content Measuring conditions Voltage (V) body
No. No.
(ohms)
Throttle position Throttle fully closed. 0.3 — 0.7
B55 1 —
sensor Throttle fully open. 4.3 — 4.9
Throttle position
Ignition switch ON (with
sensor power B55 2 4.8 — 5.3 —
engine OFF)
supply
ATF temperature 20°C (68°F) 2.9 — 4.0 2.1 k — 2.9 k
ATF temperature
B55 11 ATF temperature 80°C
sensor 1.0 — 1.4 275 — 375
(176°F)
Vehicle stopped. 0
Rear vehicle
B55 3 Vehicle speed at least 20 450 — 650
speed sensor More than 1 (AC range)
km/h (12 MPH)
Front vehicle Vehicle speed at most 10
B55 5 Less than 1←→More than 4 —
speed sensor km/h (6 MPH)
Torque converter Vehicle stopped. 0
turbine speed B55 12 Vehicle speed at least 20 450 — 650
More than 1 (AC range)
sensor km/h (12 MPH)
Vehicle speed Vehicle speed at most 10
B55 13 Less than 1←→More than 4 —
output signal km/h (6 MPH)
Ignition switch ON (with
More than 10.5
Engine speed engine OFF).
B55 4 —
signal Ignition switch ON (with
8 — 11
engine ON).
When cruise control is set
Less than 1
(SET lamp ON).
Cruise set signal B54 11 —
When cruise control is not set
More than 6.5
(SET lamp OFF).
Torque control 1 Ignition switch ON
B54 13 More than 9 —
signal (with engine ON)
Torque control 2 Ignition switch ON
B54 21 More than 9 —
signal (with engine ON)
Torque control
B54 2 Ignition switch ON 8 —
cut signal
AT load signal B55 20 Engine idling after warm-up 1.2 — 1.8 —
1st or 4th gear More than 9
Shift solenoid 1 B54 7 10 — 16
2nd or 3rd gear Less than 1
1st or 2nd gear More than 9
Shift solenoid 2 B54 6 10 — 16
3rd or 4th gear Less than 1
Throttle fully closed (with
1.5 — 4.0
Line pressure engine OFF) after warm-up.
B54 9 2.0 — 4.5
duty solenoid Throttle fully open (with
Less than 0.5
engine OFF) after warm-up.
More than 8.5
Dropping resistor B54 18 9 — 15
Throttle fully open (with
Less than 0.5
Lock-up duty When lock up occurs. More than 8.5
B54 16 10 — 17
solenoid When lock up is released. Less than 0.5
Fuse on FWD switch More than 8.5
Transfer duty Fuse removed from FWD
B54 15 switch (with throttle fully open 10 — 17
solenoid Less than 0.5
and with select lever in 1st
gear).
EN(H4)-47
Resistance to
Connector Terminal
Content Measuring conditions Voltage (V) body
No. No.
(ohms)
1.5 — 4.0
2-4 brake duty engine OFF) after warm-up.
B54 8 2.0 — 4.5
solenoid Throttle fully open (with
Less than 0.5
More than 8.5
2-4 brake duty engine OFF) after warm-up.
B54 17 9 — 15
solenoid resistor Throttle fully open (with
Less than 0.5
2-4 brake timing 3rd gear More than 9
B54 5 10 — 16
solenoid 1st gear Less than 1
Low clutch timing 2nd gear Less than 1
B54 14 10 — 16
solenoid 4th gear More than 9
Sensor ground
B55 10 — 0 Less than 1
line 1
Sensor ground
B55 21 — 0 Less than 1
line 2
System ground 9
B55 — 0 Less than 1
line 19
Fuse removed. 6 — 9.1
FWD switch B55 14 —
Fuse installed. Less than 1
Fuse on FWD switch Less than 1
FWD indicator
B54 12 Fuse removed from FWD —
lamp More than 9
switch.
Data link signal 7 — —
(Subaru Select B55 —
Monitor) 16 — —
AT diagnosis sig-
B54 4 Ignition switch ON Less than 1 ←→ More than 4 —
nal
EN(H4)-48
DATA LINK CONNECTOR
A: NOTE S008505A15
1) This connector is used both for OBD-II general scan tools and the Subaru Select Monitor.
2) Terminal No. 4 to No. 6 of the data link connector is used for the Subaru Select Monitor signal.
CAUTION:
Do not connect any scan tools other than the OBD-II general scan tools and the Subaru Select
Monitor, because the circuit for the Subaru Select Monitor may be damaged.
H2M1280
Terminal No. Contents Terminal No. Contents

1 Power supply 9 Blank
2 Blank 10 K line of ISO 9141 CARB
3 Blank 11 Blank
Subaru Select Monitor signal (ECM to
4 12 Ground
Subaru Select Monitor)*
Subaru Select Monitor signal (Subaru Select
5 13 Ground
Monitor to ECM)*
6 Line end check signal 1 14 Blank
7 Blank 15 Blank
8 Line end check signal 2 (MT vehicles) 16 Blank
*: Circuit only for Subaru Select Monitor
EN(H4)-49
OBD-II GENERAL SCAN TOOL
9. OBD-II General Scan Tool S008527

3) Using the OBD-II general scan tool, call up
diagnostic trouble code(s) and freeze frame data.
A: OPERATION S008527A16 OBD-II general scan tool functions consist of:
1. HOW TO USE OBD-II GENERAL SCAN (1) MODE $01: Current powertrain diagnostic
data
TOOL S008527A1601
(2) MODE $02: Powertrain freeze frame data
1) Prepare a general scan tool (OBD-II general (3) MODE $03: Emission-related powertrain
scan tool) required by SAE J1978. diagnostic trouble codes
2) Open the cover and connect the OBD-II general (4) MODE $04: Clear/Reset emission-related
scan tool to the data link connector located in the diagnostic information
lower portion of the instrument panel (on the driv- Read out data according to repair procedures. (For
er’s side). detailed operation procedures, refer to the OBD-II
General Scan Tool Operation Manual.)
NOTE:
For details concerning diagnostic trouble codes,
refer to the List of Diagnostic Trouble Code (DTC).
쐌 MT vehicles: <Ref. to EN(H4)-99 List of Diag-
nostic Trouble Code (DTC) for MT Vehicles.>
쐌 AT vehicles: <Ref. to EN(H4)-301 List of Diag-
nostic Trouble Code (DTC) for AT Vehicles.>
B2M2960B
2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA) S008527A1602
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 Data Unit of measure
01 Number of emission-related powertrain trouble codes and MIL status ON/OFF
03 Fuel system control status —
04 Calculated engine load value %
05 Engine coolant temperature °C
06 Short term fuel trim %
07 Long term fuel trim %
0B Intake manifold absolute pressure kPa
0C Engine revolution rpm
0D Vehicle speed km/h
0E Ignition timing advance °
10 Air flow rate from pressure sensor g/sec
11 Throttle valve opening angle %
13 Check whether oxygen sensor is installed. —
Oxygen sensor output voltage and short term fuel trim associated with oxygen
14 V and %
sensor—bank 1
Oxygen sensor output voltage and short term fuel trim associated with oxygen
15 V and %
sensor—bank 2
1C On-board diagnosis system —
NOTE:
Refer to OBD-II general scan tool manufacturer’s instruction manual to access generic OBD-II PIDs (MODE
$01).
EN(H4)-50
OBD-II GENERAL SCAN TOOL
3. MODE $02 (POWERTRAIN FREEZE FRAME DATA) S008527A1603
Refers to data denoting the operating condition when trouble is sensed by the on-board diagnosis system.
A list of the support data and PID (Parameter Identification) codes are shown in the following table.
PID Data Unit of measure
02 Trouble code that caused CARB required freeze frame data storage —
03 Fuel system control status —
04 Calculated engine load value %
05 Engine coolant temperature °C
06 Short term fuel trim %
07 Long term fuel trim %
0B Intake manifold absolute pressure kPa
0C Engine revolution rpm
0D Vehicle speed 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) S008527A1604
Refer to Read Diagnostic Trouble Code for information about data denoting emission-related powertrain
diagnostic trouble codes. <Ref. to EN(H4)-59 Read Diagnostic Trouble Code.>
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION) S008527A1605
Refers to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnos-
tic information).
NOTE:
Refer to OBD-II general scan tool manufacturer’s instruction manual to clear or reset emission-related
diagnostic information (MODE $04).
EN(H4)-51

CAUTION:
Do not connect scan tools except for Subaru
A: OPERATION S008503A16 Select Monitor and OBD-II general scan tool.
1. HOW TO USE SUBARU SELECT 5) Turn ignition switch to ON (engine OFF) and
MONITOR S008503A1601 Subaru Select Monitor switch to ON.
1) Prepare Subaru Select Monitor kit. <Ref. to
EN(H4)-8 PREPARATION TOOL, General
Description.>
S2M0288A
6) Using Subaru Select Monitor, call up diagnostic

trouble code(s) and various data, then record
S2M0285
them.
2) Connect diagnosis cable to Subaru Select 2. READ DIAGNOSTIC TROUBLE CODE

Monitor. (DTC) FOR ENGINE. (NORMAL MODE)
S008503A1610
3) Insert cartridge into Subaru Select Monitor.
<Ref. to EN(H4)-8 PREPARATION TOOL, General Refer to Read Diagnostic Trouble Code for infor-
Description.> mation about how to indicate DTC. <Ref. to
EN(H4)-59 Read Diagnostic Trouble Code.>
(DTC) FOR ENGINE. (OBD MODE) S008503A1611
Refer to Read Diagnostic Trouble Code for infor-
mation about how to indicate DTC. <Ref. to
EN(H4)-59 Read Diagnostic Trouble Code.>
S2M0286A
4) Connect Subaru Select Monitor to data link

connector.
(1) Data link connector located in the lower por-
tion of the instrument panel (on the driver’s
side).
B2M2960B

nector.
EN(H4)-52
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4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE) S008503A1604
1) On the ⰆMain MenuⰇ display screen, select the {Each System Check} and press the [YES] key.
2) On the ⰆSystem Selection MenuⰇ display screen, select the {Engine Control System} and press the
[YES] key.
3) Press the [YES] key after displayed the information of engine type.
4) On the ⰆEngine DiagnosisⰇ display screen, select the {Current Data Display & Save} and press the
[YES] key.
5) On the ⰆData Display MenuⰇ display screen, select the {Data Display} and press the [YES] key.
Contents Display Unit of measure
Battery voltage Battery Voltage V
Vehicle speed signal Vehicle Speed km/h or MPH
Engine speed signal Engine Speed rpm
Engine coolant temperature signal Coolant Temp. °C or °F
Ignition timing signal Ignition Timing deg
Throttle position signal Throttle Opening Angle %
Throttle position signal Throttle Sensor Voltage V
Injection pulse width Fuel Injection #1 Pulse ms
Idle air control signal*2 ISC Valve Duty Ratio %
Idle air control signal*1 ISC Valve Step STEP
Engine load data Engine Load %
Front oxygen (A/F) sensor output signal A/F Sensor #1 —
Front oxygen (A/F) sensor resistance A/F Sensor #1 Resistance Ω
Rear oxygen sensor output signal Rear O2 Sensor V
Short term fuel trim A/F Correction #1 %
Knock sensor signal Knocking Correction deg
mmHg or kPa or inHg or
Atmospheric absolute pressure signal Atmosphere Pressure
psi
Intake manifold relative pressure signal Mani. Relative Pressure
psi
Intake manifold absolute pressure signal Mani. Absolute Pressure
psi
A/F correction (short term fuel trim) by rear oxygen sensor A/F Correction #3 %
Long term whole fuel trim A/F Learning #1 %
Front oxygen (A/F) sensor heater current A/F Heater #1 A
Rear oxygen sensor heater voltage Rear O2 Heater Voltage V
Canister purge control solenoid valve duty ratio CPC Valve Duty Ratio %
Fuel tank pressure signal Fuel Tank Pressure
psi
Fuel temperature signal Fuel Temp. °C or °F
Fuel level signal Fuel Level V
Intake air temperature signal Intake Air Temp. °C or °F
Learned ignition timing Learned Ignition Timing V
Ignition switch signal Ignition Switch ON or OFF
Test mode connector signal Test Mode Signal ON or OFF
Neutral position switch signal Neutral Position Switch ON or OFF
Air conditioning switch signal A/C Switch ON or OFF
Air conditioning relay signal A/C Relay ON or OFF
Radiator main fan relay signal Radiator Fan Relay #1 ON or OFF
Fuel pump relay signal Fuel Pump Relay ON or OFF
Knocking signal Knocking Signal ON or OFF
Radiator sub fan relay signal Radiator Fan Relay #2 ON or OFF
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Engine torque control signal #1 Torque Control Signal #1 ON or OFF
Engine torque control permission signal Torque Control Permit ON or OFF
Rear oxygen sensor rich signal Rear O2 Rich Signal ON or OFF
Pressure control solenoid valve PCV Solenoid Valve ON or OFF
Drain valve Vent. Solenoid Valve ON or OFF
Starter switch signal Starter Switch Signal ON or OFF
Idle switch signal Idle Switch Signal ON or OFF
Crankshaft position sensor signal Crankshaft Position Sig. ON or OFF
Camshaft position sensor signal Camshaft Position Sig. ON or OFF
Rear defogger switch signal Rear Defogger Switch ON or OFF
Blower fan switch signal Blower Fan Switch ON or OFF
Small light switch signal Small Light Switch ON or OFF
Air assist injector solenoid valve signal AAI Solenoid Valve ON or OFF
*1: AT vehicles
*2: MT vehicles
NOTE:
5. READ CURRENT DATA FOR ENGINE. (OBD MODE) S008503A1605
[YES] key.
4) On the ⰆEngine DiagnosisⰇ display screen, select the {OBD System} and press the [YES] key.
5) On the ⰆOBD MenuⰇ display screen, select the {Current Data Display & Save} and press the [YES]
key.
EN(H4)-54
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Number of diagnosis code Number of Diagnosis Code —
Malfunction indicator lamp status MIL Status ON or OFF
Monitoring test of misfire Misfire monitoring ON or OFF
Monitoring test of fuel system Fuel system monitoring ON or OFF
Monitoring test of comprehensive component Component monitoring ON or OFF
Test of catalyst Catalyst Diagnosis ON or OFF
Test of heated catalyst Heated catalyst ON or OFF
Test of evaporative emission purge control system Evaporative purge system ON or OFF
Test of secondary air system Secondary air system ON or OFF
Test of air conditioning system refrigerant A/C system refrigerant ON or OFF
Test of oxygen sensor Oxygen sensor ON or OFF
Test of oxygen sensor heater Oxygen sensor heater ON or OFF
Air fuel ratio control system for bank 1 Fuel System for Bank 1 ON or OFF
Short term fuel trim by front oxygen (A/F) sensor Short term fuel trim B1 %
Long term fuel trim by front oxygen (A/F) sensor Long term fuel trim B1 %
psi
Ignition timing advance for #1 cylinder Ignition timing adv. #1 °
Intake air temperature signal Intake Air Temp. °C or °F
Throttle position signal Throttle Opening Angle %
A/F sensor equipment A/F sensor ON or OFF
Rear oxygen sensor output signal Oxygen Sensor #12 V
Air fuel ratio correction by rear oxygen sensor Short term fuel trim #12 %
On-board diagnostic system OBD System —
NOTE:
6. READ FREEZE FRAME DATA FOR ENGINE. (OBD MODE) S008503A1606
[YES] key.
5) On the ⰆOBD MenuⰇ display screen, select the {Freeze Frame Data} and press the [YES] key.
Diagnostic trouble code (DTC) for freeze frame data Freeze frame data DTC
Air fuel ratio control system for bank 1 Fuel system for Bank1 ON or OFF
Short term fuel trim by front oxygen (A/F) sensor Short term fuel trim B1 %
Long term fuel trim by front oxygen (A/F) sensor Long term fuel trim B1 %
psi
NOTE:
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7. READ OXYGEN SENSOR MONITORING TEST RESULTS DATA FOR ENGINE. (OBD
MODE) S008503A1607
[YES] key.
5) On the ⰆOBD MenuⰇ display screen, select the {O2 Sensor Monitor} and press the [YES] key.
6) On the ⰆO2 Sensor SelectⰇ display screen, select the {Bank 1-Sensor1} or {Bank 1-Sensor2} and press
the [YES] key.
쐌 Bank 1-Sensor1 indicates the front oxygen or A/F sensor, and Bank 1-Sensor2 indicates the rear oxy-
gen sensor.
Oxygen sensor for monitoring test <O2 Sensor Monitor (-------)> —
Rich to lean oxygen sensor threshold voltage Rich to lean sensor volt V
Lean to rich oxygen sensor threshold voltage Lean to rich sensor volt V
Low oxygen sensor voltage for switch time calculation Low sensor voltage V
High oxygen sensor voltage for switch time calculation High sensor voltage V
Rich to lean oxygen sensor switch time Rich to lean switch time sec
Lean to rich oxygen sensor switch time Lean to rich switch time sec
Maximum oxygen sensor voltage for test cycle Maximum sensor Voltage V
Minimum oxygen sensor voltage for test cycle Minimum sensor Voltage V
NOTE:
8. LED OPERATION MODE FOR ENGINE S008503A1608
[YES] key.
4) On the ⰆEngine DiagnosisⰇ display screen, select the {Current Data Display & Save} and press the
[YES] key.
5) On the ⰆData Display MenuⰇ display screen, select the {Data & LED Display} and press the [YES] key.
EN(H4)-56
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Contents Display Message LED “ON” requirements

Ignition switch signal Ignition Switch ON or OFF When ignition switch is turned ON.
Test mode connector signal Test Mode Signal ON or OFF When test mode connector is connected.
Neutral position switch signal Neutral Position Switch ON or OFF When neutral position signal is entered.
Air conditioning switch signal A/C Switch ON or OFF When air conditioning switch is turned ON.
Air conditioning relay signal A/C Relay ON or OFF When air conditioning relay is in function.
Radiator main fan relay signal Radiator Fan Relay #1 ON or OFF When radiator main fan relay is in function.
Fuel pump relay signal Fuel Pump Relay ON or OFF When fuel pump relay is in function.
Knocking signal Knocking Signal ON or OFF When knocking signal is entered.
Radiator sub fan relay signal Radiator Fan Relay #2 ON or OFF When radiator sub fan relay is in function.
When engine torque control signal 1 is
entered.
When engine torque control signal 2 is
entered.
Engine torque control permission When engine torque control permission sig-
Torque Control Permit ON or OFF
signal nal is entered.
Front oxygen (A/F) sensor rich When front oxygen (A/F) sensor mixture
Front O2 Rich Signal #1 ON or OFF
signal ratio is rich.
When rear oxygen sensor mixture ratio is
Rear oxygen sensor rich signal Rear O2 Rich Signal ON or OFF
rich.
When pressure control solenoid valve is in
Pressure control solenoid valve PCV Solenoid Valve ON or OFF
function.
Drain valve Vent. Solenoid Valve ON or OFF When drain valve is in function.
Starter switch signal Starter Switch Signal ON or OFF When starter switch signal is entered.
Idle switch signal Idle Switch Signal ON or OFF When idle switch signal is entered.
When crankshaft position sensor signal is
Crankshaft position sensor signal Crankshaft Position Sig. ON or OFF
entered.
When camshaft position sensor signal is
Camshaft position sensor signal Camshaft Position Sig. ON or OFF
entered.
NOTE:
9. READ CURRENT DATA FOR AT. S008503A1612
2) On the ⰆSystem Selection MenuⰇ display screen, select the {Transmission Control System} and press
the [YES] key.
3) Press the [YES] key after displayed the information of transmission type.
4) On the ⰆTransmission DiagnosisⰇ display screen, select the {Current Data Display & Save} and press
the [YES] key.
EN(H4)-57
墌 00.5.31/68j/0en4 墍

Battery voltage Battery Voltage V
Rear vehicle speed sensor signal Vehicle Speed #1 km/h or MPH
Front vehicle speed sensor signal Vehicle Speed #2 km/h or MPH
Automatic transmission fluid temperature signal ATF Temp. °C or °F
Throttle position signal Throttle Sensor Voltage V
Gear position Gear Position —
Line pressure control duty ratio Line Pressure Duty Ratio %
Lock up clutch control duty ratio Lock Up Duty Ratio %
Transfer clutch control duty ratio Transfer Duty Ratio %
Power supply for throttle position sensor Throttle Sensor Power V
Torque converter turbine speed signal AT Turbine Speed rpm
2-4 brake timing pressure control duty ratio 2-4B Duty Ratio %
Intake manifold pressure sensor voltage Mani. Pressure Voltage V
2 wheel drive switch signal 2WD Switch ON or OFF
Kick down switch signal Kick Down Switch ON or OFF
Stop lamp switch signal Stop Lamp Switch ON or OFF
Anti lock brake system signal ABS Signal ON or OFF
Cruise control system signal Cruise Control Signal ON or OFF
Neutral/Parking range signal N/P Range Signal ON or OFF
Reverse range signal R Range Signal ON or OFF
Drive range signal D Range Signal ON or OFF
3rd range signal 3rd Range Signal ON or OFF
2nd range signal 2nd Range Signal ON or OFF
1st range signal 1st Range Signal ON or OFF
Shift control solenoid A Shift Solenoid #1 ON or OFF
Shift control solenoid B Shift Solenoid #2 ON or OFF
Torque control output signal #1 Torque Control Signal #1 ON or OFF
Torque control output signal #2 Torque Control Signal #2 ON or OFF
Torque control cut signal Torque Control Cut Sig. ON or OFF
2-4 brake timing control solenoid valve 2-4 Brake Timing Sol. ON or OFF
Low clutch timing control solenoid valve Low Clutch Timing Sol. ON or OFF
Automatic transmission diagnosis indicator lamp AT Diagnosis Lamp ON or OFF
NOTE:
EN(H4)-58
墌 00.5.31/68j/0en4 墍
11. Read Diagnostic Trouble 쐌 For detailed concerning diagnostic trouble

codes, refer to the List of Diagnostic Trouble Code
Code S008508
(DTC).
1. SUBARU SELECT MONITOR (NORMAL 쐌 AT vehicles: <Ref. to EN(H4)-301 List of
MODE) S008508A1601 Diagnostic Trouble Code (DTC) for AT
Vehicles.>
the {Each System Check} and press the [YES] key. 3. OBD-II GENERAL SCAN TOOL S008508A1603
2) On the ⰆSystem Selection MenuⰇ display Refers to data denoting emission-related power-
screen, select the {Engine Control System} and train diagnostic trouble codes.
press the [YES] key. For details concerning diagnostic trouble codes,
3) Press the [YES] key after displayed the infor- refer to the List of Diagnostic Trouble Code (DTC).
mation of engine type. 쐌 MT vehicles: <Ref. to EN(H4)-99 List of Diag-
4) On the ⰆEngine DiagnosisⰇ display screen, nostic Trouble Code (DTC) for MT Vehicles.>
select the {Diagnostic Code(s) Display} and press 쐌 AT vehicles: <Ref. to EN(H4)-301 List of Diag-
the [YES] key. nostic Trouble Code (DTC) for AT Vehicles.>
5) On the ⰆDiagnostic Code(s) DisplayⰇ display NOTE:
screen, select the {Current Diagnostic Code(s)} or Refer to OBD-II general scan tool manufacturer’s
{History Diagnostic Code(s)} and press the [YES] instruction manual to access emission-related
key. powertrain diagnostic trouble codes (MODE $03).
NOTE:
MANUAL.
(DTC).
쐌 AT vehicles: <Ref. to EN(H4)-301 List of
Diagnostic Trouble Code (DTC) for AT
Vehicles.>
2. SUBARU SELECT MONITOR (OBD
MODE) S008508A1602
the {2. Each System Check} and press the [YES]
key.
screen, select the {Engine Control System} and
press the [YES] key.
4) On the ⰆEngine DiagnosisⰇ display screen,
select the {OBD System} and press the [YES] key.
5) On the ⰆOBD MenuⰇ display screen, select
the {Diagnosis Code(s) Display} and press the
[YES] key.
6) Make sure that a diagnostic trouble code (DTC)
is shown on the display screen.
NOTE:
MANUAL.
EN(H4)-59
INSPECTION MODE

1) Prepare Subaru Select Monitor kit. <Ref. to
EN(H4)-8 PREPARATION TOOL, General
A: OPERATION S008510A16 Description.>
1. PREPARATION FOR THE INSPECTION
MODE S008510A1601
Raise the vehicle using a garage jack and place on
safety stands or drive the vehicle onto free rollers.
WARNING:
쐌 Before raising the vehicle, ensure parking
brakes are applied.
쐌 Do not use a pantograph jack in place of a
safety stand.
쐌 Secure a rope or wire to the front and rear S2M0285
towing or tie-down hooks to prevent the lateral 2) Connect diagnosis cable to Subaru Select
runout of front wheels. Monitor.
쐌 Do not abruptly depress/release clutch pedal 3) Insert cartridge into Subaru Select Monitor.
or accelerator pedal during works even when <Ref. to EN(H4)-8 PREPARATION TOOL, General
engine is operating at low speeds since this Description.>
may cause vehicle to jump off free rollers.
쐌 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.
쐌 Since the rear wheels will also rotate, do not
place anything near them. Also, make sure that
nobody goes in front of the vehicle.
S2M0286A
4) Connect test mode connector at the lower por-

tion of instrument panel (on the driver’s side), to
the side of the center console box.
B2M3716A
B2M2969A
2. SUBARU SELECT MONITOR S008510A1602
After performing diagnostics and clearing the

memory, check for any remaining unresolved
trouble data.
EN(H4)-60
墌 00.5.31/68j/0en4 墍
INSPECTION MODE
5) Connect Subaru Select Monitor to data link NOTE:

connector. 쐌 For detailed operation procedure, refer to the
(1) Connect Subaru Select Monitor to data link SUBARU SELECT MONITOR OPERATION
connector located in the lower portion of the MANUAL.
instrument panel (on the driver’s side). 쐌 For detailed concerning diagnostic trouble
(DTC).
Vehicles.>
쐌 Release the parking brake.
쐌 The speed difference between front and rear
wheels may light either the ABS warning light, but
B2M2960B this indicates no malfunctions. When engine con-
trol diagnosis is finished, perform the ABS memory
(2) Connect diagnosis cable to data link con- clearance procedure of self-diagnosis system.
nector.
3. OBD-II GENERAL SCAN TOOL S008510A1603
CAUTION:
Do not connect scan tools except for Subaru After performing diagnostics and clearing the
Select Monitor and OBD-II general scan tool. memory, check for any remaining unresolved
trouble data:
6) Turn ignition switch to ON (engine OFF) and 1) Connect test mode connector at the lower side
Subaru Select Monitor switch to ON. of the instrument panel (on the driver’s side), to the
side of the center console box.
S2M0288A
B2M3716A
the {2. Each System Check} and press the [YES] 2) Connect the OBD-II general scan tool to its data
key. link connector in the lower portion of the instrument
8) On the ⰆSystem Selection MenuⰇ display panel (on the driver’s side).
screen, select the {Engine Control System} and CAUTION:
press the [YES] key. Do not connect the scan tools except for
9) Press the [YES] key after displayed the infor- Subaru Select Monitor and OBD-II general scan
mation of engine type. tool.
select the {Dealer Check Mode Procedure} and
11) When the “Perform Inspection (Dealer Check)
Mode?” is shown on the display screen, press the
[YES] key.
12) Perform subsequent procedures as instructed
on the display screen.
쐌 If trouble still remains in the memory, the corre-
sponding diagnostic trouble code (DTC) appears
on the display screen. B2M2960B
EN(H4)-61
墌 00.5.31/68j/0en4 墍
INSPECTION MODE

NOTE:
쐌 Ensure the selector lever is placed in the “P”
position before starting. (AT vehicles)
쐌 Depress clutch pedal when starting the engine.
(MT vehicles)
4) Using the selector lever or shift lever, turn the
“P” position switch and the “N” position switch to
ON.
5) Depress the brake pedal to turn the brake
switch ON. (AT vehicles)
6) Keep engine speed in the 2,500 — 3,000 rpm
range for 40 seconds.
NOTE:
On models without tachometer, use the tachom-
eter (Secondary pickup type).
7) Place the selector lever or shift lever in the “D”
position (AT vehicles) or “1st” gear (MT vehicles)
and drive the vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
쐌 On AWD vehicles, release the parking brake.
쐌 The speed difference between front and rear
wheels may light the ABS warning light, but this
indicates no malfunctions. When engine control
diagnosis is finished, perform the ABS memory
clearance procedure of self-diagnosis system.
8) Using the OBD-II general scan tool, check for
diagnostic trouble code(s) and record the result(s).
NOTE:
쐌 For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
(DTC).
Vehicles.>
EN(H4)-62
墌 00.5.31/68j/0en4 墍
CLEAR MEMORY MODE

3. OBD-II GENERAL SCAN TOOL S008513A1603
For clear memory procedures using the OBD-II

general scan tool, refer to the OBD-II General
1. SUBARU SELECT MONITOR (NORMAL Scan Tool Instruction Manual.
MODE) S008513A1601 After the memory has been cleared, the ISC must
be initialized. To do this, turn the ignition switch to
1) On the ⰆMain MenuⰇ display screen, select the ON position. Wait 3 seconds before starting the
the {2. Each System Check} and press the [YES] engine. (AT vehicles only)
key.
select the {Clear Memory} and press the [YES]
key.
5) When the ‘Done’ and ‘Turn Ignition Switch OFF’
are shown on the display screen, turn the Subaru
Select Monitor and ignition switch to OFF.
NOTE:
쐌 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. (AT vehicles only)
MANUAL.
2. SUBARU SELECT MONITOR (OBD
MODE) S008513A1602
the {2. Each System Check} and press the [YES]
key.
select the {OBD System} and press the [YES] key.
5) On the ⰆOBD MenuⰇ display screen, select
the {4. Diagnosis Code(s) Cleared} and press the
[YES] key.
6) When the ‘Clear Diagnostic Code?’ is shown on
the display screen, press the [YES] key.
7) Turn Subaru Select Monitor and ignition switch
to OFF.
NOTE:
쐌 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. (AT vehicles only)
MANUAL.
EN(H4)-63
COMPULSORY VALVE OPERATION CHECK MODE
14. Compulsory Valve 2) Connect diagnosis cable to Subaru Select

Monitor.
Operation Check Mode S008528
1. SUBARU SELECT MONITOR S008528A1601
S2M0285

Contents Display
Compulsory fuel pump relay operation check Fuel Pump Relay
Compulsory radiator fan relay operation check Radiator Fan Relay
Compulsory air conditioning relay operation check A/C Relay
Compulsory pressure control solenoid valve operation check PCV Solenoid Valve
Compulsory drain valve operation check Vent Control Solenoid Valve
NOTE:
쐌 Because ASV solenoid valve, FICD solenoid valve and air injection system diagnosis solenoid valve are
not installed, ASV Solenoid Valve, FICD Solenoid Valve and Pressure Switching Sol.2 will be displayed but
non-functional.
쐌 For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
EN(H4)-64
COMPULSORY VALVE OPERATION CHECK MODE
MEMO:
EN(H4)-65
ENGINE MALFUNCTION INDICATOR LAMP (MIL)
15. Engine Malfunction

Indicator Lamp (MIL) S008653
1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN(H4)-67 ACTIVATION OF CHECK ENGINE MAL-
FUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).>
↓
2. Check engine malfunction indicator lamp (MIL) does not come on. <Ref. to EN(H4)-68 CHECK ENGINE MALFUNCTION
INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).>
↓
3. Check engine malfunction indicator lamp (MIL) does not go off. <Ref. to EN(H4)-71 CHECK ENGINE MALFUNCTION
INDICATOR LAMP (MIL) DOES NOT GO OFF., Engine Malfunction Indicator Lamp (MIL).>
↓
4. Check engine malfunction indicator lamp (MIL) does not blink at a cycle of 3 Hz. <Ref. to EN(H4)-72 CHECK ENGINE
MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 HZ., Engine Malfunction Indicator Lamp
(MIL).>
↓
5. Check engine malfunction indicator lamp (MIL) remains blinking at a cycle of 3 Hz. <Ref. to EN(H4)-74 CHECK ENGINE
MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 HZ., Engine Malfunction Indicator Lamp
(MIL).>
EN(H4)-66
墌 00.5.31/68j/0en4 墍
B: ACTIVATION OF CHECK ENGINE 4) When ignition switch is turned to ON (engine

off) or to “START” with the test mode connector
MALFUNCTION INDICATOR LAMP connected, the MIL blinks at a cycle of 3 Hz.
(MIL) S008653E89
1) When ignition switch is turned to ON (engine

off), the CHECK ENGINE malfunction indicator
lamp (MIL) in the combination meter illuminates.
NOTE:
If the MIL does not illuminate, perform diagnostics
of the CHECK ENGINE light circuit or the combi-
nation meter circuit. <Ref. to EN(H4)-68 CHECK
ENGINE MALFUNCTION INDICATOR LAMP
(MIL) DOES NOT COME ON., Engine Malfunction OBD0055A
Indicator Lamp (MIL) Illumination Pattern.>
B2M3701C
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(H4)-67
墌 00.5.31/68j/0en4 墍
C: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT

COME ON. S008653E90
쐌 DIAGNOSIS:
쐌 The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted.
쐌 TROUBLE SYMPTOM:
쐌 When ignition switch is turned ON (engine OFF), MIL does not come on.
쐌 WIRING DIAGRAM:
B2M3916

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1 Go to step 4. Go to step 2.
1) Turn ignition switch to ON. V?
and chassis ground.
(−):
EN(H4)-68
墌 00.5.31/68j/0en4 墍

2 CHECK POOR CONTACT. Does the MIL come on Repair poor con- Go to step 3.
when shaking or pulling tact in ECM con-
ECM connector and har- nector.
ness?
3 CHECK ECM CONNECTOR. Is ECM connector correctly Replace ECM. Repair connection
connected? <Ref. to of ECM connec-
FU(H4)-67 Engine tor.
Control Module.>
4 CHECK HARNESS BETWEEN COMBINA- Is resistance less than 1 Go to step 5. Repair harness
TION METER AND ECM CONNECTOR. Ω? and connector.
1) Turn ignition switch to OFF. NOTE:
2) Remove combination meter. <Ref. to IDI-17 In this case,
Combination Meter Assembly.> repair the follow-
3) Disconnect connector from ECM and coming:
bination meter. 쐌 Open circuit in
4) Measure resistance of harness between harness between
ECM and combination meter connector. ECM and combi-
Connector & terminal nation meter con-
(B134) No. 11 — (i12) No. 12: nector
쐌 Poor contact in
coupling connec-
tor (B36)
5 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Go to step 6.
Check poor contact in combination meter con- combination meter connec- tact in combina-
nector. tor? tion meter con-
nector.
6 CHECK HARNESS BETWEEN COMBINA- Is voltage more than 10 V? Go to step 7. Check the follow-
TION METER AND IGNITION SWITCH CON- ing and repair if
NECTOR. necessary.
1) Turn ignition switch to ON. NOTE:
2) Measure voltage between combination 쐌 Broken down
meter connector and chassis ground. ignition relay.
Connector & terminal 쐌 Blown out fuse
(i10) No. 8 (+) — Chassis ground (−): (No. 5).
쐌 If replaced fuse
(No. 5) blows
easily, check the
harness for short
circuit of harness
between fuse (No.
5) and ignition
relay connector.
쐌 Open or short
circuit in harness
between fuse (No.
5) and battery ter-
minal
쐌 Open circuit in
harness between
fuse (No. 5) and
ignition relay con-
nector
쐌 Poor contact in
ignition relay con-
nector
쐌 Poor contact in
ignition switch
connector
EN(H4)-69
墌 00.5.31/68j/0en4 墍

7 CHECK HARNESS BETWEEN COMBINA- Is voltage more than 10 V? Go to step 8. Check the follow-
TION METER AND IGNITION SWITCH CON- ing and repair if
NECTOR. necessary.
Measure voltage between combination meter NOTE:
connector and chassis ground. 쐌 Broken down
Connector & terminal ignition relay.
(i12) No. 3 (+) — Chassis ground (−): 쐌 Blown out fuse
(No. 5).
쐌 If replaced fuse
(No. 5) blows
easily, check the
harness for short
circuit of harness
between fuse (No.
5) and ignition
relay connector.
쐌 Open or short
circuit in harness
between fuse (No.
5) and battery ter-
minal
쐌 Open circuit in
harness between
fuse (No. 5) and
ignition relay con-
nector
쐌 Poor contact in
ignition relay con-
nector
쐌 Poor contact in
ignition switch
connector
8 CHECK LAMP BULB. Is lamp bulb condition OK? Repair combina- Replace lamp
Remove engine malfunction indicator lamp tion meter con- bulb.
bulb. nector.
EN(H4)-70
墌 00.5.31/68j/0en4 墍
D: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT GO

OFF. S008653E91
쐌 DIAGNOSIS:
쐌 The CHECK ENGINE malfunction indicator lamp (MIL) circuit is shorted.
쐌 Although MIL comes on when engine runs, trouble code is not shown on Subaru select monitor or
OBD-II general scan tool display.
쐌 WIRING DIAGRAM:
B2M3916

1 CHECK HARNESS BETWEEN COMBINA- Does the MIL come on? Repair short cir- Replace ECM.
TION METER AND ECM CONNECTOR. cuit in harness <Ref. to 67
1) Turn ignition switch to OFF. between combina- Engine Control
2) Disconnect connector from ECM. tion meter and Module.>
3) Turn ignition switch to ON. ECM connector.
EN(H4)-71
墌 00.5.31/68j/0en4 墍
E: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT

BLINK AT A CYCLE OF 3 Hz. S008653E92
쐌 DIAGNOSIS:
쐌 The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted.
쐌 Test mode connector circuit is in open.
쐌 When inspection mode, MIL does not blink at a cycle of 3 Hz.
쐌 WIRING DIAGRAM:
B2M3917
EN(H4)-72
墌 00.5.31/68j/0en4 墍

1 CHECK STATUS OF CHECK ENGINE MAL- Does the MIL come on? Go to step 2. Repair the MIL
FUNCTION INDICATOR LAMP (MIL). circuit. <Ref. to
1) Turn ignition switch to OFF. EN(H4)-68
2) Disconnect test mode connector. CHECK ENGINE
3) Turn ignition switch to ON. (engine OFF) MALFUNCTION
INDICATOR
LAMP (MIL)
DOES NOT
COME ON.,
Engine Malfunc-
tion Indicator
Lamp (MIL).>
2 CHECK HARNESS BETWEEN COMBINA- Does the MIL come on? Repair ground Go to step 3.
TION METER AND ECM CONNECTOR. short circuit in
1) Turn ignition switch to OFF. harness between
2) Disconnect connector from ECM. combination meter
3) Turn ignition switch to ON. and ECM connec-
tor.
3 CHECK HARNESS BETWEEN TEST MODE Is resistance less than 1 Go to step 4. Repair harness
CONNECTOR AND CHASSIS GROUND. Ω? and connector.
2) Disconnect connector from ECM. In this case,
3) Measure resistance of harness between repair the follow-
test mode connector and chassis ground. ing:
Connector & terminal 쐌 Open circuit in
(B76) No. 1 — Chassis ground: harness between
test mode con-
nector and chas-
sis ground
Check poor contact in ECM connector. ECM connector? tact in ECM con-
nector.
5 CHECK HARNESS BETWEEN ECM AND Is resistance less than 1 Go to step 6. Repair open cir-
TEST MODE CONNECTOR. Ω? cuit in harness
1) Connect test mode connector. between ECM
2) Measure resistance of harness between and test mode
ECM and chassis ground. connector.
6 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace ECM.
Check poor contact in ECM connector. ECM connector? tact in ECM con- <Ref. to
nector. FU(H4)-67 Engine
Control Module.>
EN(H4)-73
墌 00.5.31/68j/0en4 墍
F: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS

BLINKING AT A CYCLE OF 3 Hz. S008653E93
쐌 DIAGNOSIS:
쐌 Test mode connector circuit is shorted.
쐌 MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON.
쐌 WIRING DIAGRAM:
B2M3917

1 CHECK TEST MODE CONNECTOR. Does MIL flash on and off? Go to step 2. System is in good
1) Disconnect test mode connector. order.
MIL blinks at a
cycle of 3 Hz
when test mode
connector is con-
nected.
EN(H4)-74
墌 00.5.31/68j/0en4 墍

2 CHECK HARNESS BETWEEN ECM CON- Is resistance less than 5 Repair short cir- Replace ECM.
NECTOR AND ENGINE GROUNDING TER- Ω? cuit in harness <Ref. to
MINAL. between ECM FU(H4)-67 Engine
1) Turn ignition switch to OFF. and test mode Control Module.>
2) Disconnect connector from ECM. connector.
ECM connector and chassis ground.
EN(H4)-75
墌 00.5.31/68j/0en4 墍
MEMO:
EN(H4)-76
墌 00.5.31/68j/0en4 墍
DIAGNOSTICS FOR ENGINE STARTING FAILURE
16. Diagnostics for Engine

Starting Failure S008533
1. Inspection of starter motor circuit. <Ref. to EN(H4)-78 STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Fail-
ure.>
↓
2. Inspection of ECM power supply and ground line. <Ref. to EN(H4)-82 CONTROL MODULE POWER SUPPLY AND
GROUND LINE, Diagnostics for Engine Starting Failure.>
↓
3. Inspection of ignition control system. <Ref. to EN(H4)-86 IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting
Failure.>
↓
4. Inspection of fuel pump circuit. <Ref. to EN(H4)-90 FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
↓
5. Inspection of fuel injector circuit. <Ref. to EN(H4)-94 FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
↓
6. Inspection of crankshaft position sensor circuit. <Ref. to EN(H4)-98 CRANKSHAFT POSITION SENSOR CIRCUIT, Diag-
nostics for Engine Starting Failure.>
↓
7. Inspection of camshaft position sensor circuit. <Ref. to EN(H4)-98 CAMSHAFT POSITION SENSOR CIRCUIT, Diagnos-
tics for Engine Starting Failure.>
↓
8. Inspection using Subaru Select Monitor or OBD-II general scan tool (MT vehicles: <Ref. to EN(H4)-106 Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC) for MT Vehicles.>, AT vehicles: <Ref. to EN(H4)-310 Diagnostic Procedure with
Diagnostic Trouble Code (DTC) for AT Vehicles.>) or inspection using “21. General Diagnostics Table”. <Ref. to EN(H4)-562
General Diagnostic Table.>
EN(H4)-77
墌 00.5.31/68j/0en4 墍
B: STARTER MOTOR CIRCUIT S008533E94
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(H4)-63 Clear
Memory Mode.> and INSPECTION MODE <Ref. to EN(H4)-60 Inspection Mode.>.
쐌 WIRING DIAGRAM:
B2M3918
EN(H4)-78
墌 00.5.31/68j/0en4 墍

1 CHECK BATTERY. Is the voltage more than 12 Go to step 2. Charge or replace
V? battery.
2 CHECK INPUT SIGNAL FOR STARTER Is the voltage more than 10 Go to step 3. Go to step 4.
MOTOR. V?
2) Disconnect connector from starter motor.
3) Turn ignition switch to ST.
4) Measure power supply voltage between
starter motor connector terminal and engine
ground.
NOTE:
쐌 On AT vehicles, place the selector lever in
the “P” or “N” position.
쐌 On MT vehicles, depress the clutch pedal.
3 CHECK GROUND CIRCUIT OF STARTER Is resistance less than 5 Check starter Repair open cir-
MOTOR. Ω? motor. <Ref. to cuit of ground
1) Turn ignition switch to OFF. SC(H4)-7 cable.
2) Disconnect terminal from starter motor. Starter.>
3) Measure resistance of ground cable
between ground cable terminal and engine
ground.
4 CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 Go to step 6. Repair open cir-
AND IGNITION SWITCH CONNECTOR. V? cuit in harness
1) Disconnect connector from ignition switch. between ignition
2) Measure power supply voltage between switch and
ignition switch connector and chassis ground. battery, and check
Connector & terminal fuse SBF No. 4
(B72) No. 1 (+) — Chassis ground (−): and SBF No.1.
5 CHECK IGNITION SWITCH. Is the resistance less than Go to step 6. Replace ignition
1) Disconnect connector from ignition switch. 5 Ω? switch.
2) Measure resistance between ignition switch
terminals while turning ignition switch to the
“ST” position.
Terminals
No. 1 — No. 3:
6 CHECK TRANSMISSION TYPE. Is transmission type AT? Go to step 7. Go to step 11.
7 CHECK INPUT VOLTAGE OF INHIBITOR Is the voltage more than 10 Go to step 8. Repair open or
SWITCH. V? ground short cir-
1) Turn ignition switch to OFF. cuit in harness
2) Disconnect connector from inhibitor switch. between inhibitor
3) Connect connector to ignition switch. switch and ignition
4) Measure input voltage between inhibitor switch.
switch connector terminal and engine ground NOTE:
while turning ignition switch to ST. Check security
Connector & terminal system (if
(B12) No. 12 (+) — Engine ground (–): equipped). <Ref.
to SL-24 Security
System.>
8 CHECK INHIBITOR SWITCH. Is the resistance less than Repair open or Replace inhibitor
1) Place the selector lever in the “P” or “N” 1 Ω? ground short cir- switch. <Ref. to
position. cuit in harness AT-28 Inhibitor
2) Measure resistance between inhibitor between inhibitor Switch.>
switch terminals. switch and starter
Connector & terminal motor.
(T3) No. 11 — No. 12:
EN(H4)-79
墌 00.5.31/68j/0en4 墍

9 CHECK INPUT VOLTAGE OF STARTER Is the voltage more than 10 Go to step 10. Repair open or
INTERLOCK RELAY. V? ground short cir-
1) Turn ignition switch to OFF. cuit in harness
2) Disconnect connector from starter interlock between starter
relay. interlock relay and
3) Connect connector to ignition switch. ignition switch.
4) Measure input voltage between starter NOTE:
interlock relay connector and chassis ground Check security
while turning ignition switch to ST. system (if
Connector & terminal equipped). <Ref.
(B105) No. 1 (+) — Chassis ground (–): to SL-24 Security
(B105) No. 3 (+) — Chassis ground (–): System.>
10 CHECK STARTER INTERLOCK RELAY. Is the resistance less than Go to step 11. Replace starter
1) Connect battery to starter interlock relay 1 Ω? interlock relay.
terminals No. 2 and No. 3.
2) Measure resistance between starter inter-
lock relay terminals.
Terminals
No. 1 — No. 4:
11 CHECK GROUND CIRCUIT OF CLUTCH Is the resistance less than Go to step 12. Repair open cir-
SWITCH. 1 Ω? cuit of ground
1) Disconnect connector from clutch switch. cable.
2) Measure resistance between clutch switch
12 CHECK CLUTCH SWITCH. Is the resistance less than Go to step 13. Replace clutch
1) Measure resistance between clutch switch 1 Ω? switch. <Ref. to
terminal while depressing the clutch pedal. CL-8 Clutch
Terminals Switch.>
No. 1 — No. 2:
13 CHECK CLUTCH SWITCH CIRCUIT. Is the resistance less than Repair open or Repair open cir-
1) Connect connector to clutch switch. 1 Ω? ground short circuit in harness
2) Measure resistance between starter inter- cuit in harness between starter
lock relay connector and chassis ground while between starter interlock relay and
depressing the clutch pedal. interlock relay and clutch switch.
Connector & terminal starter motor.
EN(H4)-80
墌 00.5.31/68j/0en4 墍
MEMO:
EN(H4)-81
墌 00.5.31/68j/0en4 墍
C: CONTROL MODULE POWER SUPPLY AND GROUND LINE S008533E37
CAUTION:
Memory Mode.> and INSPECTION MODE. <Ref. to EN(H4)-60 Inspection Mode.>
쐌 WIRING DIAGRAM:
B2M3919
EN(H4)-82
墌 00.5.31/68j/0en4 墍

1 CHECK MAIN RELAY. Is the resistance less than Go to step 2. Replace main
1) Turn the ignition switch to OFF. 10 Ω? relay.
2) Remove main relay.
3) Connect battery to main relay terminals No.
1 and No. 2.
4) Measure resistance between main relay
terminals.
Terminals
No. 3 — No. 5:
2 CHECK MAIN RELAY. Is the resistance less than Go to step 3. Replace main
Measure resistance between main relay termi- 10 Ω? relay.
nals.
Terminals
No. 4 — No. 6:
3 CHECK GROUND CIRCUIT OF ECM. Is the resistance less than Go to step 4. Repair open cir-
1) Disconnect connector from ECM. 5 Ω? cuit in harness
2) Measure resistance of harness between between ECM
ECM and chassis ground. connector and
Connector & terminal engine grounding
(B136) No. 21 — Chassis ground: terminal.
Measure resistance of harness between ECM 5 Ω? cuit in harness
and chassis ground. between ECM
Connector & terminal connector and
(B136) No. 22 — Chassis ground: engine grounding
terminal.
terminal.
terminal.
(B134) No. 7 — Chassis ground: engine ground
terminal.
8 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 Go to step 9. Repair open or
Measure voltage between ECM connector V? ground short cir-
and chassis ground. cuit of power sup-
Connector & terminal ply circuit.
(B136) No. 9 (+) — Chassis ground (–):
1) Turn ignition switch to ON. V? ground short cir-
2) Measure voltage between ECM connector cuit of power sup-
and chassis ground. ply circuit.
(B135) No. 7 (+) — Chassis ground (–):
EN(H4)-83
墌 00.5.31/68j/0en4 墍

10 CHECK HARNESS BETWEEN ECM AND Is the resistance more than Go to step 11. Repair ground
MAIN RELAY CONNECTOR. 1 MΩ? short circuit in
2) Measure resistance between ECM and ECM connector
chassis ground. and main relay
Connector & terminal connector, then
(B135) No. 19 — Chassis ground: replace ECM.
11 CHECK OUTPUT VOLTAGE FROM ECM. Is the voltage more than 10 Go to step 12. Replace ECM.
1) Connect connector to ECM. V?
and chassis ground.
(–):
12 CHECK INPUT VOLTAGE OF MAIN RELAY. Is the voltage more than 10 Go to step 13. Repair open cir-
Check voltage between main relay connector V? cuit in harness
(B47) No. 2 (+) — Chassis ground (–): main relay con-
nector.
13 CHECK GROUND CIRCUIT OF MAIN Is the resistance less than Go to step 14. Repair open cir-
RELAY. 5 Ω? cuit between main
1) Turn ignition switch to OFF. relay and chassis
2) Measure resistance between main relay ground.
14 CHECK INPUT VOLTAGE OF MAIN RELAY. Is the voltage more than 10 Go to step 15. Repair open or
Measure voltage between main relay connec- V? ground short cir-
tor and chassis ground. cuit in harness of
Connector & terminal power supply cir-
(B47) No. 5 (+) — Chassis ground (−): cuit.
15 CHECK INPUT VOLTAGE OF MAIN RELAY. Is the voltage more than 10 Go to step 16. Repair open or
Measure voltage between main relay connec- V? ground short cir-
tor and chassis ground. cuit in harness of
Connector & terminal power supply cir-
(B47) No. 6 (+) — Chassis ground (−): cuit.
1) Connect main relay connector. V? ground short cir-
2) Turn ignition switch to ON. cuit in harness
and chassis ground. connector and
Connector & terminal main relay con-
(B136) No. 1 (+) — Chassis ground (–): nector.
17 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 Check ignition Repair open or
Measure voltage between ECM connector V? control system. ground short cir-
and chassis ground. <Ref. to cuit in harness
Connector & terminal EN(H4)-86 IGNI- between ECM
(B136) No. 2 (+) — Chassis ground (–): TION CONTROL connector and
SYSTEM, Diag- main relay con-
nostics for Engine nector.
Starting Failure.>
EN(H4)-84
墌 00.5.31/68j/0en4 墍
MEMO:
EN(H4)-85
墌 00.5.31/68j/0en4 墍
D: IGNITION CONTROL SYSTEM S008533E95
CAUTION:
쐌 WIRING DIAGRAM:
B2M3920

1 CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each Check fuel pump Go to step 2.
1) Remove plug cord cap from each spark cylinder? system. <Ref. to
plug. EN(H4)-90 FUEL
2) Install new spark plug on plug cord cap. PUMP CIRCUIT,
CAUTION: Diagnostics for
Do not remove spark plug from engine. Engine Starting
3) Contact spark plug’s thread portion on Failure.>
engine.
4) While opening throttle valve fully, crank
engine to check that spark occurs at each
cylinder.
EN(H4)-86
墌 00.5.31/68j/0en4 墍

2 CHECK POWER SUPPLY CIRCUIT FOR Is the voltage more than 10 Go to step 3. Repair harness
IGNITION COIL & IGNITOR ASSEMBLY. V? and connector.
2) Disconnect connector from ignition coil & In this case,
ignitor assembly. repair the follow-
3) Turn ignition switch to ON. ing:
4) Measure power supply voltage between 쐌 Open circuit in
ignition coil & ignitor assembly connector and harness between
engine ground. ignition coil & igni-
Connector & terminal tor assembly, and
(E12) No. 2 (+) — Engine ground (−): ignition switch
connector
쐌 Poor contact in
coupling connec-
tors (B22)
3 CHECK HARNESS OF IGNITION COIL & Is the resistance between Go to step 4. Repair harness
IGNITOR ASSEMBLY GROUND CIRCUIT. less than 5 Ω? and connector.
2) Measure resistance between ignition coil & In this case,
ignitor assembly connector and engine repair the follow-
ground. ing:
(E12) No. 3 — Engine ground: harness between
ignition coil & igni-
tor assembly con-
nector and engine
grounding termi-
nal
4 CHECK IGNITION COIL & IGNITOR ASSEM- Is the resistance between Go to step 5. Replace ignition
BLY. 10 and 15 kΩ? coil & ignitor
1) Remove spark plug cords. assembly. <Ref.
2) Measure resistance between spark plug to IG(H4)-8 Igni-
cord contact portions to check secondary coil. tion Coil and Igni-
Terminals tor Assembly.>
No. 1 — No. 2:
5 CHECK IGNITION COIL & IGNITOR ASSEM- Is the resistance between Go to step 6. Replace ignition
BLY. 10 and 15 kΩ? coil & ignitor
Measure resistance between spark plug cord assembly. <Ref.
contact portions to check secondary coil. to IG(H4)-8 Igni-
Terminals tion Coil and Igni-
No. 3 — No. 4: tor Assembly.>
6 CHECK INPUT SIGNAL FOR IGNITION Is the voltage more than 10 Go to step 7. Replace ignition
COIL & IGNITOR ASSEMBLY. V? coil & ignitor
1) Connect connector to ignition coil & ignitor assembly. <Ref.
assembly. to IG(H4)-8 Igni-
2) Check if voltage varies synchronously with tion Coil and Igni-
engine speed when cranking, while monitoring tor Assembly.>
voltage between ignition coil & ignitor assem-
bly connector and engine ground.
(E12) No. 1 (+) — Engine ground (–):
7 CHECK INPUT SIGNAL FOR IGNITION Is the voltage more than 10 Go to step 8. Replace ignition
COIL & IGNITOR ASSEMBLY. V? coil & ignitor
Check if voltage varies synchronously with assembly. <Ref.
engine speed when cranking, while monitoring to IG(H4)-8 Igni-
voltage between ignition coil & ignitor assem- tion Coil and Igni-
bly connector and engine ground. tor Assembly.>
(E12) No. 4 (+) — Engine ground (–):
EN(H4)-87
墌 00.5.31/68j/0en4 墍

8 CHECK HARNESS BETWEEN ECM AND Is the resistance less than Go to step 9. Repair harness
IGNITION COIL & IGNITOR ASSEMBLY 1 Ω? and connector.
CONNECTOR. NOTE:
1) Turn ignition switch to OFF. In this case,
2) Disconnect connector from ECM. repair the follow-
3) Disconnect connector from ignition coil & ing:
ignitor assembly. 쐌 Open circuit in
4) Measure resistance of harness between harness between
ECM and ignition coil & ignitor assembly con- ECM and ignition
nector. coil & ignitor
Connector & terminal assembly connec-
(B134) No. 25 — (E12) No. 1: tor
쐌 Poor contact in
coupling connec-
tor (B22)
IGNITION COIL & IGNITOR ASSEMBLY 1 Ω? and connector.
CONNECTOR. NOTE:
Measure resistance of harness between ECM In this case,
and ignition coil & ignitor assembly connector. repair the follow-
Connector & terminal ing:
(B134) No. 26 — (E12) No. 4: 쐌 Open circuit in
harness between
ECM and ignition
coil & ignitor
assembly connec-
tor
쐌 Poor contact in
coupling connec-
tor (B22)
IGNITION COIL & IGNITOR ASSEMBLY 1 MΩ? short circuit in
CONNECTOR. harness between
Measure resistance of harness between ECM ECM and ignition
and engine ground. coil & ignitor
Connector & terminal: assembly connec-
(B134) No. 25 — Engine ground: tor.
IGNITION COIL & IGNITOR ASSEMBLY 1 MΩ? short circuit in
Measure resistance of harness between ECM ECM and ignition
and engine ground. coil & ignitor
Connector & terminal assembly connec-
(B134) No. 26 — Engine ground: tor.
12 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Check fuel pump
Check poor contact in ECM connector. ECM connector? tact in ECM con- circuit. <Ref. to
nector. EN(H4)-90 FUEL
PUMP CIRCUIT,
Diagnostics for
Engine Starting
Failure.>
EN(H4)-88
墌 00.5.31/68j/0en4 墍
MEMO:
EN(H4)-89
墌 00.5.31/68j/0en4 墍
E: FUEL PUMP CIRCUIT S008533E96
CAUTION:
쐌 WIRING DIAGRAM:
B2M3921

1 CHECK OPERATING SOUND OF FUEL Does fuel pump produce Check fuel injec- Go to step 2.
PUMP. operating sound? tor circuit. <Ref. to
Make sure that fuel pump is in operation for EN(H4)-94 FUEL
two seconds when turning ignition switch to INJECTOR
ON. CIRCUIT, Diag-
NOTE: nostics for Engine
Fuel pump operation can also be executed Starting Failure.>
using Subaru Select Monitor (Function mode:
FD01).
For the procedure, refer to “Compulsory Valve
Operation Check Mode”. <Ref. to EN(H4)-64
Compulsory Valve Operation Check Mode.>
EN(H4)-90
墌 00.5.31/68j/0en4 墍

2 CHECK GROUND CIRCUIT OF FUEL PUMP. Is the resistance less than Go to step 3. Repair harness
1) Turn ignition switch to OFF. 5 Ω? and connector.
2) Remove fuel pump access hole lid located NOTE:
on the right rear of trunk compartment floor In this case,
(Sedan) or luggage compartment floor repair the follow-
(Wagon). ing:
3) Disconnect connector from fuel pump. 쐌 Open circuit in
4) Measure resistance of harness connector harness between
between fuel pump and chassis ground. fuel pump con-
Connector & terminal nector and chas-
(R58) No. 4 — Chassis ground: sis grounding ter-
minal
쐌 Poor contact in
coupling connec-
tor (R57)
3 CHECK POWER SUPPLY TO FUEL PUMP. Is the voltage more than 10 Replace fuel Go to step 4.
1) Turn ignition switch to ON. V? pump. <Ref. to
2) Measure voltage of power supply circuit FU(H4)-90 Fuel
between fuel pump connector and chassis Pump.>
ground.
(R58) No. 1 (+) — Chassis ground (−):
4 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance less than Go to step 5. Repair harness
AND FUEL PUMP RELAY CONNECTOR. 1 Ω? and connector.
2) Measure resistance of harness connector In this case,
between fuel pump and fuel pump relay. repair the follow-
(R58) No. 1 — (B46) No. 4: 쐌 Open circuit in
harness between
fuel pump con-
nector and chas-
sis grounding ter-
minal
쐌 Poor contact in
coupling connec-
tors (R57 and
B97)
5 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance more than Go to step 6. Repair short cir-
AND FUEL PUMP RELAY CONNECTOR. 1 MΩ? cuit in harness
Measure resistance of harness between fuel between fuel
pump and fuel pump relay connector. pump and fuel
Connector & terminal pump relay con-
(R58) No. 1 — Chassis ground: nector.
6 CHECK FUEL PUMP RELAY. Is the resistance less than Go to step 7. Replace fuel
1) Disconnect connectors from fuel pump 10 Ω? pump relay. <Ref.
relay and main relay. to FU(H4)-69 Fuel
2) Remove fuel pump relay and main relay Pump Relay.>
with bracket.
3) Connect battery to fuel pump relay connec-
tor terminals No. 1 and No. 3.
terminals of fuel pump relay.
Terminals
No. 2 — No. 4:
EN(H4)-91
墌 00.5.31/68j/0en4 墍

7 CHECK HARNESS BETWEEN ECM AND Is the resistance less than Go to step 8. Repair open cir-
FUEL PUMP RELAY CONNECTOR. 1 Ω? cuit in harness
1) Disconnect connectors from ECM. between ECM
2) Measure resistance of harness between and fuel pump
ECM and fuel pump relay connector. relay connector.
(B134) No. 16 — (B46) No. 3:
8 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Check fuel injec-
Check poor contact in ECM connector. ECM connector? tact in ECM con- tor circuit. <Ref. to
nector. EN(H4)-94 FUEL
INJECTOR
CIRCUIT, Diag-
nostics for Engine
Starting Failure.>
EN(H4)-92
墌 00.5.31/68j/0en4 墍
MEMO:
EN(H4)-93
墌 00.5.31/68j/0en4 墍
F: FUEL INJECTOR CIRCUIT S008533E97
CAUTION:
쐌 Check or repair only faulty parts.
쐌 After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(H4)-63
Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(H4)-60 Inspection Mode.>
쐌 WIRING DIAGRAM:
B2M3922

1 CHECK OPERATION OF EACH FUEL Is the fuel injector emits Check fuel pres- Go to step 2.
INJECTOR. “operating” sound? sure. <Ref. to
While cranking the engine, check that each FU(H4)-70 Fuel.>
fuel injector emits “operating” sound. Use a
sound scope or attach a screwdriver to injec-
tor for this check.
EN(H4)-94
墌 00.5.31/68j/0en4 墍

2 CHECK POWER SUPPLY TO EACH FUEL Is the voltage more than 10 Go to step 3. Repair harness
INJECTOR. V? and connector.
2) Disconnect connector from #1 cylinder fuel In this case,
injector. repair the follow-
4) Measure power supply voltage between the 쐌 Open circuit in
fuel injector terminal and engine ground. harness between
Connector & terminal main relay and
#1 (E5) No. 2 (+) — Engine ground (–): fuel injector con-
nector
쐌 Poor contact in
main relay con-
nector
쐌 Poor contact in
coupling connec-
tor (B22)
쐌 Poor contact in
fuel injector con-
nector
#2 (E16) No. 2 (+) — Engine ground fuel injector con-
(−): nector
쐌 Poor contact in
main relay con-
nector
쐌 Poor contact in
coupling connec-
tor (B22)
쐌 Poor contact in
fuel injector con-
nector
#3 (E6) No. 2 (+) — Engine ground (–): fuel injector con-
nector
쐌 Poor contact in
main relay con-
nector
쐌 Poor contact in
coupling connec-
tors (B22)
쐌 Poor contact in
fuel injector con-
nector
EN(H4)-95
墌 00.5.31/68j/0en4 墍

(–): nector
쐌 Poor contact in
main relay con-
nector
쐌 Poor contact in
coupling connec-
tors (B22)
쐌 Poor contact in
fuel injector con-
nector
6 CHECK HARNESS BETWEEN ECM AND Is the resistance between 5 Go to step 7. Repair harness
FUEL INJECTOR CONNECTOR. and 20 Ω? and connector.
1) Disconnect connector from ECM. NOTE:
2) Measure resistance of harness between In this case,
ECM and fuel injector connector. repair the follow-
(B134) No. 4 — (B136) No. 2: 쐌 Open circuit in
harness between
ECM and fuel
injector connector
쐌 Poor contact in
coupling connec-
tor (B22)
7 CHECK HARNESS BETWEEN ECM AND Is the resistance less than Repair ground Go to step 8.
FUEL INJECTOR CONNECTOR. 1 Ω? short circuit in
Measure resistance of harness between ECM harness between
and fuel injector connector. ECM and fuel
Connector & terminal injector connector.
Measure resistance of harness between ECM NOTE:
and fuel injector connector. In this case,
Connector & terminal repair the follow-
(B134) No. 13 — (B136) No. 2: ing:
쐌 Open circuit in
harness between
ECM and fuel
injector connector
쐌 Poor contact in
coupling connec-
tor (B22)
EN(H4)-96
墌 00.5.31/68j/0en4 墍

(B134) No. 14 — (B136) No. 2: ing:
쐌 Open circuit in
harness between
ECM and fuel
injector connector
쐌 Poor contact in
coupling connec-
tor (B22)
(B134) No. 15 — (B136) No. 2: ing:
쐌 Open circuit in
harness between
ECM and fuel
injector connector
쐌 Poor contact in
coupling connec-
tor (B22)
14 CHECK EACH FUEL INJECTOR. Is the resistance between 5 Go to step 15. Replace faulty
1) Turn ignition switch to OFF. and 20 Ω? fuel injector.
2) Measure resistance between each fuel
injector terminals.
Terminals
No. 1 — No. 2:
15 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Check crankshaft
Check poor contact in ECM connector. ECM connector? tact in ECM con- position sensor
nector. circuit. <Ref. to
EN(H4)-98
CRANKSHAFT
POSITION SEN-
SOR CIRCUIT,
Diagnostics for
Engine Starting
Failure.>
EN(H4)-97
墌 00.5.31/68j/0en4 墍
G: CRANKSHAFT POSITION SENSOR CIRCUIT S008533E98
CAUTION:
NOTE:
Check crankshaft position sensor circuit.
쐌 MT vehicles: <Ref. to EN(H4)-182 DTC P0335 — CRANKSHAFT POSITION SENSOR CIRCUIT MAL-
FUNCTION —, Diagnostic Procedure with Diagnostic Trouble Code (DTC) for MT Vehicles.>
쐌 AT vehicles: <Ref. to EN(H4)-404 DTC P0335 — CRANKSHAFT POSITION SENSOR CIRCUIT MAL-
FUNCTION —, Diagnostic Procedure with Diagnostic Trouble Code (DTC) for AT Vehicles.>
H: CAMSHAFT POSITION SENSOR CIRCUIT S008533E99
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4)-63
OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4)-60 OPERATION, Inspec-
tion Mode.>.
NOTE:
Check camshaft position sensor circuit.
쐌 MT vehicles: <Ref. to EN(H4)-186 DTC P0340 — CAMSHAFT POSITION SENSOR CIRCUIT MAL-
FUNCTION —, Diagnostic Procedure with Diagnostic Trouble Code (DTC) for MT Vehicles.>
쐌 AT vehicles: <Ref. to EN(H4)-410 DTC P0341 — CAMSHAFT POSITION SENSOR CIRCUIT RANGE/
PERFORMANCE PROBLEM —, Diagnostic Procedure with Diagnostic Trouble Code (DTC) for AT
Vehicles.>
EN(H4)-98
墌 00.5.31/68j/0en4 墍
LIST OF DIAGNOSTIC TROUBLE CODE (DTC) FOR MT VEHICLES
17. List of Diagnostic Trouble Code (DTC) for MT Vehicles S008599
A: LIST S008599A12
DTC
Item Index
No.
P0106 Intake manifold pressure sensor circuit range/ <Ref. to EN(H4)-106 DTC P0106 — INTAKE MANIFOLD
performance problem PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE
PROBLEM —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC) for MT Vehicles.>
P0107 Intake manifold pressure sensor circuit low input <Ref. to EN(H4)-108 DTC P0107 — INTAKE MANIFOLD
PRESSURE SENSOR CIRCUIT LOW INPUT —, Diagnostic
Procedure with Diagnostic Trouble Code (DTC) for MT
Vehicles.>
P0108 Intake manifold pressure sensor circuit high input <Ref. to EN(H4)-112 DTC P0108 — INTAKE MANIFOLD
PRESSURE SENSOR CIRCUIT HIGH INPUT —, Diagnostic
Vehicles.>
P0111 Intake air temperature sensor circuit range/ <Ref. to EN(H4)-116 DTC P0111 — INTAKE AIR TEMPERA-
performance problem TURE SENSOR CIRCUIT RANGE/PERFORMANCE PROB-
LEM —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC) for MT Vehicles.>
P0112 Intake air temperature sensor circuit low input <Ref. to EN(H4)-116 DTC P0111 — INTAKE AIR TEMPERA-
TURE SENSOR CIRCUIT RANGE/PERFORMANCE PROB-
P0113 Intake air temperature sensor circuit high input <Ref. to EN(H4)-120 DTC P0113 — INTAKE AIR TEMPERA-
TURE SENSOR CIRCUIT HIGH INPUT —, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC) for MT Vehicles.>
P0116 Engine coolant temperature sensor circuit low <Ref. to EN(H4)-124 DTC P0116 — ENGINE COOLANT
input TEMPERATURE SENSOR CIRCUIT LOW INPUT —, Diag-
nostic Procedure with Diagnostic Trouble Code (DTC) for MT
Vehicles.>
P0117 Engine coolant temperature sensor circuit high <Ref. to EN(H4)-126 DTC P0117 — ENGINE COOLANT
input TEMPERATURE SENSOR CIRCUIT HIGH INPUT —, Diag-
nostic Procedure with Diagnostic Trouble Code (DTC) for MT
Vehicles.>
P0121 Throttle position sensor circuit range/ <Ref. to EN(H4)-130 DTC P0121 — THROTTLE POSITION
performance problem (high input) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM
(HIGH INPUT) —, Diagnostic Procedure with Diagnostic
Trouble Code (DTC) for MT Vehicles.>
P0122 Throttle position sensor circuit low input <Ref. to EN(H4)-132 DTC P0122 — THROTTLE POSITION
SENSOR CIRCUIT LOW INPUT —, Diagnostic Procedure
with Diagnostic Trouble Code (DTC) for MT Vehicles.>
P0123 Throttle position sensor circuit high input <Ref. to EN(H4)-136 DTC P0123 — THROTTLE POSITION
SENSOR CIRCUIT HIGH INPUT —, Diagnostic Procedure
P0125 Insufficient coolant temperature for closed loop <Ref. to EN(H4)-138 DTC P0125 — INSUFFICIENT COOL-
fuel control ANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL
—, Diagnostic Procedure with Diagnostic Trouble Code (DTC)
for MT Vehicles.>
P0131 Front oxygen (A/F) sensor circuit range/ <Ref. to EN(H4)-140 DTC P0131 — FRONT OXYGEN (A/F)
performance problem (low input) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM
(LOW INPUT) —, Diagnostic Procedure with Diagnostic
EN(H4)-99
DTC
Item Index
No.
P0133 Front oxygen (A/F) sensor circuit slow response <Ref. to EN(H4)-144 DTC P0133 — FRONT OXYGEN (A/F)
SENSOR CIRCUIT SLOW RESPONSE —, Diagnostic Proce-
P0136 Rear oxygen sensor circuit malfunction <Ref. to EN(H4)-146 DTC P0136 — REAR OXYGEN SEN-
SOR CIRCUIT MALFUNCTION —, Diagnostic Procedure with
Diagnostic Trouble Code (DTC) for MT Vehicles.>
P0139 Rear oxygen sensor circuit slow response <Ref. to EN(H4)-150 DTC P0139 — REAR OXYGEN SEN-
SOR CIRCUIT SLOW RESPONSE —, Diagnostic Procedure
P0141 Rear oxygen sensor heater circuit low input <Ref. to EN(H4)-152 DTC P0141 — REAR OXYGEN SEN-
SOR HEATER CIRCUIT LOW INPUT —, Diagnostic Proce-
P0171 Fuel trim malfunction (A/F too lean) <Ref. to EN(H4)-155 DTC P0171 — FUEL TRIM MALFUNC-
TION (A/F TOO LEAN) —, Diagnostic Procedure with Diag-
P0172 Fuel trim malfunction (A/F too rich) <Ref. to EN(H4)-156 DTC P0172 — FUEL TRIM MALFUNC-
TION (A/F TOO RICH) —, Diagnostic Procedure with Diag-
P0181 Fuel temperature sensor A circuit range/ <Ref. to EN(H4)-160 DTC P0181 — FUEL TEMPERATURE
performance problem SENSOR A CIRCUIT RANGE/PERFORMANCE PROBLEM
for MT Vehicles.>
P0182 Fuel temperature sensor A circuit low input <Ref. to EN(H4)-162 DTC P0182 — FUEL TEMPERATURE
SENSOR A CIRCUIT LOW INPUT —, Diagnostic Procedure
P0183 Fuel temperature sensor A circuit high input <Ref. to EN(H4)-164 DTC P0183 — FUEL TEMPERATURE
SENSOR A CIRCUIT HIGH INPUT —, Diagnostic Procedure
P0301 Cylinder 1 misfire detected <Ref. to EN(H4)-167 DTC P0301 — CYLINDER 1 MISFIRE
DETECTED —, Diagnostic Procedure with Diagnostic Trouble
P0325 Knock sensor circuit malfunction <Ref. to EN(H4)-178 DTC P0325 — KNOCK SENSOR CIR-
CUIT MALFUNCTION —, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC) for MT Vehicles.>
P0335 Crankshaft position sensor circuit malfunction <Ref. to EN(H4)-182 DTC P0335 — CRANKSHAFT POSI-
TION SENSOR CIRCUIT MALFUNCTION —, Diagnostic Pro-
cedure with Diagnostic Trouble Code (DTC) for MT Vehicles.>
P0336 Crankshaft position sensor circuit range/ <Ref. to EN(H4)-184 DTC P0336 — CRANKSHAFT POSI-
performance problem TION SENSOR CIRCUIT RANGE/PERFORMANCE PROB-
P0340 Camshaft position sensor circuit malfunction <Ref. to EN(H4)-186 DTC P0340 — CAMSHAFT POSITION
SENSOR CIRCUIT MALFUNCTION —, Diagnostic Procedure
P0341 Camshaft position sensor circuit range/ <Ref. to EN(H4)-188 DTC P0341 — CAMSHAFT POSITION
performance problem SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM —,
Diagnostic Procedure with Diagnostic Trouble Code (DTC) for
MT Vehicles.>
EN(H4)-100
DTC
Item Index
No.
P0420 Catalyst system efficiency below threshold <Ref. to EN(H4)-192 DTC P0420 — CATALYST SYSTEM
EFFICIENCY BELOW THRESHOLD —, Diagnostic Procedure
P0440 Evaporative emission control system malfunction <Ref. to EN(H4)-194 DTC P0440 — EVAPORATIVE EMIS-
SION CONTROL SYSTEM MALFUNCTION —, Diagnostic
Vehicles.>
P0443 Evaporative emission control system purge con- <Ref. to EN(H4)-198 DTC P0443 — EVAPORATIVE EMIS-
trol valve circuit low input SION CONTROL SYSTEM PURGE CONTROL VALVE CIR-
CUIT LOW INPUT —, Diagnostic Procedure with Diagnostic
P0446 Evaporative emission control system vent control <Ref. to EN(H4)-202 DTC P0446 — EVAPORATIVE EMIS-
low input SION CONTROL SYSTEM VENT CONTROL LOW INPUT —,
MT Vehicles.>
P0451 Evaporative emission control system pressure <Ref. to EN(H4)-206 DTC P0451 — EVAPORATIVE EMIS-
sensor range/performance problem SION CONTROL SYSTEM PRESSURE SENSOR RANGE/
PERFORMANCE PROBLEM —, Diagnostic Procedure with
sensor low input SION CONTROL SYSTEM PRESSURE SENSOR LOW
INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
sensor high input SION CONTROL SYSTEM PRESSURE SENSOR HIGH
INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
P0461 Fuel level sensor circuit range/performance prob- <Ref. to EN(H4)-216 DTC P0461 — FUEL LEVEL SENSOR
lem CIRCUIT RANGE/PERFORMANCE PROBLEM —, Diagnostic
Vehicles.>
P0462 Fuel level sensor circuit low input <Ref. to EN(H4)-218 DTC P0462 — FUEL LEVEL SENSOR
CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnos-
P0463 Fuel level sensor circuit high input <Ref. to EN(H4)-222 DTC P0463 — FUEL LEVEL SENSOR
CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diag-
P0480 Cooling fan relay 1 circuit low input <Ref. to EN(H4)-226 DTC P0480 — COOLING FAN RELAY 1
CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnos-
P0483 Cooling fan function problem <Ref. to EN(H4)-230 DTC P0483 — COOLING FAN FUNC-
TION PROBLEM —, Diagnostic Procedure with Diagnostic
P0500 Vehicle speed sensor malfunction <Ref. to EN(H4)-234 DTC P0500 — VEHICLE SPEED SEN-
SOR MALFUNCTION —, Diagnostic Procedure with Diagnos-
P0505 Idle control system circuit low input <Ref. to EN(H4)-236 DTC P0505 — IDLE CONTROL SYS-
TEM LOW INPUT —, Diagnostic Procedure with Diagnostic
P0506 Idle control system RPM lower than expected <Ref. to EN(H4)-238 DTC P0506 — IDLE CONTROL SYS-
TEM RPM LOWER THAN EXPECTED —, Diagnostic Proce-
P0507 Idle control system RPM higher than expected <Ref. to EN(H4)-240 DTC P0507 — IDLE CONTROL SYS-
TEM RPM HIGHER THAN EXPECTED —, Diagnostic Proce-
EN(H4)-101
DTC
Item Index
No.
P0601 Internal control module memory check sum error <Ref. to EN(H4)-242 DTC P0601 — INTERNAL CONTROL
MODULE MEMORY CHECK SUM ERROR —, Diagnostic
Vehicles.>
P0703 Brake switch input malfunction <Ref. to EN(H4)-244 DTC P0703 — BRAKE SWITCH INPUT
MALFUNCTION —, Diagnostic Procedure with Diagnostic
P0705 Transmission range sensor circuit malfunction <Ref. to EN(H4)-244 DTC P0705 — TRANSMISSION RANGE
P0710 Transmission fluid temperature sensor circuit <Ref. to EN(H4)-244 DTC P0710 — TRANSMISSION FLUID
malfunction TEMPERATURE SENSOR CIRCUIT MALFUNCTION —,
MT Vehicles.>
P0715 Torque converter turbine speed sensor circuit <Ref. to EN(H4)-244 DTC P0715 — TORQUE CONVERTER
malfunction TURBINE SPEED SENSOR CIRCUIT MALFUNCTION —,
MT Vehicles.>
P0720 Output speed sensor (vehicle speed sensor 2) <Ref. to EN(H4)-244 DTC P0720 — OUTPUT SPEED SEN-
circuit malfunction SOR (VEHICLE SPEED SENSOR 2) CIRCUIT MALFUNC-
TION —, Diagnostic Procedure with Diagnostic Trouble Code
P0725 Engine speed input circuit malfunction <Ref. to EN(H4)-244 DTC P0725 — ENGINE SPEED INPUT
CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diag-
P0731 Gear 1 incorrect ratio <Ref. to EN(H4)-244 DTC P0731 — GEAR 1 INCORRECT
RATIO —, Diagnostic Procedure with Diagnostic Trouble Code
P0740 Torque converter clutch system malfunction <Ref. to EN(H4)-244 DTC P0740 — TORQUE CONVERTER
CLUTCH SYSTEM MALFUNCTION —, Diagnostic Procedure
P0743 Torque converter clutch system (Lock-up duty <Ref. to EN(H4)-244 DTC P0743 — TORQUE CONVERTER
solenoid) electrical CLUTCH SYSTEM (LOCK-UP DUTY SOLENOID) ELECTRI-
CAL —, Diagnostic Procedure with Diagnostic Trouble Code
P0748 Pressure control solenoid (Line pressure duty <Ref. to EN(H4)-245 DTC P0748 — PRESSURE CONTROL
solenoid) electrical SOLENOID (LINE PRESSURE DUTY SOLENOID) ELECTRI-
P0753 Shift solenoid A (shift solenoid 1) electrical <Ref. to EN(H4)-245 DTC P0753 — SHIFT SOLENOID A
(SHIFT SOLENOID 1) ELECTRICAL —, Diagnostic Procedure
P0758 Shift solenoid B (shift solenoid 2) electrical <Ref. to EN(H4)-245 DTC P0758 — SHIFT SOLENOID B
(SHIFT SOLENOID 2) ELECTRICAL —, Diagnostic Procedure
P1100 Starter switch circuit low input <Ref. to EN(H4)-246 DTC P1100 — STARTER SWITCH CIR-
EN(H4)-102
DTC
Item Index
No.
P1101 Neutral position switch circuit low input <Ref. to EN(H4)-250 DTC P1101 — NEUTRAL POSITION
SWITCH CIRCUIT LOW INPUT —, Diagnostic Procedure with
P1103 Engine torque control signal 1 circuit malfunction <Ref. to EN(H4)-252 DTC P1103 — ENGINE TORQUE CON-
TROL SIGNAL 1 CIRCUIT MALFUNCTION —, Diagnostic
Vehicles.>
P1106 Engine torque control signal 2 circuit malfunction <Ref. to EN(H4)-252 DTC P1106 — ENGINE TORQUE CON-
TROL SIGNAL 2 CIRCUIT MALFUNCTION —, Diagnostic
Vehicles.>
P1110 Atmospheric pressure sensor circuit low input <Ref. to EN(H4)-252 DTC P1110 — ATMOSPHERIC PRES-
SURE SENSOR CIRCUIT LOW INPUT —, Diagnostic Proce-
P1111 Atmospheric pressure sensor circuit high input <Ref. to EN(H4)-253 DTC P1111 — ATMOSPHERIC PRES-
SURE SENSOR CIRCUIT HIGH INPUT —, Diagnostic Proce-
P1112 Atmospheric pressure sensor circuit range/ <Ref. to EN(H4)-253 DTC P1112 — ATMOSPHERIC PRES-
performance problem SURE SENSOR CIRCUIT RANGE/PERFORMANCE PROB-
P1115 Engine torque control cut signal circuit high input <Ref. to EN(H4)-253 DTC P1115 — ENGINE TORQUE CON-
TROL CUT SIGNAL CIRCUIT HIGH INPUT —, Diagnostic
Vehicles.>
P1116 Engine torque control cut signal circuit low input <Ref. to EN(H4)-253 DTC P1116 — ENGINE TORQUE CON-
TROL CUT SIGNAL CIRCUIT LOW INPUT —, Diagnostic Pro-
P1120 Starter switch circuit high input <Ref. to EN(H4)-254 DTC P1120 — STARTER SWITCH CIR-
CUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic
P1121 Neutral position switch circuit high input <Ref. to EN(H4)-258 DTC P1121 — NEUTRAL POSITION
SWITCH CIRCUIT HIGH INPUT —, Diagnostic Procedure
P1130 Front oxygen (A/F) sensor circuit malfunction <Ref. to EN(H4)-260 DTC P1130 — FRONT OXYGEN (A/F)
(open circuit) SENSOR CIRCUIT MALFUNCTION (OPEN CIRCUIT) —,
MT Vehicles.>
(short circuit) SENSOR CIRCUIT MALFUNCTION (SHORT CIRCUIT) —,
MT Vehicles.>
P1132 Front oxygen (A/F) sensor heater circuit low <Ref. to EN(H4)-264 DTC P1132 — FRONT OXYGEN (A/F)
input SENSOR HEATER CIRCUIT LOW INPUT —, Diagnostic Pro-
P1133 Front oxygen (A/F) sensor heater circuit high <Ref. to EN(H4)-268 DTC P1133 — FRONT OXYGEN (A/F)
input SENSOR HEATER CIRCUIT HIGH INPUT —, Diagnostic Pro-
P1134 Front oxygen (A/F) sensor micro-computer prob- <Ref. to EN(H4)-270 DTC P1134 — FRONT OXYGEN (A/F)
lem SENSOR MICRO-COMPUTER PROBLEM —, Diagnostic Pro-
P1139 Front oxygen (A/F) sensor #1 heater circuit <Ref. to EN(H4)-272 DTC P1139 — FRONT OXYGEN (A/F)
range/performance problem SENSOR #1 HEATER CIRCUIT RANGE/PERFORMANCE
EN(H4)-103
DTC
Item Index
No.
P1151 Rear oxygen sensor heater circuit high input <Ref. to EN(H4)-276 DTC P1151 — REAR OXYGEN SEN-
SOR HEATER CIRCUIT HIGH INPUT —, Diagnostic Proce-
P1400 Fuel tank pressure control solenoid valve circuit <Ref. to EN(H4)-278 DTC P1400 — FUEL TANK PRESSURE
low input CONTROL SOLENOID VALVE CIRCUIT LOW INPUT —,
MT Vehicles.>
P1420 Fuel tank pressure control solenoid valve circuit <Ref. to EN(H4)-282 DTC P1420 — FUEL TANK PRESSURE
high input CONTROL SOLENOID VALVE CIRCUIT HIGH INPUT —,
MT Vehicles.>
trol valve circuit high input SION CONTROL SYSTEM PURGE CONTROL VALVE CIR-
high input SION CONTROL SYSTEM VENT CONTROL HIGH INPUT —,
MT Vehicles.>
function problem SION CONTROL SYSTEM VENT CONTROL FUNCTION
P1505 Idle control system circuit high input <Ref. to EN(H4)-290 DTC P1505 — IDLE CONTROL SYS-
TEM CIRCUIT HIGH INPUT —, Diagnostic Procedure with
P1507 Idle control system malfunction (fail-safe) <Ref. to EN(H4)-292 DTC P1507 — IDLE CONTROL SYS-
TEM MALFUNCTION (FAIL-SAFE) —, Diagnostic Procedure
P1520 Cooling fan relay 1 circuit high input <Ref. to EN(H4)-294 DTC P1520 — COOLING FAN RELAY 1
P1560 Back-up voltage circuit malfunction <Ref. to EN(H4)-298 DTC P1560 — BACK-UP VOLTAGE
CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diag-
P1700 Throttle position sensor circuit malfunction for <Ref. to EN(H4)-300 DTC P1700 — THROTTLE POSITION
automatic transmission SENSOR CIRCUIT MALFUNCTION FOR AUTOMATIC
TRANSMISSION —, Diagnostic Procedure with Diagnostic
P1701 Cruise control set signal circuit malfunction for <Ref. to EN(H4)-300 DTC P1701 — CRUISE CONTROL SET
automatic transmission SIGNAL CIRCUIT MALFUNCTION FOR AUTOMATIC
P1702 Automatic transmission diagnosis input signal <Ref. to EN(H4)-300 DTC P1702 — AUTOMATIC TRANSMIS-
circuit low input SION DIAGNOSIS INPUT SIGNAL CIRCUIT LOW INPUT —,
MT Vehicles.>
P1703 Low clutch timing control solenoid valve circuit <Ref. to EN(H4)-300 DTC P1703 — LOW CLUTCH TIMING
malfunction CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION —,
MT Vehicles.>
EN(H4)-104
DTC
Item Index
No.
P1704 2-4 brake timing control solenoid valve circuit <Ref. to EN(H4)-300 DTC P1704 — 2-4 BRAKE TIMING
MT Vehicles.>
P1705 2-4 brake pressure control solenoid valve circuit <Ref. to EN(H4)-300 DTC P1705 — 2-4 BRAKE PRESSURE
MT Vehicles.>
circuit high input SION DIAGNOSIS INPUT SIGNAL CIRCUIT HIGH INPUT —,
MT Vehicles.>
circuit malfunction SION DIAGNOSIS INPUT SIGNAL CIRCUIT MALFUNCTION
for MT Vehicles.>
EN(H4)-105
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) FOR
MT VEHICLES
18. Diagnostic Procedure with Diagnostic Trouble Code (DTC) for

MT Vehicles S008600
A: DTC P0106 — INTAKE MANIFOLD PRESSURE SENSOR CIRCUIT RANGE/

PERFORMANCE PROBLEM — S008600F00
쐌 DTC DETECTING CONDITION:

쐌 Two consecutive driving cycles with fault
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3923
EN(H4)-106
MT VEHICLES

1 CHECK IDLE SWITCH SIGNAL. Does the LED of {Idle Go to step 2. Check throttle
1) Turn ignition switch to ON. Switch Signal} come on? position sensor
2) Operate the LED operation mode for circuit. <Ref. to
engine using Subaru Select Monitor. EN(H4)-130 DTC
NOTE: P0121 —
쐌 Subaru Select Monitor THROTTLE
For detailed operation procedure, refer to the POSITION SEN-
“LED OPERATION MODE FOR ENGINE”. SOR CIRCUIT
<Ref. to EN(H4)-52 Subaru Select Monitor.> RANGE/
PERFORMANCE
PROBLEM (HIGH
INPUT) —, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0106.
2 CHECK ANY OTHER DTC ON DISPLAY. Inspect DTC
Does the Subaru Select Go to step 3.
P0107 or P0108
Monitor or OBD-II general
using “17. List of
scan tool indicate DTC
P0107 or P0108? Diagnostic
Trouble Code
(DTC) for MT
Vehicles”. <Ref. to
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0106.
3 CHECK CONDITION OF INTAKE MANIFOLD Is the intake manifold pres- Go to step 4. Tighten intake
PRESSURE SENSOR. sure sensor installation bolt manifold pressure
tightened securely? sensor installation
bolt securely.
4 CHECK CONDITION OF THROTTLE BODY. Is the throttle body installa- Replace intake Tighten throttle
tion bolt tightened manifold pressure body installation
securely? sensor. <Ref. to bolt securely.
FU(H4)-49 Intake
Manifold Pressure
Sensor.>
EN(H4)-107
MT VEHICLES
B: DTC P0107 — INTAKE MANIFOLD PRESSURE SENSOR CIRCUIT LOW

INPUT — S008600F01

쐌 Immediately at fault recognition
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3923
EN(H4)-108
MT VEHICLES

1 CHECK CURRENT DATA. Is the value less than 3.3 Go to step 3. Go to step 2.
1) Start engine. kPa (25 mmHg, 0.98
2) Read the data of intake manifold absolute inHg)?
pressure signal using Subaru Select Monitor
or OBD-II general scan tool.
NOTE:
쐌 Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”.
<Ref. to EN(H4)-52 Subaru Select Monitor.>
쐌 OBD-II general scan tool
For detailed operation procedures, refer to the
2 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Even if MIL lights
Check poor contact in ECM and pressure ECM or pressure sensor tact in ECM or up, the circuit has
sensor connector. connector? pressure sensor returned to a nor-
connector. mal condition at
this time.
3 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than Go to step 5. Go to step 4.
Measure voltage between ECM connector 4.5 V?
and chassis ground.
(−):
4 CHECK INPUT SIGNAL FOR ECM. Does the voltage change Repair poor con- Contact with SOA
Measure voltage between ECM connector more than 4.5 V by shaking tact in ECM con- service.
and chassis ground. harness and connector of nector. NOTE:
Connector & terminal ECM while monitoring the Inspection by
(B136) No. 15 (+) — Chassis ground value with voltage meter? DTM is required,
(−): because probable
cause is deterio-
ration of multiple
parts.
5 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 0.7 Go to step 7. Go to step 6.
Measure voltage between ECM and chassis V?
ground.
6 CHECK INPUT SIGNAL FOR ECM. (USING Does the value change Repair poor con- Go to step 7.
SUBARU SELECT MONITOR.) more than 3.3 kPa (25 tact in ECM con-
Read data of atmospheric absolute pressure mmHg, 0.98 inHg) by shak- nector.
signal using Subaru Select Monitor. ing harness and connector
NOTE: of ECM while monitoring
쐌 Subaru Select Monitor the value with Subaru
For detailed operation procedure, refer to the Select Monitor?
7 CHECK HARNESS BETWEEN ECM AND Is the voltage more than Go to step 8. Repair open cir-
INTAKE MANIFOLD PRESSURE SENSOR 4.5 V? cuit in harness
CONNECTOR. between ECM
1) Turn ignition switch to OFF. and intake mani-
2) Disconnect connector from intake manifold fold pressure sen-
pressure sensor. sor connector.
4) Measure voltage between intake manifold
pressure sensor connector and engine
ground.
(E21) No. 3 (+) — Engine ground (−):
EN(H4)-109
MT VEHICLES

INTAKE MANIFOLD PRESSURE SENSOR 1 Ω? cuit in harness
2) Disconnect connector from ECM. fold pressure sen-
3) Measure resistance of harness between sor connector.
ECM and intake manifold pressure sensor
connector.
(B136) No. 16 — (E21) No. 2:
INTAKE MANIFOLD PRESSURE SENSOR 500 kΩ? short circuit in
Measure resistance of harness between ECM and intake
intake manifold pressure sensor connector manifold pressure
and engine ground. sensor connector.
(E21) No. 1 — Engine ground:
10 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace intake
Check poor contact in intake manifold pres- intake manifold pressure tact in intake manifold pressure
sure sensor connector. sensor connector? manifold pressure sensor. <Ref. to
sensor connector. FU(H4)-49 Intake
Manifold Pressure
Sensor.>
EN(H4)-110
MT VEHICLES
MEMO:
EN(H4)-111
MT VEHICLES
C: DTC P0108 — INTAKE MANIFOLD PRESSURE SENSOR CIRCUIT HIGH

INPUT — S008600F02

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3923
EN(H4)-112
MT VEHICLES

1 CHECK CURRENT DATA. Is the value more than 130 Go to step 10. Go to step 2.
NOTE:
and chassis ground.
(−):
cause is deterio-
ration of multiple
parts.
Measure voltage between ECM connector V?
and chassis ground.
INTAKE MANIFOLD PRESSURE SENSOR 4.5 V? cuit in harness
2) Disconnect connector from intake manifold fold pressure sen-
pressure sensor. sor connector.
4) Measure voltage between intake manifold
pressure sensor connector and engine
ground.
EN(H4)-113
MT VEHICLES

2) Disconnect connector from ECM. fold pressure sen-
ECM and intake manifold pressure sensor
connector.
(B136) No. 5 — (E21) No. 1:
Measure resistance of harness between ECM and intake mani-
and intake manifold pressure sensor connec- fold pressure sen-
tor. sor connector.
(B136) No. 16 — (E21) No. 2:
9 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace intake
Check poor contact in intake manifold pres- intake manifold pressure tact in intake manifold pressure
sure sensor connector. sensor connector? manifold pressure sensor. <Ref. to
sensor connector. FU(H4)-49 Intake
Manifold Pressure
Sensor.>
10 CHECK HARNESS BETWEEN ECM AND Is the value more than 130 Repair battery Replace intake
PRESSURE SENSOR CONNECTOR. kPa (975 mmHg, 38.39 short circuit in manifold pressure
1) Turn ignition switch to OFF and Subaru inHg)? harness between sensor. <Ref. to
Select Monitor or the OBD-II general scan ECM and intake FU(H4)-49 Intake
tool switch to OFF. manifold pressure Manifold Pressure
2) Disconnect connector from pressure sen- sensor connector. Sensor.>
sor.
3) Turn ignition switch to ON and Subaru
Select Monitor or the OBD-II general scan
tool switch to ON.
4) Read data of intake manifold absolute
NOTE:
EN(H4)-114
MT VEHICLES
MEMO:
EN(H4)-115
MT VEHICLES
D: DTC P0111 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT RANGE/

PERFORMANCE PROBLEM — S008600B14

쐌 Erroneous idling
쐌 Poor driving performance
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3924
EN(H4)-116
MT VEHICLES

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace intake air
Monitor or OBD-II general P0112 or P0113 temperature sen-
scan tool indicate DTC using “17. List of sor. <Ref. to
P0112 or P0113? Diagnostic FU(H4)-50 Intake
Trouble Code Air Temperature
(DTC) for MT Sensor.>
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0111.
EN(H4)-117
MT VEHICLES
E: DTC P0112 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW INPUT

— S008600B15

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3924
EN(H4)-118
MT VEHICLES

1 CHECK CURRENT DATA. Is the value greater than Go to step 2. Repair poor con-
1) Start engine. 120°C (248°F)? tact.
2) Read data of intake air temperature sensor NOTE:
signal using Subaru Select Monitor or the In this case,
OBD-II general scan tool. repair the follow-
NOTE: ing:
쐌 Subaru Select Monitor 쐌 Poor contact in
For detailed operation procedure, refer to the intake air tem-
“READ CURRENT DATA FOR ENGINE”. perature sensor
<Ref. to EN(H4)-52 Subaru Select Monitor.> 쐌 Poor contact in
쐌 OBD-II general scan tool ECM
For detailed operation procedure, refer to the 쐌 Poor contact in
OBD-II General Scan Tool Instruction Manual. coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
2 CHECK HARNESS BETWEEN INTAKE AIR Is the value less than Replace intake air Repair ground
TEMPERATURE SENSOR AND ECM CON- −40°C (−40°F)? temperature sen- short circuit in
NECTOR. sor. <Ref. to harness between
1) Turn ignition switch to OFF. FU(H4)-50 Intake intake air tem-
2) Disconnect connector from intake air tem- Air Temperature perature sensor
perature sensor. Sensor.> and ECM connec-
3) Turn ignition switch to ON. tor.
4) Read data of intake air temperature sensor
signal using Subaru Select Monitor or the
OBD-II general scan tool.
NOTE:
EN(H4)-119
MT VEHICLES
F: P0113 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH INPUT —

S008600B16

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3924
EN(H4)-120
MT VEHICLES

1 CHECK CURRENT DATA. Is the value less than Go to step 2. Repair poor con-
1) Turn ignition switch to ON. −40°C (−40°F)? tact.
2) Start engine. NOTE:
3) Read data of intake air temperature sensor In this case,
signal using Subaru Select Monitor or the repair the follow-
OBD-II general scan tool. ing:
NOTE: 쐌 Poor contact in
쐌 Subaru Select Monitor intake air tem-
For detailed operation procedure, refer to the perature sensor
“READ CURRENT DATA FOR ENGINE”. 쐌 Poor contact in
<Ref. to EN(H4)-52 Subaru Select Monitor.> ECM
쐌 OBD-II general scan tool 쐌 Poor contact in
For detailed operation procedure, refer to the coupling connec-
OBD-II General Scan Tool Instruction Manual. tor (B21)
쐌 Poor contact in
joint connector
(B83)
2 CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 10 Repair battery Go to step 3.
TEMPERATURE SENSOR AND ECM CON- V? short circuit in
NECTOR. harness between
1) Turn ignition switch to OFF. intake air tem-
2) Disconnect connector from intake air temperature sensor
perature sensor. and ECM connec-
3) Measure voltage between intake air tem- tor.
perature sensor connector and engine
ground.
TEMPERATURE SENSOR AND ECM CON- V? short circuit in
1) Turn ignition switch to ON. intake air tem-
2) Measure voltage between intake air temperature sensor
perature sensor connector and engine and ECM connec-
ground. tor.
4 CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 3 Go to step 5. Repair harness
TEMPERATURE SENSOR AND ECM CON- V? and connector.
NECTOR. NOTE:
Measure voltage between intake air tempera- In this case,
ture sensor connector and engine ground. repair the follow-
(E20) No. 1 (+) — Engine ground (−): 쐌 Open circuit in
harness between
intake air tem-
perature sensor
and ECM connec-
tor
쐌 Poor contact in
intake air tem-
perature sensor
쐌 Poor contact in
ECM
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
EN(H4)-121
MT VEHICLES

5 CHECK HARNESS BETWEEN INTAKE AIR Is the resistance less than Replace intake air Repair harness
TEMPERATURE SENSOR AND ECM CON- 5 Ω? temperature sen- and connector.
NECTOR. sor. <Ref. to NOTE:
1) Turn ignition switch to OFF. FU(H4)-50 Intake In this case,
2) Measure resistance of harness between Air Temperature repair the follow-
intake air temperature sensor connector and Sensor.> ing:
engine ground. 쐌 Open circuit in
Connector & terminal harness between
(E20) No. 2 — Engine ground: intake air tem-
perature sensor
and ECM connec-
tor
쐌 Poor contact in
intake air tem-
perature sensor
쐌 Poor contact in
ECM
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
EN(H4)-122
MT VEHICLES
MEMO:
EN(H4)-123
MT VEHICLES
G: DTC P0116 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT

LOW INPUT — S008600B17

쐌 Hard to start
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3925
EN(H4)-124
MT VEHICLES

2) Read data of engine coolant temperature NOTE:
sensor signal using Subaru Select Monitor or In this case,
NOTE: ing:
For detailed operation procedure, refer to the engine coolant
“READ CURRENT DATA FOR ENGINE”. temperature sen-
<Ref. to EN(H4)-52 Subaru Select Monitor.> sor
For detailed operation procedures, refer to the ECM
OBD-II General Scan Tool Instruction Manual. 쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
2 CHECK HARNESS BETWEEN ENGINE Is the value less than Replace engine Repair ground
COOLANT TEMPERATURE SENSOR AND −40°C (−40°F)? coolant tempera- short circuit in
ECM CONNECTOR. ture sensor. <Ref. harness between
1) Turn ignition switch to OFF. to CO(H4)-40 engine coolant
2) Disconnect connector from engine coolant Engine Coolant temperature sen-
temperature sensor. Temperature Sen- sor and ECM con-
3) Turn ignition switch to ON. sor.> nector.
4) Read data of engine coolant temperature
sensor signal using Subaru Select Monitor or
NOTE:
EN(H4)-125
MT VEHICLES
H: DTC P0117 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT

HIGH INPUT — S008600B18

쐌 Hard to start
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3925
EN(H4)-126
MT VEHICLES

1) Start engine. −40°C (−40°F)? tact.
NOTE: ing:
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
2 CHECK HARNESS BETWEEN ENGINE Is the voltage more than 10 Repair battery Go to step 3.
COOLANT TEMPERATURE SENSOR AND V? short circuit in
ECM CONNECTOR. harness between
1) Turn ignition switch to OFF. ECM and engine
2) Disconnect connector from engine coolant coolant tempera-
temperature sensor. ture sensor con-
3) Measure voltage between engine coolant nector.
temperature sensor connector and engine
ground.
1) Turn ignition switch to ON. ECM and engine
2) Measure voltage between engine coolant coolant tempera-
temperature sensor connector and engine ture sensor con-
ground. nector.
EN(H4)-127
MT VEHICLES

4 CHECK HARNESS BETWEEN ENGINE Is the voltage more than 4 Go to step 5. Repair harness
COOLANT TEMPERATURE SENSOR AND V? and connector.
ECM CONNECTOR. NOTE:
Measure voltage between engine coolant tem- In this case,
perature sensor connector and engine repair the follow-
ground. ing:
(E8) No. 1 (+) — Engine ground (−): harness between
ECM and engine
coolant tempera-
ture sensor con-
nector
쐌 Poor contact in
engine coolant
temperature sen-
sor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
5 CHECK HARNESS BETWEEN ENGINE Is the resistance less than Replace engine Repair harness
COOLANT TEMPERATURE SENSOR AND 5 Ω? coolant tempera- and connector.
ECM CONNECTOR. ture sensor. <Ref. NOTE:
1) Turn ignition switch to OFF. to CO(H4)-40 In this case,
2) Measure resistance of harness between Engine Coolant repair the follow-
engine coolant temperature sensor connector Temperature Sen- ing:
and engine ground. sor.> 쐌 Open circuit in
(E8) No. 2 — Engine ground: ECM and engine
coolant tempera-
ture sensor con-
nector
쐌 Poor contact in
engine coolant
temperature sen-
sor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
EN(H4)-128
MT VEHICLES
MEMO:
EN(H4)-129
MT VEHICLES
I: DTC P0121 — THROTTLE POSITION SENSOR CIRCUIT

RANGE/PERFORMANCE PROBLEM (HIGH INPUT) — S008600B19

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3926
EN(H4)-130
MT VEHICLES

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Go to step 2.
Monitor or OBD-II general P0107, P0108,
scan tool indicate DTC P0122 or P0123
P0107, P0108, P0122 or using “17. List of
P0123? Diagnostic
Trouble Code
(DTC) for MT
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0121.
2 CHECK CURRENT DATA. Is the value more than 53.3 Replace intake Replace throttle
1) Start engine. kPa (400 mmHg, 15.75 manifold pressure position sensor.
2) Read the data of intake manifold absolute inHg)? sensor. <Ref. to <Ref. to
pressure signal using Subaru Select Monitor FU(H4)-49 Intake FU(H4)-45
or OBD-II general scan tool. Manifold Pressure Throttle Position
NOTE: Sensor.> Sensor.>
EN(H4)-131
MT VEHICLES
J: DTC P0122 — THROTTLE POSITION SENSOR CIRCUIT LOW INPUT — S008600B20

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3926
EN(H4)-132
MT VEHICLES

1 CHECK CURRENT DATA. Is the value less than 0.1 Go to step 2. Even if MIL lights
1) Start engine. V? up, the circuit has
2) Read data of throttle position sensor signal returned to a nor-
using Subaru Select Monitor or OBD-II gen- mal condition at
eral scan tool. this time. A tem-
NOTE: porary poor con-
쐌 Subaru Select Monitor tact of the con-
For detailed operation procedure, refer to the nector may be the
“READ CURRENT DATA FOR ENGINE”. cause.
<Ref. to EN(H4)-52 Subaru Select Monitor.> NOTE:
쐌 OBD-II general scan tool In this case,
For detailed operation procedures, refer to the repair the follow-
OBD-II General Scan Tool Instruction Manual. ing:
쐌 Poor contact in
throttle position
sensor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
and chassis ground while throttle valve is fully
closed.
(−):
cause is deterio-
ration of multiple
parts.
and chassis ground.
(−):
5 CHECK INPUT SIGNAL FOR ECM. (USING Does the voltage change Repair poor con- Go to step 6.
SUBARU SELECT MONITOR.) more than 0.1 V by shaking tact in ECM con-
Measure voltage between ECM connector harness and connector of nector.
and chassis ground. ECM while monitoring the
value with Subaru Select
Monitor?
EN(H4)-133
MT VEHICLES

6 CHECK HARNESS BETWEEN ECM AND Is the voltage more than Go to step 7. Repair harness
THROTTLE POSITION SENSOR CONNEC- 4.5 V? and connector.
TOR. NOTE:
2) Disconnect connectors from throttle posi- repair the follow-
tion sensor. ing:
3) Turn ignition switch to ON. 쐌 Open circuit in
4) Measure voltage between throttle position harness between
sensor connector and engine ground. throttle position
Connector & terminal sensor and ECM
(E13) No. 1 (+) — Engine ground (−): connector
쐌 Poor contact in
throttle position
sensor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
THROTTLE POSITION SENSOR CONNEC- 1 Ω? and connector.
TOR. NOTE:
ECM connector and throttle position sensor ing:
connector. 쐌 Open circuit in
(B136) No. 17 — (E13) No. 3: throttle position
sensor and ECM
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
throttle position
sensor connector
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
THROTTLE POSITION SENSOR CONNEC- 10 Ω? short circuit in
TOR. harness between
Measure resistance of harness between throttle position
throttle position sensor connector and engine sensor and ECM
ground. connector.
9 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace throttle
Check poor contact in throttle position sensor throttle position sensor contact in throttle position sensor.
connector. nector? position sensor <Ref. to
connector. FU(H4)-45
Throttle Position
Sensor.>
EN(H4)-134
MT VEHICLES
MEMO:
EN(H4)-135
MT VEHICLES
K: DTC P0123 — THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT — S008600B21

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3926
EN(H4)-136
MT VEHICLES

1 CHECK CURRENT DATA. Is the value more than 4.9 Go to step 2. Even if MIL lights
쐌 Poor contact in
throttle position
sensor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
2 CHECK HARNESS BETWEEN THROTTLE Is the resistance less than Go to step 3. Repair harness
POSITION SENSOR AND ECM CONNEC- 5 Ω? and connector.
TOR. NOTE:
2) Disconnect connector from throttle position repair the follow-
sensor. ing:
3) Measure resistance of harness between 쐌 Open circuit in
throttle position sensor connector and engine harness between
ground. throttle position
(E13) No. 2 — Engine ground: connector
쐌 Poor contact in
coupling connec-
tor (B21)
3 CHECK HARNESS BETWEEN THROTTLE Is the voltage more than Repair battery Replace throttle
POSITION SENSOR AND ECM CONNEC- 4.9 V? short circuit in position sensor.
TOR. harness between <Ref. to
1) Turn ignition switch to ON. throttle position FU(H4)-45
2) Measure voltage between throttle position sensor and ECM Throttle Position
sensor connector and engine ground. connector. After Sensor.>
Connector & terminal repair, replace
(E13) No. 3 (+) — Engine ground (−): ECM. <Ref. to
FU(H4)-67 Engine
Control Module.>
EN(H4)-137
MT VEHICLES
L: DTC P0125 — INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED

LOOP FUEL CONTROL — S008600B22

쐌 Engine would not return to idling.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3925
EN(H4)-138
MT VEHICLES

Monitor or OBD-II general P0116 or P0117
scan tool indicate DTC using “17. List of
Trouble Code
(DTC) for MT
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0125.
2 CHECK THERMOSTAT. Does thermostat remain Replace thermo- Replace engine
opened? stat. <Ref. to coolant tempera-
CO(H4)-13 Ther- ture sensor. <Ref.
mostat.> to FU(H4)-40
Engine Coolant
Temperature Sen-
sor.>
EN(H4)-139
MT VEHICLES
M: DTC P0131 — FRONT OXYGEN (A/F) SENSOR CIRCUIT

RANGE/PERFORMANCE PROBLEM (LOW INPUT) — S008600B24
NOTE:
For the diagnostic procedure, refer to DTC P0132. <Ref. to EN(H4)-142 DTC P0132 — FRONT OXYGEN
(A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) —, Diagnostic Procedure
EN(H4)-140
MT VEHICLES
MEMO:
EN(H4)-141
MT VEHICLES
N: DTC P0132 — FRONT OXYGEN (A/F) SENSOR CIRCUIT


CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3927
EN(H4)-142
MT VEHICLES

scan tool indicate DTC P1132, P1133 or
P1130, P1131, P1132, P1134 using “17.
P1133 or P1134? List of Diagnostic
Trouble Code
(DTC) for MT
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
2 CHECK FRONT (A/F) OXYGEN SENSOR Is the value equal to or Go to step 3. Go to step 4.
DATA. more than 0.85 and equal
1) Start engine. to less 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
70°C (158°F).
If the engine is already warmed-up, operate at
idle speed for at least 1 minute.
3) Read data of front oxygen (A/F) sensor
signal using Subaru Select Monitor or OBD-II
general scan tool.
NOTE:
3 CHECK REAR OXYGEN SENSOR SIGNAL. Does the LED of {Rear O2 Repair poor con- Check rear oxy-
1) Race engine at speeds from idling to 5,000 Rich Signal} blink? tact in front oxygen sensor circuit.
rpm for a total of 5 cycles. gen (A/F) sensor <Ref. to
NOTE: and rear oxygen FU(H4)-65 Rear
To increase engine speed to 5,000 rpm, sensor connector. Oxygen Sensor.>
slowly depress accelerator pedal, taking
approximately 5 seconds, and quickly release
accelerator pedal to decrease engine speed.
2) Operate the LED operation mode for
engine.
NOTE:
“LED OPERATION MODE FOR ENGINE”.
4 CHECK EXHAUST SYSTEM. Is there a fault in exhaust Repair or replace Replace front oxy-
Check exhaust system parts. system? faulty parts. gen (A/F) sensor.
NOTE: <Ref. to
Check the following items. FU(H4)-63 Front
쐌 Loose installation of portions Oxygen (A/F)
쐌 Damage (crack, hole etc.) of parts Sensor.>
쐌 Looseness of front oxygen (A/F) sensor
쐌 Looseness and ill fitting of parts between
front oxygen (A/F) sensor and rear oxygen
sensor
EN(H4)-143
MT VEHICLES
O: DTC P0133 — FRONT OXYGEN (A/F) SENSOR CIRCUIT SLOW

RESPONSE — S008600B26

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3927
EN(H4)-144
MT VEHICLES

P1130, P1131, P1132, P1134 using “17.
Trouble Code
(DTC) for MT
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0133.
2 CHECK EXHAUST SYSTEM. Is there a fault in exhaust Repair exhaust Replace front oxy-
NOTE: system? system. gen (A/F) sensor.
Check the following items. <Ref. to
쐌 Loose installation of front portion of exhaust FU(H4)-63 Front
pipe onto cylinder heads Oxygen (A/F)
쐌 Loose connection between front exhaust Sensor.>
pipe and front catalytic converter
쐌 Damage of exhaust pipe resulting in a hole
EN(H4)-145
MT VEHICLES
P: DTC P0136 — REAR OXYGEN SENSOR CIRCUIT MALFUNCTION — S008600B28

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3928

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Go to step 2. Go to step 3.
P1130 or P1131?
EN(H4)-146
MT VEHICLES

2 CHECK FAILURE CAUSE OF P1130 or Is the failure cause of Check fuel sys- Go to step 3.
P1131. P1130 or P1131 in the fuel tem.
Inspect DTC P1130 or P1131 using “17. List system? NOTE:
of Diagnostic Trouble Code (DTC) for MT In this case, it is
Vehicles”. <Ref. to EN(H4)-99 List of Diagnos- not necessary to
tic Trouble Code (DTC) for MT Vehicles.> inspect DTC
P0136.
3 CHECK REAR OXYGEN SENSOR DATA. Does the value fluctuate? Go to step 7. Go to step 4.
2) Warm-up the engine until engine coolant
temperature is above 70°C (158°F), and keep
the engine speed at 2,000 rpm to 3,000 rpm
for two minutes.
3) Read data of rear oxygen sensor signal
using Subaru Select Monitor or OBD-II gen-
eral scan tool.
NOTE:
4 CHECK REAR OXYGEN SENSOR DATA. Is the value fixed between Go to step 5. Replace rear oxy-
Read data of rear oxygen sensor signal using 0.2 and 0.4 V? gen sensor. <Ref.
Subaru Select Monitor or OBD-II General to FU(H4)-65
Scan Tool. Rear Oxygen
Sensor.>
5 CHECK HARNESS BETWEEN ECM AND Is the resistance more than Repair open cir- Go to step 6.
REAR OXYGEN SENSOR CONNECTOR. 3 Ω? cuit in harness
1) Turn ignition switch to OFF. between ECM
2) Disconnect connectors from ECM and rear and rear oxygen
oxygen sensor. sensor connector.
ECM and rear oxygen sensor connector.
(B136) No. 16 — (T6) No. 3:
6 CHECK HARNESS BETWEEN REAR OXY- Is the voltage more than Replace rear oxy- Repair harness
GEN SENSOR AND ECM CONNECTOR. 0.2 V? gen sensor. <Ref. and connector.
1) Connect connector to ECM. to FU(H4)-65 NOTE:
2) Turn ignition switch to ON. Rear Oxygen In this case,
3) Measure voltage between rear oxygen sen- Sensor.> repair the follow-
sor harness connector and engine ground or ing:
chassis ground. 쐌 Open circuit in
(T6) No. 4 (+) — Engine ground (−): rear oxygen sen-
sor and ECM con-
nector
쐌 Poor contact in
rear oxygen sen-
sor connector
쐌 Poor contact in
ECM connector
EN(H4)-147
MT VEHICLES

7 CHECK EXHAUST SYSTEM. Is there a fault in exhaust Repair or replace Replace rear oxy-
Check exhaust system parts. system? faulty parts. gen sensor. <Ref.
NOTE: to FU(H4)-65
Check the following items. Rear Oxygen
쐌 Loose installation of portions Sensor.>
쐌 Damage (crack, hole etc.) of parts
sensor
EN(H4)-148
MT VEHICLES
MEMO:
EN(H4)-149
MT VEHICLES
Q: DTC P0139 — REAR OXYGEN SENSOR CIRCUIT SLOW RESPONSE —

S008600B29

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3928
EN(H4)-150
MT VEHICLES

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace rear oxy-
Monitor or OBD-II general P0136 using “17. gen sensor. <Ref.
scan tool indicate DTC Diagnostics Chart to FU(H4)-65
P0136? with Trouble Code Rear Oxygen
for MT Vehicles”. Sensor.>
<Ref. to
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0139.
EN(H4)-151
MT VEHICLES
R: DTC P0141 — REAR OXYGEN SENSOR HEATER CIRCUIT LOW INPUT —

S008600F03

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3928

P0141 and P0135 at the
same time?
EN(H4)-152
MT VEHICLES

2 CHECK GROUND CIRCUIT OF ECM. Is the resistance less than Go to step 4. Go to step 3.
1) Turn ignition switch to OFF. 10 Ω?
3 CHECK GROUND CIRCUIT OF ECM. Is the resistance less than Go to step 4. Repair harness
1) Repair harness and connector. 5 Ω? and connector.
NOTE: NOTE:
In this case, repair the following: In this case,
쐌 Open circuit in harness between ECM and repair the follow-
engine ground terminal ing:
쐌 Poor contact in ECM connector 쐌 Open circuit in
쐌 Poor contact in coupling connector (B22) harness between
2) Measure resistance of harness between ECM and engine
ECM connector and chassis ground. ground terminal
Connector & terminal 쐌 Poor contact in
(B134) No. 34 — Chassis ground: ECM connector
Poor contact in
coupling connec-
tor (B22)
REAR OXYGEN SENSOR CONNECTOR. 10 Ω? short circuit in
connector and chassis ground. ECM and rear
Connector & terminal oxygen sensor
(B134) No. 21 — Chassis ground: connector.
1) Disconnect connector from rear oxygen between ECM
sensor. and rear oxygen
2) Measure resistance of harness between sensor connector.
(B134) No. 21 — (T6) No. 4:
6 CHECK POWER SUPPLY TO REAR OXY- Is the voltage more than 10 Go to step 7. Repair power sup-
GEN SENSOR. V? ply line.
1) Connect connector to ECM. NOTE:
2) Turn ignition switch to ON. In this case,
3) Measure voltage between rear oxygen sen- repair the follow-
sor connector and engine ground or chassis ing:
ground. 쐌 Open circuit in
(T6) No. 2 (+) — Engine ground (−): main relay and
rear oxygen sen-
sor connector
쐌 Poor contact in
rear oxygen sen-
sor connector
쐌 Poor contact in
coupling connec-
tor (T5)
EN(H4)-153
MT VEHICLES

7 CHECK REAR OXYGEN SENSOR. Is the resistance less than Repair harness Replace rear oxy-
1) Turn ignition switch to OFF. 30 Ω? and connector. gen sensor. <Ref.
2) Measure resistance between rear oxygen NOTE: to FU(H4)-65
sensor connector terminals. In this case, Rear Oxygen
Terminals repair the follow- Sensor.>
No. 2 — No. 4: ing:
쐌 Open circuit in
harness between
rear oxygen sen-
sor and ECM con-
nector
쐌 Poor contact in
rear oxygen sen-
sor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (T5)
EN(H4)-154
MT VEHICLES
S: DTC P0171 — FUEL TRIM MALFUNCTION (A/F TOO LEAN) — S008600B33
NOTE:
For the diagnostic procedure, refer to DTC P0172. <Ref. to EN(H4)-156 DTC P0172 — FUEL TRIM MAL-
FUNCTION (A/F TOO RICH) —, Diagnostic Procedure with Diagnostic Trouble Code (DTC) for MT
Vehicles.>
EN(H4)-155
MT VEHICLES
T: DTC P0172 — FUEL TRIM MALFUNCTION (A/F TOO RICH) — S008600B32

쐌 Engine stalls.
CAUTION:
tion Mode.>.
1 CHECK EXHAUST SYSTEM. Are there holes or loose Repair exhaust Go to step 2.
bolts on exhaust system? system.
2 CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts Repair air intake Go to step 3.
or disconnection of hose on system.
air intake system?
3 CHECK FUEL PRESSURE. Is fuel pressure between Go to step 4. Repair the follow-
WARNING: 284 and 314 kPa (2.9 — ing items.
쐌 Place “NO FIRE” signs near the working 3.2 kg/cm2, 41 — 46 psi)? Fuel pressure
area. too high
쐌 Be careful not to spill fuel on the floor. 쐌 Clogged fuel
1) Release fuel pressure. return line or bent
(1) Disconnect connector from fuel pump hose
relay. Fuel pressure
(2) Start the engine and run it until it stalls. too low
(3) After the engine stalls, crank it for five 쐌 Improper fuel
more seconds. pump discharge
(4) Turn ignition switch to OFF. 쐌 Clogged fuel
2) Connect connector to fuel pump relay. supply line
3) Disconnect fuel delivery hose from fuel
filter, and connect fuel pressure gauge.
4) Install fuel filler cap.
5) Start the engine and idle while gear posi-
tion is neutral.
6) Measure fuel pressure while disconnecting
pressure regulator vacuum hose from intake
manifold.
WARNING:
Before removing fuel pressure gauge,
release fuel pressure.
NOTE:
If fuel pressure does not increase, squeeze
fuel return hose 2 to 3 times, then measure
fuel pressure again.
EN(H4)-156
MT VEHICLES

After connecting pressure regulator vacuum 206 and 235 kPa (2.1 — ing items.
hose, measure fuel pressure. 2.4 kg/cm2, 30 — 34 psi)? Fuel pressure
WARNING: too high
Before removing fuel pressure gauge, 쐌 Faulty pressure
release fuel pressure. regulator
NOTE: 쐌 Clogged fuel
쐌 If fuel pressure does not increase, squeeze return line or bent
fuel return hose 2 to 3 times, then measure hose
fuel pressure again. Fuel pressure
쐌 If out of specification as measured at this too low
step, check or replace pressure regulator and 쐌 Faulty pressure
pressure regulator vacuum hose. regulator
쐌 Improper fuel
pump discharge
쐌 Clogged fuel
supply line
5 CHECK ENGINE COOLANT TEMPERA- Is temperature greater than Go to step 6. Replace engine
TURE SENSOR. 60°C (140°F)? coolant tempera-
1) Start the engine and warm-up completely. ture sensor. <Ref.
2) Read data of engine coolant temperature to FU(H4)-40
sensor signal using Subaru Select Monitor or Engine Coolant
OBD-II general scan tool. Temperature Sen-
NOTE: sor.>
6 CHECK INTAKE MANIFOLD PRESSURE Is the value within the Go to step 7. Replace intake
SENSOR. specifications? manifold pressure
1) Start the engine and warm-up engine until sensor. <Ref. to
coolant temperature is greater than 60°C FU(H4)-49 Intake
(140°F). Manifold Pressure
2) Place the shift lever in neutral position. Sensor.>
3) Turn A/C switch to OFF.
4) Turn all accessory switches to OFF.
5) Read data of intake manifold pressure sen-
sor signal using Subaru Select Monitor or
NOTE:
Specification:
쐌 Intake manifold absolute pressure
Ignition ON
73.3 — 106.6 kPa (550 — 800 mmHg,
21.65 — 31.50 inHg)
Idling
24.0 — 41.3 kPa (180 — 310 mmHg,
7.09 — 12.20 inHg)
EN(H4)-157
MT VEHICLES

7 CHECK INTAKE AIR TEMPERATURE SEN- Is value obtained when Contact with SOA Check intake air
SOR. ambient temperature is service. temperature sen-
1) Start the engine and warm-up engine until subtracted from intake air NOTE: sor. <Ref. to
coolant temperature is greater than 60°C temperature greater than Inspection by FU(H4)-50 Intake
(140°F). −10°C (14°F) and less than DTM is required, Air Temperature
2) Place the shift lever in neutral position. 50°C (122°F)? because probable Sensor.>
3) Turn A/C switch to OFF. cause is deterio-
4) Turn all accessory switches to OFF. ration of multiple
5) Open front hood. parts.
6) Measure ambient temperature.
NOTE:
EN(H4)-158
MT VEHICLES
MEMO:
EN(H4)-159
MT VEHICLES
U: DTC P0181 — FUEL TEMPERATURE SENSOR A CIRCUIT

RANGE/PERFORMANCE PROBLEM — S008600B34

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3929
EN(H4)-160
MT VEHICLES

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace fuel tem-
Monitor or OBD-II general P0182 or P0183 perature sensor.
scan tool indicate DTC using “17. List of <Ref. to
P0182 or P0183? Diagnostic EC(H4)-10 Fuel
Trouble Code Temperature Sen-
(DTC) for MT sor.>
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0181.
EN(H4)-161
MT VEHICLES
V: DTC P0182 — FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT —

S008600B35

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3929
EN(H4)-162
MT VEHICLES

1 CHECK CURRENT DATA. Is the value greater than Go to step 2. Even if MIL lights
1) Start engine. 150°C (302°F)? up, the circuit has
2) Read data of fuel temperature sensor sig- returned to a nor-
nal using Subaru Select Monitor or OBD-II mal condition at
general scan tool. this time.
NOTE:
2 CHECK CURRENT DATA. Is the value less than Replace fuel tem- Repair ground
1) Turn ignition switch to OFF. −40°C (−40°F)? perature sensor. short circuit in
2) Remove access hole lid. <Ref. to harness between
3) Disconnect connector from fuel pump. EC(H4)-10 Fuel fuel pump and
4) Turn ignition switch to ON. Temperature Sen- ECM connector.
5) Read data of fuel temperature sensor sig- sor.>
nal using Subaru Select Monitor or the OBD-II
general scan tool.
NOTE:
EN(H4)-163
MT VEHICLES
W: DTC P0183 — FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT —

S008600B36

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3929
EN(H4)-164
MT VEHICLES

2) Read data of fuel temperature sensor sig- NOTE:
nal using Subaru Select Monitor or OBD-II In this case,
general scan tool. repair the follow-
NOTE: ing:
For detailed operation procedure, refer to the fuel pump con-
“READ CURRENT DATA FOR ENGINE”. nector
쐌 OBD-II general scan tool ECM connector
For detailed operation procedures, refer to the 쐌 Poor contact in
tors (B22, B99
and R57)
쐌 Poor contact in
joint connector
(B83)
2 CHECK HARNESS BETWEEN FUEL TEM- Is the voltage more than 10 Repair battery Go to step 3.
PERATURE SENSOR AND ECM CONNEC- V? short circuit in
1) Turn ignition switch to OFF. ECM and fuel
2) Remove access hole lid. pump connector.
3) Disconnect connector from fuel pump.
4) Measure voltage between fuel pump con-
1) Turn ignition switch to ON. ECM and fuel
2) Measure voltage between fuel pump con- pump connector.
4 CHECK HARNESS BETWEEN FUEL TEM- Is the voltage more than 4 Go to step 5. Repair harness
PERATURE SENSOR AND ECM CONNEC- V? and connector.
TOR. NOTE:
Measure voltage between fuel pump connec- In this case,
tor and chassis ground. repair the follow-
(R58) No. 6 (+) — Chassis ground (−): 쐌 Open circuit in
harness between
ECM and fuel
pump connector
쐌 Poor contact in
fuel pump con-
nector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tors (B99 and
R57)
EN(H4)-165
MT VEHICLES

5 CHECK HARNESS BETWEEN FUEL TEM- Is the resistance less than Replace fuel tem- Repair harness
PERATURE SENSOR AND ECM CONNEC- 5 Ω? perature sensor. and connector.
TOR. <Ref. to NOTE:
1) Turn ignition switch to OFF. EC(H4)-10 Fuel In this case,
2) Measure resistance of harness between Temperature Sen- repair the follow-
fuel pump connector and chassis ground. sor.> ing:
(R58) No. 5 — Chassis ground: harness between
ECM and fuel
pump connector
쐌 Poor contact in
fuel pump con-
nector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tors (B22, B99
and R57)
쐌 Poor contact in
joint connector
(B83)
EN(H4)-166
MT VEHICLES
X: DTC P0301 — CYLINDER 1 MISFIRE DETECTED — S008600B37
NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(H4)-168 DTC P0304 — CYLINDER 4 MIS-
FIRE DETECTED —, Diagnostic Procedure with Diagnostic Trouble Code (DTC) for MT Vehicles.>
Y: DTC P0302 — CYLINDER 2 MISFIRE DETECTED — S008600B38
NOTE:
Z: DTC P0303 — CYLINDER 3 MISFIRE DETECTED — S008600B39
NOTE:
EN(H4)-167
MT VEHICLES
AA: DTC P0304 — CYLINDER 4 MISFIRE DETECTED — S008600B40

쐌 Immediately at fault recognition (A misfire which could damage catalyst occurs.)
쐌 Engine stalls.
쐌 Rough driving
CAUTION:
tion Mode.>.
EN(H4)-168
MT VEHICLES
쐌 WIRING DIAGRAM:
B2M3964
EN(H4)-169
MT VEHICLES
B2M3965
EN(H4)-170
MT VEHICLES

scan tool indicate DTC P0108, P0116,
P0106, P0107, P0108, P0117 or P0125
P0116, P0117 or P0125? using “17. List of
Diagnostic
Trouble Code
(DTC) for MT
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0301, P0302,
P0303 and
P0304.
2 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 Go to step 7. Go to step 3.
and chassis ground on faulty cylinders.
#1 (B134) No. 4 (+) — Chassis ground
(−):
(−):
(−):
(−):
3 CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance less than Repair ground Go to step 4.
TOR AND ECM CONNECTOR. 10 Ω? short circuit in
2) Disconnect connector from fuel injector on fuel injector and
faulty cylinders. ECM connector.
and engine ground on faulty cylinders.
#1 (E5) No. 1 — Engine ground:
4 CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance less than Go to step 5. Repair harness
TOR AND ECM CONNECTOR. 1 Ω? and connector.
Measure resistance of harness connector NOTE:
between ECM connector and fuel injector on In this case,
faulty cylinders. repair the follow-
#1 (B134) No. 4 — (E5) No. 1: 쐌 Open circuit in
#2 (B134) No. 13 — (E16) No. 1: harness between
#3 (B134) No. 14 — (E6) No. 1: ECM and fuel
#4 (B134) No. 15 — (E17) No. 1: injector connector
쐌 Poor contact in
coupling connec-
tor (B22)
EN(H4)-171
MT VEHICLES

5 CHECK FUEL INJECTOR. Is the resistance between 5 Go to step 6. Replace faulty
Measure resistance between fuel injector ter- and 20 Ω? fuel injector. <Ref.
minals on faulty cylinder. to FU(H4)-56 Fuel
Terminals Injector.>
No. 1 — No. 2:
6 CHECK POWER SUPPLY LINE. Is the voltage more than 10 Repair poor con- Repair harness
1) Turn ignition switch to ON. V? tact in all connec- and connector.
2) Measure voltage between fuel injector and tors in fuel injector NOTE:
engine ground on faulty cylinders. circuit. In this case,
#1 (E5) No. 2 (+) — Engine ground (−): ing:
#2 (E16) No. 2 (+) — Engine ground 쐌 Open circuit in
(−): harness between
#3 (E6) No. 2 (+) — Engine ground (−): main relay and
(−): nector on faulty
cylinders
쐌 Poor contact in
coupling connec-
tor (B22)
쐌 Poor contact in
main relay con-
nector
쐌 Poor contact in
fuel injector con-
nector on faulty
cylinders
7 CHECK HARNESS BETWEEN FUEL INJEC- Is the voltage more than 10 Repair battery Go to step 8.
TOR AND ECM CONNECTOR. V? short circuit in
2) Disconnect connector from fuel injector on ECM and fuel
faulty cylinder. injector. After
3) Turn ignition switch to ON. repair, replace
4) Measure voltage between ECM connector ECM. <Ref. to
and chassis ground on faulty cylinders. FU(H4)-67 Engine
Connector & terminal Control Module.>
(−):
(−):
(−):
(−):
8 CHECK FUEL INJECTOR. Is the resistance less than Replace faulty Go to step 9.
1) Turn ignition switch to OFF. 1 Ω? fuel injector <Ref.
2) Measure resistance between fuel injector to FU(H4)-56 Fuel
terminals on faulty cylinder. Injector.> and
Terminals ECM <Ref. to
No. 1 — No. 2: FU(H4)-67 Engine
Control Module.>.
9 CHECK INSTALLATION OF CAMSHAFT Is camshaft position sensor Tighten camshaft Go to step 10.
POSITION SENSOR/CRANKSHAFT POSI- or crankshaft position sen- position sensor or
TION SENSOR. sor loosely installed? crankshaft posi-
tion sensor.
10 CHECK CRANKSHAFT SPROCKET. Is crankshaft sprocket Replace crank- Go to step 11.
Remove timing belt cover. rusted or does it have bro- shaft sprocket.
ken teeth? <Ref. to
ME(H4)-51 Crank-
shaft Sprocket.>
EN(H4)-172
MT VEHICLES

11 CHECK TIMING BELT. Is timing belt out of align- Align timing belt. Go to step 12.
ment? <Ref. to
ME(H4)-46 Timing
Belt Assembly.>
12 CHECK FUEL LEVEL. Is the fuel meter indication Go to step 13. Replenish fuel so
higher than the “Lower” fuel meter indica-
level? tion is higher than
the “Lower” level.
After replenishing
fuel, Go to step
13.
13 CHECK STATUS OF CHECK ENGINE MAL- Is the MIL coming on or Go to step 15. Go to step 14.
FUNCTION INDICATOR LAMP (MIL). blinking?
1) Clear memory using Subaru Select Moni-
tor.
<Ref. to EN(H4)-63 Clear Memory Mode.>
2) Start engine, and drive the vehicle more
than 10 minutes.
14 CHECK CAUSE OF MISFIRE DIAGNOSED. Was the cause of misfire Finish diagnostics Repair poor con-
diagnosed when the engine operation, if the tact.
is running? engine has no NOTE:
abnormality. In this case,
NOTE: repair the follow-
Ex. Remove spark ing:
plug cord, etc. 쐌 Poor contact in
ignitor connector
쐌 Poor contact in
ignition coil con-
nector
쐌 Poor contact in
fuel injector con-
nector on faulty
cylinders
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B22)
15 CHECK AIR INTAKE SYSTEM. Is there a fault in air intake Repair air intake Go to step 16.
system? system.
NOTE:
Check the follow-
ing items:
쐌 Are there air
leaks or air suc-
tion caused by
loose or dislo-
cated nuts and
bolts?
쐌 Are there
cracks or any dis-
connection of
hoses?
EN(H4)-173
MT VEHICLES

16 CHECK MISFIRE SYMPTOM. Does the Subaru Select Go to step 21. Go to step 17.
1) Turn ignition switch to ON. Monitor or OBD-II general
2) Read diagnostic trouble code (DTC). <Ref. scan tool indicate only one
to EN(H4)-59 Read Diagnostic Trouble DTC?
Code.>
NOTE:
Perform diagnosis according to the items
listed below.
17 CHECK DIAGNOSTIC TROUBLE CODE Does the Subaru Select Go to step 22. Go to step 18.
(DTC) ON DISPLAY. Monitor or OBD-II general
P0301 and P0302?
P0303 and P0304?
P0301 and P0303?
P0302 and P0304?
21 ONLY ONE CYLINDER Is there a fault in that cylin- Repair or replace Go to DTC P0171
der? faulty parts. <Ref. to EN(H4)-
NOTE: 155 DTC P0171
Check the follow- — FUEL TRIM
ing items. MALFUNCTION
쐌 Spark plug (A/F TOO LEAN)
쐌 Spark plug cord —, Diagnostic
쐌 Fuel injector Procedure with
쐌 Compression Diagnostic
ratio Trouble Code
(DTC) for MT
Vehicles.> and
P0172. <Ref. to
EN(H4)-156 DTC
P0172 — FUEL
TRIM MALFUNC-
TION (A/F TOO
RICH) —, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
EN(H4)-174
MT VEHICLES

22 GROUP OF #1 AND #2 CYLINDERS Are there faults in #1 and Repair or replace Go to DTC P0171
#2 cylinders? faulty parts. <Ref. to EN(H4)-
NOTE: 155 DTC P0171
쐌 Check the fol- — FUEL TRIM
lowing items. MALFUNCTION
Spark plugs (A/F TOO LEAN)
Fuel injectors —, Diagnostic
Ignition coil Procedure with
Compression ratio Diagnostic
쐌 If no abnormal Trouble Code
is discovered, (DTC) for MT
check for “IGNI- Vehicles.> and
TION CONTROL P0172. <Ref. to
SYSTEM” of #1 EN(H4)-156 DTC
and #2 cylinders P0172 — FUEL
side. <Ref. to TRIM MALFUNC-
EN(H4)-86 IGNI- TION (A/F TOO
TION CONTROL RICH) —, Diag-
SYSTEM, Diag- nostic Procedure
nostics for Engine with Diagnostic
Starting Failure.> Trouble Code
(DTC) for MT
Vehicles.>
NOTE: 155 DTC P0171
쐌 Check the fol- — FUEL TRIM
lowing items. MALFUNCTION
Spark plugs (A/F TOO LEAN)
Fuel injectors —, Diagnostic
Ignition coil Procedure with
쐌 If no abnormal Diagnostic
is discovered, Trouble Code
check for “IGNI- (DTC) for MT
TION CONTROL Vehicles.> and
SYSTEM” of #3 P0172. <Ref. to
and #4 cylinders EN(H4)-156 DTC
side. <Ref. to P0172 — FUEL
EN(H4)-86 IGNI- TRIM MALFUNC-
TION CONTROL TION (A/F TOO
SYSTEM, Diag- RICH) —, Diag-
nostics for Engine nostic Procedure
Starting Failure.> with Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
EN(H4)-175
MT VEHICLES

NOTE: 155 DTC P0171
쐌 Spark plugs (A/F TOO LEAN)
쐌 Fuel injectors —, Diagnostic
쐌 Skipping timing Procedure with
belt teeth Diagnostic
Trouble Code
(DTC) for MT
Vehicles.> and
P0172. <Ref. to
EN(H4)-156 DTC
P0172 — FUEL
TRIM MALFUNC-
TION (A/F TOO
RICH) —, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
NOTE: 155 DTC P0171
쐌 Spark plugs (A/F TOO LEAN)
쐌 Fuel injectors —, Diagnostic
쐌 Compression Procedure with
ratio Diagnostic
쐌 Skipping timing Trouble Code
belt teeth (DTC) for MT
Vehicles.> and
P0172. <Ref. to
EN(H4)-156 DTC
P0172 — FUEL
TRIM MALFUNC-
TION (A/F TOO
RICH) —, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
EN(H4)-176
MT VEHICLES

26 CYLINDER AT RANDOM Is the engine idle rough? Go to DTC P0171 Repair or replace
<Ref. to EN(H4)- faulty parts.
155 DTC P0171 NOTE:
— FUEL TRIM Check the follow-
MALFUNCTION ing items.
(A/F TOO LEAN) 쐌 Spark plugs
—, Diagnostic 쐌 Fuel injectors
Procedure with 쐌 Compression
Diagnostic ratio
Trouble Code
(DTC) for MT
Vehicles.> and
P0172. <Ref. to
EN(H4)-156 DTC
P0172 — FUEL
TRIM MALFUNC-
TION (A/F TOO
RICH) —, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
EN(H4)-177
MT VEHICLES
AB: DTC P0325 — KNOCK SENSOR CIRCUIT MALFUNCTION — S008600F04

쐌 Knocking occurs.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3930
EN(H4)-178
MT VEHICLES

1 CHECK HARNESS BETWEEN KNOCK Is the resistance more than Go to step 3. Go to step 2.
SENSOR AND ECM CONNECTOR. 700 kΩ?
3) Measure resistance between ECM harness
2 CHECK HARNESS BETWEEN KNOCK Is the resistance less than Go to step 5. Go to step 6.
Measure resistance of harness between ECM
3 CHECK KNOCK SENSOR. Is the resistance more than Go to step 4. Repair harness
1) Disconnect connector from knock sensor. 700 kΩ? and connector.
2) Measure resistance between knock sensor NOTE:
connector terminal and engine ground. In this case,
Terminal repair the follow-
No. 2 — Engine ground: ing:
쐌 Open circuit in
harness between
knock sensor and
ECM connector
쐌 Poor contact in
knock sensor con-
nector
쐌 Poor contact in
coupling connec-
tor (B21)
4 CHECK CONDITION OF KNOCK SENSOR Is the knock sensor instal- Replace knock Tighten knock
INSTALLATION. lation bolt tightened sensor. <Ref. to sensor installation
securely? FU(H4)-43 Knock bolt securely.
Sensor.>
5 CHECK KNOCK SENSOR. Is the resistance less than Replace knock Repair ground
1) Disconnect connector from knock sensor. 400 kΩ? sensor. <Ref. to short circuit in
2) Measure resistance between knock sensor FU(H4)-43 Knock harness between
connector terminal and engine ground. Sensor.> knock sensor con-
Terminal nector and ECM
No. 2 — Engine ground: connector.
NOTE:
The harness
between both
connectors is
shielded. Repair
short circuit of
harness together
with shield.
EN(H4)-179
MT VEHICLES

6 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 2 Even if MIL lights Repair poor con-
1) Connect connectors to ECM and knock V? up, the circuit has tact in ECM con-
sensor. returned to a nor- nector.
2) Turn ignition switch to ON. mal condition at
3) Measure voltage between ECM and chas- this time.
sis ground. (However, the
Connector & terminal possibility of poor
(B136) No. 4 (+) — Chassis ground (−): contact still
remains.)
NOTE:
In this case,
repair the follow-
ing:
쐌 Poor contact in
knock sensor con-
nector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
EN(H4)-180
MT VEHICLES
MEMO:
EN(H4)-181
MT VEHICLES
AC: DTC P0335 — CRANKSHAFT POSITION SENSOR CIRCUIT

MALFUNCTION — S008600B42

쐌 Engine stalls.
쐌 Failure of engine to start
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3931
EN(H4)-182
MT VEHICLES

1 CHECK HARNESS BETWEEN CRANK- Is the resistance more than Repair harness Go to step 2.
SHAFT POSITION SENSOR AND ECM 100 kΩ? and connector.
CONNECTOR. NOTE:
2) Disconnect connector from crankshaft posi- repair the follow-
tion sensor. ing:
crankshaft position sensor connector and harness between
engine ground. crankshaft posi-
Connector & terminal tion sensor and
(E10) No. 1 — Engine ground: ECM connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
2 CHECK HARNESS BETWEEN CRANK- Is the resistance less than Repair ground Go to step 3.
SHAFT POSITION SENSOR AND ECM 10 Ω? short circuit in
Measure resistance of harness between crankshaft posi-
crankshaft position sensor connector and tion sensor and
engine ground. ECM connector.
Connector & terminal NOTE:
(E10) No. 1 — Engine ground: The harness
between both
connectors are
shielded. Repair
ground short cir-
cuit in harness
together with
shield.
3 CHECK HARNESS BETWEEN CRANK- Is the resistance less than Go to step 4. Repair harness
SHAFT POSITION SENSOR AND ECM 5 Ω? and connector.
CONNECTOR. NOTE:
Measure resistance of harness between In this case,
crankshaft position sensor connector and repair the follow-
engine ground. ing:
crankshaft posi-
tion sensor and
ECM connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
4 CHECK CONDITION OF CRANKSHAFT Is the crankshaft position Go to step 5. Tighten crankshaft
POSITION SENSOR. sensor installation bolt position sensor
tightened securely? installation bolt
securely.
5 CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1 Repair poor con- Replace crank-
1) Remove crankshaft position sensor. and 4 kΩ? tact in crankshaft shaft position sen-
2) Measure resistance between connector position sensor sor. <Ref. to
terminals of crankshaft position sensor. connector. FU(H4)-41 Crank-
Terminals shaft Position
No. 1 — No. 2: Sensor.>
EN(H4)-183
MT VEHICLES
AD: DTC P0336 — CRANKSHAFT POSITION SENSOR CIRCUIT


쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3931
EN(H4)-184
MT VEHICLES

Monitor or OBD-II general P0335 using “17.
scan tool indicate DTC List of Diagnostic
P0335? Trouble Code
(DTC) for MT
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
Turn ignition switch to OFF. tightened securely? installation bolt
securely.
3 CHECK CRANKSHAFT SPROCKET. Are crankshaft sprocket Replace crank- Go to step 4.
Remove front belt cover. teeth cracked or damaged? shaft sprocket.
<Ref. to
ME(H4)-52 Crank-
shaft Sprocket.>
4 CHECK INSTALLATION CONDITION OF Is timing belt dislocated Repair installation Replace crank-
TIMING BELT. from its proper position? condition of timing shaft position sen-
Turn crankshaft using ST, and align alignment belt. <Ref. to sor. <Ref. to
mark on crankshaft sprocket with alignment ME(H4)-46 Timing FU(H4)-41 Crank-
mark on cylinder block. Belt Assembly.> shaft Position
ST 499987500 CRANKSHAFT SOCKET Sensor.>
EN(H4)-185
MT VEHICLES
AE: DTC P0340 — CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

— S008600B44

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3932
EN(H4)-186
MT VEHICLES

1 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance more than Repair harness Go to step 2.
POSITION SENSOR AND ECM CONNEC- 100 kΩ? and connector.
TOR. NOTE:
2) Disconnect connector from camshaft posi- repair the follow-
tion sensor. ing:
camshaft position sensor connector and harness between
engine ground. camshaft position
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
2 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than Repair ground Go to step 3.
POSITION SENSOR AND ECM CONNEC- 10 Ω? short circuit in
Measure resistance of harness between cam- camshaft position
shaft position sensor connector and engine sensor and ECM
ground. connector.
between both
connectors are
shielded. Repair
ground short cir-
cuit in harness
together with
shield.
3 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than Go to step 4. Repair harness
TOR. NOTE:
Measure resistance of harness between cam- In this case,
shaft position sensor connector and engine repair the follow-
ground. ing:
camshaft position
sensor and ECM
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
4 CHECK CONDITION OF CAMSHAFT POSI- Is the camshaft position Go to step 5. Tighten camshaft
TION SENSOR. sensor installation bolt position sensor
securely.
5 CHECK CAMSHAFT POSITION SENSOR. Is the resistance between 1 Repair poor con- Replace camshaft
1) Remove camshaft position sensor. and 4 kΩ? tact in camshaft position sensor.
2) Measure resistance between connector position sensor <Ref. to
terminals of camshaft position sensor. connector. FU(H4)-42 Cam-
EN(H4)-187
MT VEHICLES
AF: DTC P0341 — CAMSHAFT POSITION SENSOR CIRCUIT


쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3932
EN(H4)-188
MT VEHICLES

P0340 using “17.
List of Diagnostic
P0340? Trouble Code
(DTC) for MT
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
TOR. NOTE:
tion sensor. ing:
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
ground. connector.
between both
connectors are
shielded. Repair
ground short cir-
cuit in harness
together with
shield.
TOR. NOTE:
ground. ing:
camshaft position
sensor and ECM
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
EN(H4)-189
MT VEHICLES

securely.
6 CHECK CAMSHAFT POSITION SENSOR. Is the resistance between 1 Go to step 7. Replace camshaft
1) Remove camshaft position sensor. and 4 kΩ? position sensor.
2) Measure resistance between connector <Ref. to
terminals of camshaft position sensor. FU(H4)-42 Cam-
securely.
8 CHECK CAMSHAFT SPROCKET. Are camshaft sprocket Replace camshaft Go to step 9.
Remove front belt cover. <Ref. to ME(H4)-45 teeth cracked or damaged? sprocket. <Ref. to
Belt Cover.> ME(H4)-51 Cam-
shaft Sprocket.>
9 CHECK INSTALLATION CONDITION OF Is timing belt dislocated Repair installation Replace camshaft
TIMING BELT. from its proper position? condition of timing position sensor.
Turn camshaft using ST, and align alignment belt. <Ref. to <Ref. to
mark on camshaft sprocket with alignment ME(H4)-46 Timing FU(H4)-42 Cam-
mark on timing belt cover LH. Belt Assembly.> shaft Position
ST 499207100 CAMSHAFT SPROCKET Sensor.>
WRENCH
EN(H4)-190
MT VEHICLES
MEMO:
EN(H4)-191
MT VEHICLES
AG: DTC P0420 — CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD

— S008600B46

쐌 Engine stalls.
쐌 Idle mixture is out of specifications.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3933
EN(H4)-192
MT VEHICLES

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect the rel- Go to step 2.
Monitor or OBD-II general evant DTC using
scan tool indicate DTC “17. List of Diag-
P0131, P0132, P0133, nostic Trouble
P0135, P0136, P0139, Code (DTC) for
P0141, P0301, P0302, MT Vehicles”.
P0303, P0304, P1130, <Ref. to
P1131, P1134, P1139, EN(H4)-99 List of
P1150 and P1151? Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0420.
2 CHECK EXHAUST SYSTEM. Is there a fault in exhaust Repair or replace Go to step 3.
Check for gas leaks or air suction caused by system? exhaust system.
loose or dislocated nuts and bolts, and open <Ref. to EX(H4)-2
hole at exhaust pipes. General Descrip-
NOTE: tion.>
Check the following positions.
쐌 Between cylinder head and front exhaust
pipe
쐌 Between front exhaust pipe and front cata-
lytic converter
쐌 Between front catalytic converter and rear
catalytic converter
3 CHECK REAR CATALYTIC CONVERTER. Is there damage at rear Replace front Go to step 4.
Separate rear catalytic converter from rear face of rear catalyst? catalytic converter
exhaust pipe. <Ref. to EC(H4)-3
Front Catalytic
Converter.> and
rear catalytic con-
verter <Ref. to
EC(H4)-6 Rear
Catalytic Con-
verter.>.
4 CHECK FRONT CATALYTIC CONVERTER. Is there damage at rear Replace front Contact with SOA
Remove front catalytic converter. face or front face of front catalytic con- service.
catalyst? verter. <Ref. to NOTE:
EC(H4)-3 Front Inspection by
Catalytic Con- DTM is required,
verter.> because probable
cause is deterio-
ration of multiple
parts.
EN(H4)-193
MT VEHICLES
AH: DTC P0440 — EVAPORATIVE EMISSION CONTROL SYSTEM


쐌 Gasoline smell
쐌 There is a hole of more than 1.0 mm (0.04 in) dia. in evaporation system or fuel tank.
CAUTION:
tion Mode.>.
EN(H4)-194
MT VEHICLES
쐌 WIRING DIAGRAM:
B2M3882
EN(H4)-195
MT VEHICLES

1 CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on Inspect the rel- Go to step 2.
display? evant DTC using
“17. List of Diag-
nostic Trouble
Code (DTC) for
MT Vehicles”.
<Ref. to
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
2 CHECK FUEL FILLER CAP. Is the fuel filler cap tight- Go to step 3. Tighten fuel filler
1) Turn ignition switch to OFF. ened securely? cap securely.
2) Check the fuel filler cap.
NOTE:
The DTC code is stored in memory if fuel filler
cap is or was loose or if the cap chain was
caught while tightening.
3 CHECK FUEL FILLER PIPE PACKING. Is there any damage to the Repair or replace Go to step 4.
seal between fuel filler cap fuel filler cap and
and fuel filler pipe? fuel filler pipe.
<Ref. to
FU(H4)-82 Fuel
Filler Pipe.>
4 CHECK DRAIN VALVE. Does drain valve produce Go to step 5. Replace drain
1) Connect test mode connector. operating sound? valve. <Ref. to
2) Turn ignition switch to ON. EC(H4)-17 Drain
3) Operate drain valve. Valve.>
NOTE:
Drain valve operation can also be executed
using Subaru Select Monitor. For the
procedure, refer to “Compulsory Valve Opera-
tion Check Mode”. <Ref. to EN(H4)-64 Com-
pulsory Valve Operation Check Mode.>
5 CHECK PURGE CONTROL SOLENOID Does purge control sole- Go to step 6. Replace purge
VALVE. noid valve produce operat- control solenoid
Operate purge control solenoid valve. ing sound? valve. <Ref. to
NOTE: EC(H4)-8 Purge
Purge control solenoid valve operation can Control Solenoid
also be executed using Subaru Select Moni- Valve.>
tor. For the procedure, refer to “Compulsory
Valve Operation Check Mode”. <Ref. to
EN(H4)-64 Compulsory Valve Operation
Check Mode.>
6 CHECK PRESSURE CONTROL SOLENOID Does pressure control sole- Go to step 7. Replace pressure
Operate pressure control solenoid valve. ing sound? valve. <Ref. to
NOTE: EC(H4)-13 Pres-
Pressure control solenoid valve operation can sure Control Sole-
also be executed using Subaru Select Moni- noid Valve.>
Check Mode.>
EN(H4)-196
MT VEHICLES

7 CHECK EVAPORATIVE EMISSION CON- Is there a hole of more Repair or replace Go to step 8.
TROL SYSTEM LINE. than 1.0 mm (0.04 in) dia. fuel line. <Ref. to
Turn ignition switch to OFF. on fuel line? FU(H4)-98 Fuel
Delivery, Return
and Evaporation
Lines.>
8 CHECK CANISTER. Is canister damaged or is Repair or replace Go to step 9.
there a hole of more than canister. <Ref. to
1.0 mm (0.04 in) dia. in it? EC(H4)-7 Canis-
ter.>
9 CHECK FUEL TANK. Is fuel tank damaged or is Repair or replace Go to step 10.
Remove fuel tank. <Ref. to FU(H4)-73 Fuel there a hole of more than fuel tank. <Ref. to
Tank.> 1.0 mm (0.04 in) dia. in it? FU(H4)-73 Fuel
Tank.>
10 CHECK ANY OTHER MECHANICAL Are there holes of more Repair or replace Contact with SOA
TROUBLE IN EVAPORATIVE EMISSION than 1.0 mm (0.04 in) dia., hoses or pipes. service.
CONTROL SYSTEM. cracks, clogging or discon- NOTE:
nections of hoses or pipes Inspection by
in evaporative emission DTM is required,
control system? because probable
cause is deterio-
ration of multiple
parts.
EN(H4)-197
MT VEHICLES
AI: DTC P0443 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE

CONTROL VALVE CIRCUIT LOW INPUT — S008600B49

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3935
EN(H4)-198
MT VEHICLES

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 Even if MIL lights Go to step 2.
1) Turn ignition switch to ON. V? up, the circuit has
2) Measure voltage between ECM and chas- returned to a nor-
sis ground. mal condition at
Connector & terminal this time. Contact
(B134) No. 2 (+) — Chassis ground (−): with SOA service.
NOTE:
Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
2 CHECK HARNESS BETWEEN PURGE Is the resistance less than Repair ground Go to step 3.
CONTROL SOLENOID VALVE AND ECM 10 Ω? short circuit in
1) Turn ignition switch to OFF. ECM and purge
2) Disconnect connectors from purge control control solenoid
solenoid valve and ECM. valve connector.
purge control solenoid valve connector and
engine ground.
3 CHECK HARNESS BETWEEN PURGE Is the resistance less than Go to step 4. Repair open cir-
CONTROL SOLENOID VALVE AND ECM 1 Ω? cuit in harness
Measure resistance of harness between ECM and purge control
and purge control solenoid valve of harness solenoid valve
connector. connector.
(B134) No. 2 — (E4) No. 2: In this case,
repair the follow-
ing:
쐌 Open circuit in
harness between
ECM and purge
control solenoid
valve connector
쐌 Poor contact in
coupling connec-
tor (B22)
4 CHECK PURGE CONTROL SOLENOID Is the resistance between Go to step 5. Replace purge
VALVE. 10 and 100 Ω? control solenoid
1) Remove purge control solenoid valve. valve. <Ref. to
2) Measure resistance between purge control EC(H4)-8 Purge
solenoid valve terminals. Control Solenoid
Terminals Valve.>
No. 1 — No. 2:
5 CHECK POWER SUPPLY TO PURGE CON- Is the voltage more than 10 Go to step 6. Repair open cir-
TROL SOLENOID VALVE. V? cuit in harness
1) Turn ignition switch to ON. between main
2) Measure voltage between purge control relay and purge
solenoid valve and engine ground. control solenoid
Connector & terminal valve connector.
EN(H4)-199
MT VEHICLES

6 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Contact with SOA
Check poor contact in purge control solenoid purge control solenoid tact in purge con- service.
valve connector. valve connector? trol solenoid valve NOTE:
connector. Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(H4)-200
MT VEHICLES
MEMO:
EN(H4)-201
MT VEHICLES
AJ: DTC P0446 — EVAPORATIVE EMISSION CONTROL SYSTEM VENT

CONTROL LOW INPUT — S008600B50

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3936
EN(H4)-202
MT VEHICLES

sis ground.
(−):
Check poor contact in ECM connector. ECM connector? tact in ECM con- up, the circuit has
nector. returned to a nor-
mal condition at
this time.
(However, the
possibility of poor
contact still
remains.)
NOTE:
In this case,
repair the follow-
ing:
쐌 Poor contact in
drain valve con-
nector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tors (B97 and
B99)
3 CHECK HARNESS BETWEEN DRAIN Is the resistance less than Repair ground Go to step 4.
VALVE AND ECM CONNECTOR. 10 Ω? short circuit in
2) Disconnect connectors from drain valve ECM and drain
and ECM. valve connector.
drain valve connector and chassis ground.
4 CHECK HARNESS BETWEEN DRAIN Is the voltage less than 1 Go to step 5. Repair harness
VALVE AND ECM CONNECTOR. Ω? and connector.
and drain valve connector. In this case,
(B134) No. 10 — (R69) No. 2: ing:
쐌 Open circuit in
harness between
ECM and drain
valve connector
쐌 Poor contact in
coupling connec-
tors (B99)
5 CHECK DRAIN VALVE. Is the resistance between Go to step 6. Replace drain
Measure resistance between drain valve ter- 10 and 100 Ω? valve. <Ref. to
minals. EC(H4)-17 Drain
Terminals Valve.>
No. 1 — No. 2:
EN(H4)-203
MT VEHICLES

6 CHECK POWER SUPPLY TO DRAIN Is the voltage more than 10 Go to step 7. Repair harness
VALVE. V? and connector.
2) Measure voltage between drain valve and In this case,
chassis ground. repair the follow-
harness between
main relay and
drain valve
쐌 Poor contact in
coupling connec-
tors (B97)
쐌 Poor contact in
main relay con-
nector
Check poor contact in drain valve connector. drain valve connector? tact in drain valve service.
connector. NOTE:
Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(H4)-204
MT VEHICLES
MEMO:
EN(H4)-205
MT VEHICLES
AK: DTC P0451 — EVAPORATIVE EMISSION CONTROL SYSTEM

PRESSURE SENSOR RANGE/PERFORMANCE PROBLEM — S008600B51

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3937
EN(H4)-206
MT VEHICLES

1 CHECK ANY OTHER DTC ON DISPLAY. Is there any DTC on dis- Inspect the rel- Go to step 2.
play? evant DTC using
nostic Trouble
Code (DTC) for
MT Vehicles”.
<Ref. to
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
2) Open the fuel flap.
3 CHECK PRESSURE/VACUUM LINE. Is there a fault in pressure/ Repair or replace Replace fuel tank
NOTE: vacuum line? hoses and pipes. pressure sensor.
쐌 Disconnection, leakage and clogging of the EC(H4)-12 Fuel
vacuum hoses and pipes between fuel tank Tank Pressure
pressure sensor and fuel tank Sensor.>
쐌 Disconnection, leakage and clogging of air
ventilation hoses and pipes between fuel filler
pipe and fuel tank
EN(H4)-207
MT VEHICLES
AL: DTC P0452 — EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE

SENSOR LOW INPUT — S008600B52

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3937
EN(H4)-208
MT VEHICLES

1 CHECK CURRENT DATA. Is the value less than −2.8 Go to step 2. Even if MIL lights
1) Turn ignition switch to OFF. kPa (−21.0 mmHg, −0.827 up, the circuit has
2) Remove fuel filler cap. inHg)? returned to a nor-
3) Install fuel filler cap. mal condition at
4) Turn ignition switch to ON. this time.
5) Read the data of fuel tank pressure sensor
NOTE:
2 CHECK POWER SUPPLY TO FUEL TANK Is the voltage more than Go to step 4. Go to step 3.
PRESSURE SENSOR. 4.5 V?
Measure voltage between ECM connector
and chassis ground.
(−):
3 CHECK POWER SUPPLY TO FUEL TANK Does the voltage change Repair poor con- Contact with SOA
PRESSURE SENSOR. more than 4.5 V by shaking tact in ECM con- service.
Measure voltage between ECM connector harness and connector of nector. NOTE:
and chassis ground. ECM while monitoring the Inspection by
Connector & terminal value with voltage meter? DTM is required,
(B136) No. 15 (+) — Chassis ground because probable
(−): cause is deterio-
ration of multiple
parts.
ground.
(−):
SUBARU SELECT MONITOR.) more than −2.8 kPa (−21.0 tact in ECM con-
Read data of fuel tank pressure sensor signal mmHg, −0.827 inHg) by nector.
using Subaru Select Monitor. shaking harness and con-
NOTE: nector of ECM while moni-
쐌 Subaru Select Monitor toring the value with
For detailed operation procedure, refer to the Subaru Select Monitor?
EN(H4)-209
MT VEHICLES

COUPLING CONNECTOR IN REAR WIRING 4.5 V? and connector.
HARNESS. NOTE:
2) Remove rear seat cushion (Sedan) or repair the follow-
move rear seat cushion (Wagon). ing:
3) Separate rear wiring harness and fuel tank 쐌 Open circuit in
cord. harness between
4) Turn ignition switch to ON. ECM and rear
5) Measure voltage between rear wiring har- wiring harness
ness connector and chassis ground. connector (R134)
(R134) No. 5 (+) — Chassis ground (−): coupling connec-
tor (B99)
COUPLING CONNECTOR IN REAR WIRING 1 Ω? and connector.
HARNESS. NOTE:
3) Measure resistance of harness between ing:
ECM and rear wiring harness connector. 쐌 Open circuit in
(B136) No. 16 — (R134) No. 3: ECM and rear
wiring harness
connector (R134)
쐌 Poor contact in
coupling connec-
tor (B99)
쐌 Poor contact in
joint connector
(B83)
COUPLING CONNECTOR IN REAR WIRING 500 kΩ? short circuit in
HARNESS. harness between
Measure resistance of harness between rear ECM and rear
wiring harness connector and chassis ground. wiring harness
Connector & terminal connector (R134).
9 CHECK FUEL TANK CORD. Is the resistance less than Go to step 10. Repair open cir-
1) Disconnect connector from fuel tank pres- 1 Ω? cuit in fuel tank
sure sensor. cord.
2) Measure resistance of fuel tank cord.
(R135) No. 5 — (R47) No. 3:
Measure resistance of fuel tank cord. 1 Ω? cuit in fuel tank
Connector & terminal cord.
(R135) No. 3 — (R47) No. 1:
11 CHECK FUEL TANK CORD. Is the resistance more than Go to step 12. Repair ground
Measure resistance of harness between fuel 500 kΩ? short circuit in fuel
tank pressure sensor connector and chassis tank cord.
ground.
12 CHECK POOR CONTACT. Is there poor contact in fuel Repair poor con- Replace fuel tank
Check poor contact in fuel tank pressure sen- tank pressure sensor contact in fuel tank pressure sensor.
sor connector. nector? pressure sensor <Ref. to
connector. EC(H4)-12 Fuel
Tank Pressure
Sensor.>
EN(H4)-210
MT VEHICLES
MEMO:
EN(H4)-211
MT VEHICLES
AM: DTC P0453 — EVAPORATIVE EMISSION CONTROL SYSTEM

PRESSURE SENSOR HIGH INPUT — S008600B53

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3937
EN(H4)-212
MT VEHICLES

1 CHECK CURRENT DATA. Is the value more than 2.8 Go to step 12. Go to step 2.
1) Turn ignition switch to OFF. kPa (21.0 mmHg, 0.827
2) Remove fuel filler cap. inHg)?
5) Read data of fuel tank pressure sensor sig-
nal using Subaru Select Monitor or OBD-II
general scan tool.
NOTE:
and chassis ground.
(−):
3 CHECK POWER SUPPLY TO FUEL TANK Does the voltage change Repair poor con- Replace ECM.
PRESSURE SENSOR. more than 4.5 V by shaking tact in ECM con- <Ref. to
Measure voltage between ECM connector harness and connector of nector. FU(H4)-67 Engine
and chassis ground. ECM while monitoring the Control Module.>
Connector & terminal value with voltage meter?
(−):
ground.
(−):
HARNESS. NOTE:
tor (B99)
EN(H4)-213
MT VEHICLES

HARNESS. NOTE:
wiring harness
connector (R134)
쐌 Poor contact in
coupling connec-
tor (B99)
8 CHECK HARNESS BETWEEN ECM AND Is the resistance less than Go to step 9. Repair ground
COUPLING CONNECTOR IN REAR WIRING 1 Ω? short circuit in
(B136) No. 16 — (R134) No. 3:
sure sensor. cord.
(R135) No. 6 — (R47) No. 2:
(R135) No. 3 — (R47) No. 1:
Tank Pressure
Sensor.>
12 CHECK HARNESS BETWEEN ECM AND Is the value more than 2.8 Repair battery Replace fuel tank
FUEL TANK PRESSURE SENSOR CON- kPa (21.0 mmHg, 0.827 short circuit in pressure sensor.
NECTOR. inHg)? harness between <Ref. to
1) Turn ignition switch to OFF and Subaru ECM and fuel EC(H4)-12 Fuel
Select Monitor or the OBD-II general scan tank pressure Tank Pressure
tool switch to OFF. sensor connector. Sensor.>
2) Disconnect connector from fuel tank pres-
sure sensor.
tool switch to ON.
general scan tool.
NOTE:
EN(H4)-214
MT VEHICLES
MEMO:
EN(H4)-215
MT VEHICLES
AN: DTC P0461 — FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM — S008600B54

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3938
EN(H4)-216
MT VEHICLES

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace fuel level
Monitor or OBD-II general P0462 or P0463 sensor <Ref. to
scan tool indicate DTC using “17. List of FU(H4)-93 Fuel
P0462 or P0463? Diagnostic Level Sensor.>
Trouble Code and fuel sub level
(DTC) for MT sensor <Ref. to
Vehicles”. <Ref. to FU(H4)-94 Fuel
EN(H4)-99 List of Sub Level Sen-
Diagnostic sor.>.
Trouble Code
(DTC) for MT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect this
trouble.
EN(H4)-217
MT VEHICLES
AO: DTC P0462 — FUEL LEVEL SENSOR CIRCUIT LOW INPUT — S008600B55

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3938

1 CHECK SPEEDOMETER AND TACHOM- Does speedometer and Go to step 2. Repair or replace
ETER OPERATION IN COMBINATION tachometer operate nor- combination
METER. mally? meter.
EN(H4)-218
MT VEHICLES

2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than Go to step 4. Go to step 3.
1) Turn ignition switch to ON. (Engine OFF) 0.12 V?
and chassis ground.
(−):
3 CHECK INPUT SIGNAL FOR ECM. (USING Does the value change Repair poor con- Even if MIL lights
SUBARU SELECT MONITOR.) less than 0.12 V by shak- tact in ECM con- up, the circuit has
Read data of fuel level sensor signal using ing harness and connector nector. returned to a nor-
Subaru Select Monitor. of ECM while monitoring mal condition at
NOTE: the value with Subaru this time. A tem-
쐌 Subaru Select Monitor Select Monitor? porary poor con-
For detailed operation procedure, refer to the tact of the con-
“READ CURRENT DATA FOR ENGINE”. nector may be the
<Ref. to EN(H4)-52 Subaru Select Monitor.> cause.
NOTE:
In this case,
repair the follow-
ing:
쐌 Poor contact in
combination meter
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tors (R98)
4 CHECK INPUT VOLTAGE OF ECM. Is the voltage less than Go to step 5. Go to step 7.
1) Turn ignition switch to OFF. 0.12 V?
2) Separate fuel tank cord connector (R57)
and rear wiring harness connector (R15).
4) Measure voltage of harness between ECM
(–):
COMBINATION METER. 1 MΩ? short circuit in
2) Disconnect connector from connector (i10) ECM and combi-
and ECM connector. nation meter con-
3) Measure resistance between ECM and nector.
chassis ground.
6 CHECK HARNESS BETWEEN ECM AND Is the resistance less than Repair or replace Repair open cir-
COMBINATION METER. 10 Ω? combination cuit between ECM
Measure resistance between ECM and combi- meter. <Ref. to and combination
nation meter connector. IDI-17 Combina- meter connector.
Connector & terminal tion Meter Assem- NOTE:
(B136) No. 27 — (i10) No. 3: bly.> In this case,
repair the follow-
ing:
Poor contact in
coupling connec-
tor (R98)
EN(H4)-219
MT VEHICLES

1) Turn ignition switch to OFF. 1 MΩ? short circuit in fuel
2) Disconnect connector from fuel sub level tank cord.
sensor.
3) Measure resistance between fuel sub level
1) Disconnect connector from fuel pump 1 MΩ? short circuit in fuel
assembly. tank cord.
2) Measure resistance between fuel pump
assembly and chassis ground.
9 CHECK FUEL LEVEL SENSOR. Is the resistance between Go to step 10. Replace fuel level
WARNING: 0.5 and 2.5 Ω? sensor.
During work procedures, if fuel tank is
more than 3/4 full, be careful because fuel
may spill.
1) Remove fuel pump assembly. <Ref. to
FU(H4)-90 Fuel Pump.>
2) Measure resistance between fuel level sen-
sor and terminals with its float set to the full
position.
Terminals
No. 3 — No. 6:
10 CHECK FUEL SUB LEVEL SENSOR. Is the resistance between Repair poor con- Replace fuel sub
WARNING: 0.5 and 2.5 Ω? tact in harness level sensor.
During work procedures, if fuel tank is between ECM <Ref. to
more than 3/4 full, be careful because fuel and combination FU(H4)-94 Fuel
may spill. meter connector. Sub Level Sen-
1) Remove fuel sub level sensor. <Ref. to sor.>
FU(H4)-94 Fuel Sub Level Sensor.>
sensor and terminals with its float set to the
full position.
Terminals
No. 1 — No. 2:
EN(H4)-220
MT VEHICLES
MEMO:
EN(H4)-221
MT VEHICLES
AP: DTC P0463 — FUEL LEVEL SENSOR CIRCUIT HIGH INPUT — S008600B56

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3938

METER. mally? meter. <Ref. to
IDI-17 Combina-
tion Meter Assem-
bly.>
EN(H4)-222
MT VEHICLES

2 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than Go to step 3. Even if MIL lights
1) Turn ignition switch to ON. (Engine OFF) 4.75 V? up, the circuit has
2) Measure voltage between ECM connector returned to a nor-
and chassis ground. mal condition at
Connector & terminal this time. A tem-
(B136) No. 27 (+) — Chassis ground porary poor con-
(−): tact of the con-
nector may be the
cause.
NOTE:
In this case,
repair the follow-
ing:
쐌 Poor contact in
fuel pump con-
nector
쐌 Poor contact in
coupling connec-
tor (B22, R98 and
R57)
3 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than Go to step 4. Repair battery
1) Turn ignition switch to OFF. 4.75 V? short circuit
2) Disconnect combination meter connector between ECM
(i10) and ECM connector. and combination
3) Turn ignition switch to ON. meter connector.
and chassis ground.
(−):
FUEL TANK CORD. 5 Ω? cuit between ECM
1) Turn ignition switch to OFF. and fuel tank
2) Separate fuel tank cord connector (R57) cord.
3) Measure resistance between ECM and fuel
tank cord.
(B136) No. 27 — (R15) No. 6:
5 CHECK HARNESS BETWEEN FUEL TANK Is the resistance less than Go to step 6. Repair open cir-
CORD AND CHASSIS GROUND. 5 Ω? cuit between fuel
Measure resistance between fuel tank cord tank cord and
and chassis ground. chassis ground.
(R15) No. 5 — Chassis ground: In this case,
repair the follow-
ing:
Poor contact in
coupling connec-
tors (B99 and
B22)
1) Disconnect connector from fuel level sen- 10 Ω? cuit between cou-
sor. pling connector
2) Measure resistance between fuel level sen- and fuel level sen-
sor and coupling connector. sor.
(R57) No. 5 — (R58) No. 3:
EN(H4)-223
MT VEHICLES

1) Disconnect connector from fuel sub level 10 Ω? cuit between fuel
sensor. level sensor and
2) Measure resistance between fuel level sen- fuel sub level sen-
sor and fuel sub level sensor. sor.
(R58) No. 6 — (R59) No. 2:
Measure resistance between fuel sub level 10 Ω? cuit between cou-
sensor and coupling connector. pling connector
Connector & terminal and fuel sub level
(R57) No. 6 — (R59) No. 1: sensor.
9 CHECK FUEL LEVEL SENSOR. Is the resistance more than Replace fuel level Go to step 10.
WARNING: 54.5 Ω? sensor. <Ref. to
During work procedures, if fuel tank is FU(H4)-93 Fuel
more than 3/4 full, be careful because fuel Level Sensor.>
may spill.
1) Remove fuel pump assembly. <Ref. to 2-8
[W3A0].>
2) While moving fuel level sensor float up and
down, measure resistance between fuel level
sensor terminals.
Terminals
No. 3 — No. 6:
10 CHECK FUEL SUB LEVEL SENSOR. Is the resistance more than Replace fuel sub Replace combina-
WARNING: 41.5 Ω? level sensor. tion meter. <Ref.
During work procedures, if fuel tank is <Ref. to to IDI-17 Combi-
more than 3/4 full, be careful because fuel FU(H4)-94 Fuel nation Meter
may spill. Sub Level Sen- Assembly.>
2) While moving fuel sub level sensor float up
and down, measure resistance between fuel
sub level sensor terminals.
Terminals
No. 1 — No. 2:
EN(H4)-224
MT VEHICLES
MEMO:
EN(H4)-225
MT VEHICLES
AQ: DTC P0480 — COOLING FAN RELAY 1 CIRCUIT LOW INPUT — S008600B57

쐌 Radiator fan does not operate properly.
쐌 Overheating
CAUTION:
tion Mode.>.
EN(H4)-226
MT VEHICLES
쐌 WIRING DIAGRAM:
B2M3939
EN(H4)-227
MT VEHICLES

1 CHECK OUTPUT SIGNAL FROM ECM. Does voltage change Repair poor con- Go to step 2.
1) Turn ignition switch to OFF. between 0 and 10 V? tact in ECM con-
2) Connect test mode connector at the lower nector.
portion of instrument panel (on the driver’s
side), to the side of the center console box.
4) While checking radiator fan relay operation,
measure voltage between ECM terminal and
ground.
NOTE:
Radiator fan relay operation check can be
executed using Subaru Select Monitor. For
2 CHECK GROUND SHORT CIRCUIT IN Is the resistance less than Repair ground Go to step 3.
RADIATOR FAN RELAY CONTROL CIR- 10 Ω? short circuit in
CUIT. radiator fan relay
1) Turn ignition switch to OFF. control circuit.
2) Disconnect connectors from ECM.
3 CHECK POWER SUPPLY FOR RELAY. Is the voltage more than 10 Go to step 4. Repair open cir-
1) Remove main fan relay from A/C relay V? cuit in harness
holder. between ignition
2) Turn ignition switch to ON. switch and fuse
3) Measure voltage between fuse and relay and relay box
box (F/B) connector and chassis ground. (F/B) connector.
4 CHECK MAIN FAN RELAY. Is the resistance between Go to step 5. Replace main fan
2) Measure resistance between main fan
relay terminals.
Terminal
No. 5 — No. 6:
5 CHECK OPEN CIRCUIT IN MAIN FAN Is the resistance less than Go to step 6. Repair harness
RELAY CONTROL CIRCUIT. 1 Ω? and connector.
and main fan relay connector. In this case,
(B134) No. 3 — (F66) No. 6: ing:
쐌 Open circuit in
harness between
ECM and main
fan relay connec-
tor
쐌 Poor contact in
coupling connec-
tor (F45)
Check poor contact in ECM or main fan relay ECM or main fan relay contact in ECM or service.
connector. nector? main fan relay
connector.
EN(H4)-228
MT VEHICLES
MEMO:
EN(H4)-229
MT VEHICLES
AR: DTC P0483 — COOLING FAN FUNCTION PROBLEM — S008600B58

쐌 Occurrence of noise
쐌 Overheating
CAUTION:
tion Mode.>.
NOTE:
If the vehicle, with the engine idling, is placed very close to a wall or another vehicle, preventing normal
cooling function, the OBD system may detect malfunction.
EN(H4)-230
MT VEHICLES
쐌 WIRING DIAGRAM:
B2M3939
EN(H4)-231
MT VEHICLES

1 CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on Inspect the rel- Check radiator fan
display? evant DTC using and fan motor.
“17. List of Diag- <Ref. to
nostic Trouble CO(H4)-22
Code (DTC) for INSPECTION,
MT Vehicles”. Radiator Main
<Ref. to Fan and Fan
EN(H4)-99 List of Motor.> and <Ref.
Diagnostic to CO(H4)-24
Trouble Code INSPECTION,
(DTC) for MT Radiator Sub Fan
Vehicles.> and Fan Motor.>
EN(H4)-232
MT VEHICLES
MEMO:
EN(H4)-233
MT VEHICLES
AS: DTC P0500 — VEHICLE SPEED SENSOR MALFUNCTION — S008600B59

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3940

1 CHECK SPEEDOMETER OPERATION IN Does speedometer operate Go to step 2. Check speedom-
COMBINATION METER. normally? eter and vehicle
speed sensor.
<Ref. to IDI-19
Speedometer.>
and <Ref. to
MT-37 Vehicle
Speed Sensor.>
EN(H4)-234
MT VEHICLES

2 CHECK HARNESS BETWEEN ECM AND Is the resistance less than Repair poor con- Repair harness
COMBINATION METER CONNECTOR. 10 Ω? tact in ECM con- and connector.
1) Turn ignition switch to OFF. nector. NOTE:
2) Disconnect connector from combination In this case,
meter. repair the follow-
3) Measure resistance between ECM and ing:
combination meter. 쐌 Open circuit in
(B135) No. 24 — (i10) No. 13: ECM and combi-
nation meter con-
nector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
combination meter
connector
쐌 Poor contact in
coupling connec-
tor (B36)
EN(H4)-235
MT VEHICLES
AT: DTC P0505 — IDLE CONTROL SYSTEM CIRCUIT LOW INPUT — S008600B60

쐌 Engine stalls.
쐌 Engine breathing
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3941
EN(H4)-236
MT VEHICLES

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 3 Repair poor con- Go to step 2.
1) Turn ignition switch to ON. V? tact in ECM con-
2) Measure voltage between ECM and chas- nector.
sis ground.
2 CHECK POWER SUPPLY TO IDLE AIR Is the voltage more than 10 Go to step 3. Repair harness
CONTROL SOLENOID VALVE. V? and connector.
2) Disconnect connector from idle air control In this case,
solenoid valve. repair the follow-
4) Measure voltage between idle air control 쐌 Open circuit in
solenoid valve and engine ground. harness between
Connector & terminal idle air control
(E7) No. 2 (+) — Engine ground (−): solenoid valve
and main relay
connector
쐌 Poor contact in
coupling connec-
tor (B22)
IDLE AIR CONTROL SOLENOID VALVE 1 Ω? and connector.
CONNECTOR. NOTE:
ECM and idle air control solenoid valve con- 쐌 Open circuit in
nector. harness between
Connector & terminal ECM and idle air
(B134) No. 5 — (E7) No. 1: control solenoid
valve connector
쐌 Poor contact in
coupling connec-
tor (B21)
IDLE AIR CONTROL SOLENOID VALVE 10 Ω? short circuit in
Measure resistance of harness between ECM ECM and idle air
and chassis ground. control solenoid
5 CHECK GROUND CIRCUIT OF IDLE AIR Is the resistance less than Go to step 6. Repair open cir-
CONTROL SOLENOID VALVE. 5 Ω? cuit in harness
Measure resistance of harness between idle between idle air
air control solenoid valve connector and control solenoid
engine ground. valve connector
Connector & terminal and engine
(E7) No. 3 — Engine ground: ground terminal.
6 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace idle air
Check poor contact in ECM and idle air con- ECM and idle air control tact in ECM and control solenoid
trol solenoid valve connectors. solenoid valve connectors? idle air control valve. <Ref. to
solenoid valve FU(H4)-53 Idle Air
connectors. Control Solenoid
Valve.>
EN(H4)-237
MT VEHICLES
AU: DTC P0506 — IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED
— S008600B61

쐌 Engine is difficult to start.
쐌 Engine does not start.
쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3941
EN(H4)-238
MT VEHICLES

Trouble Code
(DTC) for MT
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0506.
2 CHECK IDLE AIR CONTROL SOLENOID Does air flow out? Go to step 4. Replace idle air
VALVE. control solenoid
1) Turn ignition switch to OFF. valve. <Ref. to
2) Remove idle air control solenoid valve from FU(H4)-54 MT
throttle body. <Ref. to FU(H4)-53 MT VEHICLES
VEHICLES, REMOVAL, Idle Air Control Sole- INSTALLATION,
noid Valve.> Idle Air Control
3) Using an air gun, force air into idle air con- Solenoid Valve.>
trol solenoid valve by-pass air inlet. Confirm After replace, Go
that forced air subsequently escapes from to step 3.
both main air passage and assist air passage.
3 CHECK IDLE AIR CONTROL SOLENOID Is the value more than Go to step 4. END.
VALVE DUTY RATIO. 60%?
2) Start engine, and warm-up the engine.
3) Turn all accessory switches to OFF.
4) Read data of idle air control solenoid valve
duty ratio using Subaru Select Monitor or
NOTE:
4 CHECK BY-PASS AIR LINE. Does air flow out? Replace idle air Replace throttle
1) Turn ignition switch to OFF. control solenoid body. <Ref. to
2) Remove idle air control solenoid valve from valve. <Ref. to FU(H4)-17 MT
throttle body. <Ref. to FU(H4)-53 MT FU(H4)-54 MT VEHICLES,
VEHICLES, REMOVAL, Idle Air Control Sole- VEHICLES INSTALLATION,
noid Valve.> INSTALLATION, Throttle Body.>
3) Remove throttle body to intake manifold. Idle Air Control
<Ref. to FU(H4)-16 MT VEHICLES, Solenoid Valve.>
REMOVAL, Throttle Body.>
4) Using an air gun, force air into solenoid
valve installation area and throttle valve inte-
rior. Confirm that forced air subsequently
escapes from both these areas.
EN(H4)-239
MT VEHICLES
AV: DTC P0507 — IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED
— S008600B62

쐌 Engine keeps running at higher revolution than specified idling revolution.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3941
EN(H4)-240
MT VEHICLES

Trouble Code
(DTC) for MT
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0507.
2 CHECK THROTTLE CABLE. Does throttle cable have Go to step 3. Adjust throttle
play for adjustment? cable. <Ref. to
SP(H4)-6
INSTALLATION,
Accelerator Con-
trol Cable.>
3 CHECK AIR INTAKE SYSTEM. Is there a fault in air intake Repair air suction Replace idle air
1) Turn ignition switch to ON. system? and leaks. control solenoid
2) Start engine, and idle it. valve. <Ref. to
3) Check the following items. FU(H4)-53 Idle Air
쐌 Loose installation of intake manifold, idle air Control Solenoid
control solenoid valve and throttle body Valve.>
쐌 Cracks of intake manifold gasket, idle air
control solenoid valve gasket and throttle
body gasket
쐌 Disconnections of vacuum hoses
EN(H4)-241
MT VEHICLES
AW: DTC P0601 — INTERNAL CONTROL MODULE MEMORY CHECK SUM

ERROR — S008600B63

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3942
EN(H4)-242
MT VEHICLES

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Replace ECM. It is not necessary
Monitor or OBD-II general <Ref. to to inspect DTC
scan tool indicate DTC FU(H4)-67 Engine P0601.
P0601? Control Module.>
EN(H4)-243
MT VEHICLES
AX: DTC P0703 — BRAKE SWITCH INPUT MALFUNCTION — S008600B64
NOTE:
This DTC code is not applicable to MT vehicles.
AY: DTC P0705 — TRANSMISSION RANGE SENSOR CIRCUIT
MALFUNCTION — S008600F05
NOTE:
AZ: DTC P0710 — TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT
NOTE:
BA: DTC P0715 — TORQUE CONVERTER TURBINE SPEED SENSOR
CIRCUIT MALFUNCTION — S008600B67
NOTE:
BB: DTC P0720 — OUTPUT SPEED SENSOR (VEHICLE SPEED SENSOR 2)
NOTE:
BC: DTC P0725 — ENGINE SPEED INPUT CIRCUIT MALFUNCTION — S008600B69
NOTE:
BD: DTC P0731 — GEAR 1 INCORRECT RATIO — S008600B70
NOTE:
BE: DTC P0732 — GEAR 2 INCORRECT RATIO — S008600B71
NOTE:
BF: DTC P0733 — GEAR 3 INCORRECT RATIO — S008600B72
NOTE:
BG: DTC P0734 — GEAR 4 INCORRECT RATIO — S008600B73
NOTE:
BH: DTC P0740 — TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION
— S008600B74
NOTE:
BI: DTC P0743 — TORQUE CONVERTER CLUTCH SYSTEM (LOCK-UP DUTY
SOLENOID) ELECTRICAL — S008600B75
NOTE:
EN(H4)-244
MT VEHICLES
BJ: DTC P0748 — PRESSURE CONTROL SOLENOID (LINE PRESSURE

DUTY SOLENOID) ELECTRICAL — S008600B76
NOTE:
BK: DTC P0753 — SHIFT SOLENOID A (SHIFT SOLONOID 1) ELECTRICAL
— S008600B77
NOTE:
BL: DTC P0758 — SHIFT SOLENOID B (SHIFT SOLONOID 2) ELECTRICAL —
S008600B78
NOTE:
EN(H4)-245
MT VEHICLES
BM: DTC P1100 — STARTER SWITCH CIRCUIT LOW INPUT — S008600B79

CAUTION:
tion Mode.>.
EN(H4)-246
MT VEHICLES
쐌 WIRING DIAGRAM:
B2M4144
EN(H4)-247
MT VEHICLES

1 CHECK OPERATION OF STARTER MOTOR. Does starter motor operate Repair harness Check starter
Depress the clutch pedal. when ignition switch to and connector. motor circuit.
“ST”? NOTE: <Ref. to
In this case, EN(H4)-78
repair the follow- STARTER
ing: MOTOR CIRCUIT,
쐌 Open or ground Diagnostics for
short circuit in Engine Starting
harness between Failure.>
ECM and starter
motor connector.
쐌 Poor contact in
ECM connector.
EN(H4)-248
MT VEHICLES
MEMO:
EN(H4)-249
MT VEHICLES
BN: DTC P1101 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT — S008600F06

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3943
EN(H4)-250
MT VEHICLES

1 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 Go to step 2. Go to step 4.
1) Turn ignition switch to ON. V in neutral position?
sis ground.
(−):
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 1 V Go to step 3. Go to step 4.
Measure voltage between ECM and chassis in other positions?
ground.
(−):
Check poor contact in ECM connector. ECM connector? tact in ECM con- service.
nector. NOTE:
Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
4 CHECK NEUTRAL POSITION SWITCH. Is the resistance more than Go to step 5. Repair short cir-
1) Turn ignition switch to OFF. 1 MΩ in neutral position? cuit in transmis-
2) Disconnect connector from transmission sion harness or
harness. replace neutral
3) Measure resistance between transmission position switch.
harness and connector terminals.
(T2) No. 1 — No. 2:
NEUTRAL POSITION SWITCH CONNEC- 10 Ω? short circuit in
Measure resistance between ECM and chas- ECM and trans-
sis ground. mission harness
Connector & terminal connector.
Check poor contact in transmission harness transmission harness contact in transmis- service.
connector. nector? sion harness con- NOTE:
nector. Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(H4)-251
MT VEHICLES
BO: DTC P1103 — ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT

NOTE:
BP: DTC P1106 — ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT
NOTE:
BQ: DTC P1110 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW
INPUT — S008600B84

CAUTION:
tion Mode.>.
NOTE:
Atmospheric pres-
sure sensor is
built into ECM.
EN(H4)-252
MT VEHICLES
BR: DTC P1111 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH

INPUT — S008600B85

CAUTION:
tion Mode.>.
NOTE:
Atmospheric pres-
sure sensor is
built into ECM.
BS: DTC P1112 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGE/


CAUTION:
tion Mode.>.
1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace ECM.
Monitor or OBD-II general P0106, P0107, <Ref. to
scan tool indicate DTC P0108, P1110 or FU(H4)-67 Engine
P0106, P0107, P0108, P1111 using “17. Control Module.>
P1110 or P1111? List of Diagnostic NOTE:
Trouble Code Atmospheric pres-
(DTC) for MT sure sensor is
Vehicles”. <Ref. to built into ECM.
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
BT: DTC P1115 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH
INPUT — S008600B87
NOTE:
BU: DTC P1116 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW
INPUT — S008600B88
NOTE:
EN(H4)-253
MT VEHICLES
BV: DTC P1120 — STARTER SWITCH CIRCUIT HIGH INPUT — S008600B89

CAUTION:
tion Mode.>.
EN(H4)-254
MT VEHICLES
쐌 WIRING DIAGRAM:
B2M4144
EN(H4)-255
MT VEHICLES

1 CHECK OPERATION OF STARTER MOTOR. Does starter motor operate Repair battery Check starter
NOTE: when ignition switch to short circuit in motor circuit.
Depress or release the clutch pedal. “ON”? starter motor cir- <Ref. to
cuit. After repair, EN(H4)-78
replace ECM. STARTER
<Ref. to MOTOR CIRCUIT,
FU(H4)-67 Engine Diagnostics for
Control Module.> Engine Starting
Failure.>
EN(H4)-256
MT VEHICLES
MEMO:
EN(H4)-257
MT VEHICLES
BW: DTC P1121 — NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT — S008600B90

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3943
EN(H4)-258
MT VEHICLES

1) Turn ignition switch to ON. V in neutral position?
sis ground.
(−):
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 1 V Go to step 3. Go to step 4.
Measure voltage between ECM and chassis in other positions?
ground.
(−):
nector. NOTE:
Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
4 CHECK NEUTRAL POSITION SWITCH. Is the resistance less than Go to step 5. Repair open cir-
Measure resistance between transmission 1 Ω in other positions? cuit in transmis-
harness connector terminals. sion harness or
Connector & terminal replace neutral
(T2) No. 1 — No. 2: position switch.
NEUTRAL POSITION SWITCH CONNEC- 1 Ω? cuit in harness
TOR. between ECM
1) Disconnect connector from ECM. and transmission
2) Measure resistance of harness between harness connec-
ECM and transmission harness connector. tor.
(B135) No. 26 — (B25) No. 1:
NEUTRAL POSITION SWITCH CONNEC- 5 Ω? and connector.
TOR. NOTE:
transmission harness connector and engine repair the follow-
ground. ing:
(B25) No. 2 — Engine ground: harness between
transmission har-
ness connector
and engine
grounding termi-
nal
쐌 Poor contact in
coupling connec-
tor (B22)
Check poor contact in transmission harness transmission harness contact in transmis- service.
connector. nector? sion harness con- NOTE:
nector. Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(H4)-259
MT VEHICLES
BX: DTC P1130 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION

(OPEN CIRCUIT) — S008600B92

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3927
EN(H4)-260
MT VEHICLES

FRONT OXYGEN (A/F) SENSOR CONNEC- 1 Ω? and connector.
TOR. NOTE:
2) Disconnect connectors from ECM and front repair the follow-
oxygen (A/F) sensor connector. ing:
ECM and front oxygen (A/F) sensor connec- harness between
tor. ECM and front
Connector & terminal oxygen (A/F) sen-
(B136) No. 7 — (B18) No. 1: sor connector
쐌 Poor contact in
front oxygen (A/F)
sensor connector
쐌 Poor contact in
ECM connector
TOR. NOTE:
and front oxygen (A/F) sensor connector. repair the follow-
harness between
ECM and front
oxygen (A/F) sen-
sor connector
쐌 Poor contact in
front oxygen (A/F)
sensor connector
쐌 Poor contact in
ECM connector
3 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace front oxy-
Check poor contact in front oxygen (A/F) sen- front oxygen (A/F) sensor tact in front oxygen (A/F) sensor.
sor connector. connector? gen (A/F) sensor <Ref. to
connector. FU(H4)-63 Front
Oxygen (A/F)
Sensor.>
EN(H4)-261
MT VEHICLES
BY: DTC P1131 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION

(SHORT CIRCUIT) — S008600B93

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3927
EN(H4)-262
MT VEHICLES

FRONT OXYGEN (A/F) SENSOR CONNEC- 10 Ω? short circuit in
1) Turn ignition switch to OFF. ECM and front
2) Disconnect connector from ECM. oxygen (A/F) sen-
FRONT OXYGEN (A/F) SENSOR CONNEC- 10 Ω? short circuit in
Measure resistance of harness between ECM ECM and front
connector and chassis ground. oxygen (A/F) sen-
Connector & terminal sor connector.
3 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than Go to step 4. Go to step 5.
1) Connect connector to ECM. 4.5 V?
and chassis ground.
4 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 10 Repair battery Repair poor con-
Measure voltage between ECM connector V? short circuit in tact in ECM con-
and chassis ground. harness between nector.
Connector & terminal ECM and front
(B136) No. 7 (+) — Chassis ground (−): oxygen (A/F) sen-
sor connector.
After repair,
replace ECM.
<Ref. to
FU(H4)-67 Engine
Control Module.>
5 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than Go to step 6. Replace front oxy-
Measure voltage between ECM connector 4.95 V? gen (A/F) sensor.
and chassis ground. <Ref. to
Connector & terminal FU(H4)-63 Front
(B136) No. 20 (+) — Chassis ground Oxygen (A/F)
(−): Sensor.>
6 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 10 Repair battery Repair poor con-
Measure voltage between ECM connector V? short circuit in tact in ECM con-
and chassis ground. harness between nector.
Connector & terminal ECM and front
(B136) No. 20 (+) — Chassis ground oxygen (A/F) sen-
(−): sor connector.
After repair,
replace ECM.
<Ref. to
FU(H4)-67 Engine
Control Module.>
EN(H4)-263
MT VEHICLES
BZ: DTC P1132 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT LOW
INPUT — S008600B94

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3927
EN(H4)-264
MT VEHICLES

same time?
Measure resistance of harness between ECM 5 Ω? and connector.
connector and chassis ground. NOTE:
Connector & terminal In this case,
(B134) No. 35 — Chassis ground: repair the follow-
ing:
쐌 Open circuit in
harness between
ECM and engine
ground terminal
쐌 Poor contact in
ECM connector
Poor contact in
coupling connec-
tor (B22)
3 CHECK GROUND CIRCUIT OF ECM. Is there resistance less Go to step 6. Repair harness
1) Repair harness and connector. than 5 Ω? and connector.
NOTE: NOTE:
Poor contact in
coupling connec-
tor (B22)
4 CHECK POWER SUPPLY CIRCUIT OF Is the voltage more than 8 Go to step 3. Repair open or
ECM. V? ground short cir-
1) Disconnect connectors from ECM. cuit in harness of
2) Turn ignition switch to ON. power supply cir-
3) Measure power supply voltage between cuit.
ECM connector terminals.
(B136) No. 3 (+) — (B134) No. 34 (−):
5 CHECK POWER SUPPLY CIRCUIT OF Is the voltage more than 8 Go to step 4. Repair open or
ECM. V? ground short cir-
Measure power supply voltage between ECM cuit in harness of
connector terminals. power supply cir-
Connector & terminal cuit.
(B136) No. 3 (+) — (B136) No. 35 (−):
EN(H4)-265
MT VEHICLES

6 CHECK CURRENT DATA. Is the value more than 0.2 Repair poor con- Go to step 7.
1) Start engine A? tact in connector.
2) Read data of front oxygen (A/F) sensor NOTE:
heater current using Subaru Select Monitor or In this case,
NOTE: ing:
For detailed operation procedure, refer to the front oxygen (A/F)
“READ CURRENT DATA FOR ENGINE”. sensor connector
쐌 OBD-II scan tool ECM connector
7 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1.0 Go to step 9. Go to step 8.
1) Start and idle the engine. V?
and chassis ground.
(−):
8 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Repair poor con- Go to step 9.
Measure voltage between ECM connector less than 1.0 V by shaking tact in ECM con-
and chassis ground. harness and connector of nector.
Connector & terminal ECM while monitoring the
(B134) No. 22 (+) — Chassis ground value with voltage meter?
(−):
and chassis ground.
(−):
(−):
11 CHECK POWER SUPPLY TO FRONT OXY- Is the voltage more than 10 Go to step 12. Repair power sup-
GEN (A/F) SENSOR. V? ply line.
2) Disconnect connector from front oxygen In this case,
(A/F) sensor. repair the follow-
4) Measure voltage between front oxygen 쐌 Open circuit in
(A/F) sensor connector and engine ground. harness between
(E18) No. 2 (+) — Engine ground (−): front oxygen (A/F)
sensor connector
쐌 Poor contact in
front oxygen (A/F)
sensor connector
쐌 Poor contact in
main relay con-
nector
EN(H4)-266
MT VEHICLES

12 CHECK FRONT OXYGEN (A/F) SENSOR. Is the resistance less than Repair harness Replace front oxy-
1) Turn ignition switch to OFF. 10 Ω? and connector. gen (A/F) sensor.
2) Measure resistance between front oxygen NOTE: <Ref. to
(A/F) sensor connector terminals. In this case, FU(H4)-63 Front
Terminals repair the follow- Oxygen (A/F)
No. 2 — No. 4: ing: Sensor.>
쐌 Open or ground
short circuit in
harness between
front oxygen (A/F)
sensor and ECM
connector
쐌 Poor contact in
front oxygen (A/F)
sensor connector
쐌 Poor contact in
ECM connector
EN(H4)-267
MT VEHICLES
CA: DTC P1133 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT HIGH
INPUT — S008600B95

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3927
EN(H4)-268
MT VEHICLES

and chassis ground.
(−):
and chassis ground.
(−):
3 CHECK FRONT OXYGEN (A/F) SENSOR Is the value more than 2.3 Replace ECM. END
HEATER CURRENT. A? <Ref. to
1) Turn ignition switch to OFF. FU(H4)-67 Engine
2) Repair battery short circuit in harness Control Module.>
between ECM and front oxygen (A/F) sensor
connector.
heater current using Subaru Select Monitor or
the OBD-II general scan tool.
NOTE:
4 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Repair battery Go to step 5.
Measure voltage between ECM connector more than 8 V by shaking short circuit in
and chassis ground. harness and connector of harness between
Connector & terminal ECM while monitoring the ECM and front
(B134) No. 23 (+) — Chassis ground value with voltage meter? oxygen (A/F) sen-
5 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Repair battery END
EN(H4)-269
MT VEHICLES
CB: DTC P1134 — FRONT OXYGEN (A/F) SENSOR MICRO-COMPUTER


CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3927
EN(H4)-270
MT VEHICLES

EN(H4)-271
MT VEHICLES
CC: DTC P1139 — FRONT OXYGEN (A/F) SENSOR #1 HEATER CIRCUIT


CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3927
EN(H4)-272
MT VEHICLES

FRONT OXYGEN (A/F) SENSOR CONNEC- 1 Ω? cuit in harness
TOR. between ECM
1) Start engine, and warm-up the engine. and front oxygen
2) Turn ignition switch to OFF. (A/F) sensor con-
3) Disconnect connectors from ECM and front nector.
oxygen (A/F) sensor.
ECM and front oxygen (A/F) sensor connec-
tor.
(B134) No. 22 — (B18) No. 4:
TOR. between ECM
Measure resistance of harness between ECM and front oxygen
and front oxygen (A/F) sensor connector. (A/F) sensor con-
Connector & terminal nector.
(B136) No. 7 — (B18) No. 1:
TOR. between ECM
(B136) No. 20 — (B18) No. 3:
TOR. between ECM
(B136) No. 3 — (B18) No. 2:
5 CHECK FRONT OXYGEN (A/F) SENSOR. Is the resistance less than Go to step 6. Replace front oxy-
Measure resistance between front oxygen 5 Ω? gen (A/F) sensor.
(A/F) sensor connector terminals. <Ref. to FU(H4)-3
Terminals Front Oxygen
No. 2 — No. 4: (A/F) Sensor.>
Check poor contact in ECM and front oxygen ECM or front oxygen (A/F) tact in ECM or gen (A/F) sensor.
(A/F) sensor connector. sensor connector? front oxygen (A/F) <Ref. to FU(H4)-3
sensor connector. Front Oxygen
(A/F) Sensor.>
EN(H4)-273
MT VEHICLES
CD: DTC P1142 — THROTTLE POSITION SENSOR CIRCUIT


쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3926
EN(H4)-274
MT VEHICLES

P0106, P0107, P0108, P0123 using “17.
Trouble Code
(DTC) for MT
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1142.
2 CHECK CURRENT DATA. Is the value less than 0 Replace intake Replace throttle
1) Start engine. kPa (0 mmHg, 0 inHg)? manifold pressure position sensor.
2) Read the data of intake manifold absolute sensor. <Ref. to <Ref. to
pressure signal using Subaru Select Monitor FU(H4)-49 Intake FU(H4)-45
or OBD-II general scan tool. Manifold Pressure Throttle Position
NOTE: Sensor.> Sensor.>
EN(H4)-275
MT VEHICLES
CE: DTC P1151 — REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT
— S008600C03

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3928
EN(H4)-276
MT VEHICLES

and chassis ground.
(−):
2 CHECK DTC P1151 ON DISPLAY. Does the Subaru Select Replace ECM. END
1) Turn ignition switch to OFF. Monitor or OBD-II general <Ref. to
2) Repair battery short circuit in harness scan tool indicate DTC FU(H4)-67 Engine
between ECM and rear oxygen sensor con- P1151? Control Module.>
nector.
3) Operate the INSPECTION MODE. <Ref. to
EN(H4)-60 OPERATION, Inspection Mode.>
3 CHECK INPUT SIGNAL FOR ECM. Does the voltage change Repair poor con- Go to step 4.
Measure voltage between ECM connector more than 8 V by shaking tact in ECM con-
(−):
4 CHECK INPUT SIGNAL FOR ECM. Does the voltage change Repair poor con- Go to step 5.
Measure voltage between ECM connector more than 8 V by shaking tact in rear oxy-
and chassis ground. harness and connector of gen sensor con-
Connector & terminal rear oxygen sensor while nector.
(B134) No. 21 (+) — Chassis ground monitoring the value with
(−): voltage meter?
5 CHECK INPUT SIGNAL FOR ECM. Does the voltage change Repair poor con- Even if MIL lights
Measure voltage between ECM connector more than 8 V by shaking tact in coupling up, the circuit has
and chassis ground. coupling connector (E2) connector. returned to normal
Connector & terminal while monitoring the value condition at this
(B134) No. 21 (+) — Chassis ground with voltage meter? time.
(−):
EN(H4)-277
MT VEHICLES
CF: DTC P1400 — FUEL TANK PRESSURE CONTROL SOLENOID VALVE

CIRCUIT LOW INPUT — S008600C07

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3944

sis ground.
EN(H4)-278
MT VEHICLES

nector. NOTE:
Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
3 CHECK HARNESS BETWEEN FUEL TANK Is the resistance less than Repair ground Go to step 4.
PRESSURE CONTROL SOLENOID VALVE 10 Ω? short circuit in
AND ECM CONNECTOR. harness between
2) Disconnect connectors from fuel tank pres- tank pressure
sure control solenoid valve and ECM. control solenoid
3) Measure resistance of harness between valve connector.
fuel tank pressure control solenoid valve con-
4 CHECK HARNESS BETWEEN FUEL TANK Is the voltage less than 1 Go to step 5. Repair harness
PRESSURE CONTROL SOLENOID VALVE Ω? and connector.
AND ECM CONNECTOR. NOTE:
and fuel tank pressure control solenoid valve repair the follow-
connector. ing:
(B134) No. 1 — (R68) No. 2: harness between
ECM and fuel
tank pressure
control solenoid
valve connector
쐌 Poor contact in
coupling connec-
tors (B99 and
R134)
5 CHECK FUEL TANK PRESSURE CONTROL Is the resistance between Go to step 6. Replace fuel tank
SOLENOID VALVE. 10 and 100 Ω? pressure control
Measure resistance between fuel tank pres- solenoid valve.
sure control solenoid valve terminals. <Ref. to
Terminals EC(H4)-13 Pres-
No. 1 — No. 2: sure Control Sole-
noid Valve.>
EN(H4)-279
MT VEHICLES

6 CHECK POWER SUPPLY TO FUEL TANK Is the voltage more than 10 Go to step 7. Repair harness
PRESSURE CONTROL SOLENOID VALVE. V? and connector.
2) Measure voltage between fuel tank pres- In this case,
sure control solenoid valve and chassis repair the follow-
ground. ing:
(R68) No. 1 (+) — Chassis ground (−): harness between
main relay and
fuel tank pressure
control solenoid
valve connector
쐌 Poor contact in
coupling connec-
tors (B97 and
R134)
쐌 Poor contact in
main relay con-
nector
7 CHECK POOR CONTACT. Is there poor contact in fuel Repair poor con- Contact with SOA
Check poor contact in fuel tank pressure con- tank pressure control sole- tact in fuel tank service.
trol solenoid valve connector. noid valve connector? pressure control NOTE:
solenoid valve Inspection by
connector. DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(H4)-280
MT VEHICLES
MEMO:
EN(H4)-281
MT VEHICLES
CG: DTC P1420 — FUEL TANK PRESSURE CONTROL SOLENOID VALVE

CIRCUIT HIGH INPUT — S008600C08

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3944
EN(H4)-282
MT VEHICLES

1 CHECK OUTPUT SIGNAL FROM ECM. Does voltage change Go to step 2. Even if MIL light
1) Turn ignition switch to OFF. between 0 and 10 V? up, the circuit has
2) Connect test mode connector at the lower returned to a nor-
portion of instrument panel (on the driver’s mal condition at
side), to the side of the center console box. this time. In this
3) Turn ignition switch to ON. case, repair poor
4) While operating fuel tank pressure control contact in ECM
solenoid valve, measure voltage between connector.
ECM and chassis ground.
NOTE:
Fuel tank pressure control solenoid valve
operation can be executed using Subaru
Select Monitor. For procedure, refer to “Com-
pulsory Valve Operation Check Mode”. <Ref.
to EN(H4)-64 Compulsory Valve Operation
Check Mode.>
sis ground.
Check poor contact in ECM connector. <Ref. ECM connector? tact in ECM con- <Ref. to
to FOREWORD [T3C1].> nector. FU(H4)-67 Engine
Control Module.>
4 CHECK HARNESS BETWEEN FUEL TANK Is the voltage more than 10 Repair battery Go to step 5.
PRESSURE CONTROL SOLENOID VALVE V? short circuit in
2) Disconnect connector from fuel tank pres- tank pressure
sure control solenoid valve. control solenoid
3) Turn ignition switch to ON. valve connector.
4) Measure voltage between ECM and chas- After repair,
sis ground. replace ECM.
Connector & terminal <Ref. to
(B134) No. 1 (+) — Chassis ground (−): FU(H4)-67 Engine
Control Module.>
5 CHECK FUEL TANK PRESSURE CONTROL Is the resistance less than Replace fuel tank Go to step 6.
SOLENOID VALVE. 1 Ω? pressure control
1) Turn ignition switch to OFF. solenoid valve
2) Measure resistance between fuel tank <Ref. to
pressure control solenoid valve terminals. EC(H4)-13 Pres-
Terminals sure Control Sole-
No. 1 — No. 2: noid Valve.> and
ECM <Ref. to
FU(H4)-67 Engine
Control Module.>.
Control Module.>
EN(H4)-283
MT VEHICLES
CH: DTC P1422 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE

CONTROL VALVE CIRCUIT HIGH INPUT — S008600C09

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3935
EN(H4)-284
MT VEHICLES

4) While operationg purge control solenoid contact in ECM
valve, measure voltage between ECM and connector.
chassis ground.
NOTE:
Purge control solenoid valve operation can be
sis ground.
Check poor contact in ECM connector. <Ref. ECM connector? tact in ECM con- <Ref. to
to FOREWORD [T3C1].> nector. FU(H4)-67 Engine
Control Module.>
4 CHECK HARNESS BETWEEN PURGE Is the voltage more than 10 Repair battery Go to step 5.
CONTROL SOLENOID VALVE AND ECM V? short circuit in
2) Disconnect connector from purge control control solenoid
solenoid valve. valve connector.
3) Turn ignition switch to ON. After repair,
4) Measure voltage between ECM and chas- replace ECM.
sis ground. <Ref. to
Connector & terminal FU(H4)-67 Engine
(B134) No. 2 (+) — Chassis ground (−): Control Module.>
5 CHECK PURGE CONTROL SOLENOID Is the resistance less than Replace purge Go to step 6.
VALVE. 1 Ω? control solenoid
1) Turn ignition switch to OFF. valve <Ref. to
2) Measure resistance between purge control FU(H4)-8 Purge
Terminals Valve.> and ECM
No. 1 — No. 2: <Ref. to
FU(H4)-67 Engine
Control Module.>
Control Module.>
EN(H4)-285
MT VEHICLES
CI: DTC P1423 — EVAPORATIVE EMISSION CONTROL SYSTEM VENT

CONTROL HIGH INPUT — S008600C10

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3936
EN(H4)-286
MT VEHICLES

4) While operating drain valve, measure volt- contact in ECM
age between ECM and chassis ground. connector.
NOTE:
Drain valve operation can be excecuted using
Subaru Select Monitor. For procedure, refer to
“Compulsory Valve Operation Check Mode”.
<Ref. to EN(H6)-64 Compulsory Valve Opera-
tion Check Mode.>
(−):
sis ground.
(−):
Control Module.>
4 CHECK HARNESS BETWEEN DRAIN Is the voltage more than 10 Repair battery Go to step 5.
VALVE AND ECM CONNECTOR. V? short circuit in
2) Disconnect connector from drain valve. ECM and drain
(B134) No. 10 (+) — Chassis ground FU(H4)-67 Engine
(−): Control Module.>
5 CHECK DRAIN VALVE. Is the resistance less than Replace drain Go to step 6.
1) Turn ignition switch to OFF. 1 Ω? valve <Ref. to
2) Measure resistance between drain valve FU(H4)-17 Drain
terminals. Valve.> and ECM
Terminals <Ref. to
Control Module.>
Control Module.>
EN(H4)-287
MT VEHICLES
CJ: DTC P1443 — EVAPORATIVE EMISSION CONTROL SYSTEM VENT

CONTROL FUNCTION PROBLEM — S008600C12

쐌 Immediately after fault occurrence
쐌 Improper fuel supply
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3936
EN(H4)-288
MT VEHICLES

nostic Trouble
Code (DTC) for
MT Vehicles”.
<Ref. to
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
2 CHECK VENT LINE HOSES. Is there a fault in vent line? Repair or replace Go to step 3.
Check the following items. the faulty part.
쐌 Clogging of vent hoses between canister
and drain valve
쐌 Clogging of vent hose between drain valve
and drain filter
쐌 Clogging of drain filter
3 CHECK DRAIN VALVE OPERATION. Does drain valve produce Contact with SOA Replace drain
1) Turn ignition switch to OFF. operating sound? service. valve. <Ref. to
2) Connect test mode connector at the lower NOTE: EC(H4)-17 Drain
portion of instrument panel (on the driver’s Inspection by Valve.>
side), to the side of the center console box. DTM is required,
3) Turn ignition switch to ON. because probable
4) Operate drain valve. cause is deterio-
NOTE: ration of multiple
Drain valve operation can also be executed parts.
procedure, refer to the “Compulsory Valve
EN(H4)-289
MT VEHICLES
CK: DTC P1505 — IDLE CONTROL SYSTEM CIRCUIT HIGH INPUT — S008600C15

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3941
EN(H4)-290
MT VEHICLES

SP(H4)-6
INSTALLATION,
Accelerator Con-
trol Cable.>
sis ground.
3 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 Repair battery Replace idle air
1) Turn ignition switch to OFF. V? short circuit in control solenoid
2) Disconnect connector from idle air control harness between valve <Ref. to
solenoid valve. ECM and idle air FU(H4)-53 Idle Air
3) Turn ignition switch to ON. control solenoid Control Solenoid
4) Measure voltage between ECM and chas- valve connector. Valve.> and ECM
sis ground. After repair, <Ref. to
Connector & terminal replace ECM. FU(H4)-67 Engine
(B134) No. 5 (+) — Chassis ground (−): <Ref. to Control Module.>.
FU(H4)-67 Engine
Control Module.>
4 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Repair battery Contact with SOA
Measure voltage between ECM and chassis more than 10 V by shaking short circuit in service.
ground. harness and connector of harness between NOTE:
Connector & terminal ECM while monitoring the ECM and idle air Insepction by
(B134) No. 5 (+) — Chassis ground (−): value with voltage meter? control solenoid DTM is required,
valve connector. because probable
After repair, cause is deterio-
replace ECM. ration of multiple
<Ref. to parts.
FU(H4)-67 Engine
Control Module.>
EN(H4)-291
MT VEHICLES
CL: DTC P1507 — IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE) —

S008600C16

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3941
EN(H4)-292
MT VEHICLES

scan tool indicate DTC or P0505 or
P0116 or P0117 or P0505 P1505 using “17.
or P1505? List of Diagnostic
Trouble Code
(DTC) for MT
EN(H4)-99 List of
Diagnostic
Trouble Code
(DTC) for MT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1507.
SP(H4)-6
INSTALLATION,
Accelerator Con-
trol Cable.>
3 CHECK AIR INTAKE SYSTEM. Is there a fault in air intake Repair air suction Replace idle air
1) Turn ignition switch to ON. system? and leaks. control solenoid
2) Start engine, and idle it. valve. <Ref. to
3) Check the following items. FU(H4)-53 Idle Air
쐌 Loose installation of intake manifold, idle air Control Solenoid
control solenoid valve and throttle body Valve.>
body gasket
EN(H4)-293
MT VEHICLES
CM: DTC P1520 — COOLING FAN RELAY 1 CIRCUIT HIGH INPUT — S008600C25

쐌 Overheating
CAUTION:
tion Mode.>.
EN(H4)-294
MT VEHICLES
쐌 WIRING DIAGRAM:
B2M3939
EN(H4)-295
MT VEHICLES

1 CHECK OUTPUT SIGNAL FROM ECM. Does voltage change Even if MIL lights Go to step 2.
4) While operating radiator fan relay, measure contact in ECM
voltage between ECM and chassis ground. connector.
NOTE:
Radiator fan relay operation can be executed
using Subaru Select Monitor. For procedure,
refer to “Compulsory Valve Operation Check
Mode”. <Ref. to EN(H4)-64 Compulsory Valve
Operation Check Mode.>
2 CHECK SHORT CIRCUIT IN RADIATOR Is the voltage more than 10 Repair battery Go to step 3.
FAN RELAY CONTROL CIRCUIT. V? short circuit in
1) Turn ignition switch to OFF. radiator fan relay
2) Remove main fan relay and sub fan relay. control circuit.
(with A/C models) After repair,
3) Disconnect test mode connector. replace ECM.
4) Turn ignition switch to ON. <Ref. to
5) Measure voltage between ECM and chas- FU(H4)-67 Engine
sis ground. Control Module.>
3 CHECK MAIN FAN RELAY. Is the resistance less than Replace main fan Go to step 4.
1) Turn ignition switch to OFF. 1 Ω? relay and ECM.
2) Remove main fan relay. <Ref. to
3) Measure resistance between main fan FU(H4)-67 Engine
relay terminals. Control Module.>
Terminal
No. 1 — No. 3:
4 CHECK SUB FAN RELAY. Is the resistance less than Replace sub fan Go to step 5.
1) Remove sub fan relay. 1 Ω? relay and ECM.
2) Measure resistance between sub fan relay <Ref. to
terminals. FU(H4)-67 Engine
Terminal Control Module.>
No. 1 — No. 3:
Control Module.>
EN(H4)-296
MT VEHICLES
MEMO:
EN(H4)-297
MT VEHICLES
CN: DTC P1560 — BACK-UP VOLTAGE CIRCUIT MALFUNCTION — S008600C27

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3945

1 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 Repair poor con- Go to step 2.
1) Turn ignition switch to OFF. V? tact in ECM con-
sis ground.
EN(H4)-298
MT VEHICLES

MAIN FUSE BOX CONNECTOR. 10 Ω? short circuit in
1) Disconnect connector from ECM. harness between
2) Measure resistance of harness between ECM connector
ECM and chassis ground. and battery termi-
Connector & terminal nal.
3 CHECK FUSE SBF-5. Is fuse blown? Replace fuse. Repair harness
and connector.
NOTE:
In this case,
repair the follow-
ing:
쐌 Open circuit in
harness between
ECM and battery
쐌 Poor contact in
ECM connector
쐌 Poor contact in
battery terminal
EN(H4)-299
MT VEHICLES
CO: DTC P1700 — THROTTLE POSITION SENSOR CIRCUIT MALFUNCTION

FOR AUTOMATIC TRANSMISSION — S008600C28
NOTE:
CP: DTC P1701 — CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION
NOTE:
CQ: DTC P1702 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL
NOTE:
CR: DTC P1703 — LOW CLUTCH TIMING CONTROL SOLENOID VALVE
CIRCUIT MALFUNCTION — S008600C31
NOTE:
CS: DTC P1704 — 2-4 BRAKE TIMING CONTROL SOLENOID VALVE
NOTE:
CT: DTC P1705 — 2-4 BRAKE PRESSURE CONTROL SOLENOID VALVE
CIRCUIT MALFUNCTION — S008600F10
NOTE:
CU: DTC P1722 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL
NOTE:
CV: DTC P1742 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL
NOTE:
EN(H4)-300
LIST OF DIAGNOSTIC TROUBLE CODE (DTC) FOR AT VEHICLES
19. List of Diagnostic Trouble Code (DTC) for AT Vehicles S008601
A: LIST S008601A12
DTC
Item Index
No.
P0031 Front oxygen (A/F) sensor heater circuit low <Ref. to EN(H4)-310 DTC P0031 — FRONT OXYGEN (A/F)
input SENSOR HEATER CIRCUIT LOW INPUT —, Diagnostic Pro-
cedure with Diagnostic Trouble Code (DTC) for AT Vehicles.>
P0032 Front oxygen (A/F) sensor heater circuit high <Ref. to EN(H4)-314 DTC P0032 — FRONT OXYGEN (A/F)
input SENSOR HEATER CIRCUIT HIGH INPUT —, Diagnostic
Procedure with Diagnostic Trouble Code (DTC) for AT
Vehicles.>
P0037 Rear oxygen sensor heater circuit malfunction <Ref. to EN(H4)-316 DTC P0037 — REAR OXYGEN SEN-
SOR HEATER CIRCUIT MALFUNCTION —, Diagnostic Pro-
P0038 Rear oxygen sensor heater circuit high input <Ref. to EN(H4)-320 DTC P0038 — REAR OXYGEN SEN-
SOR HEATER CIRCUIT HIGH INPUT —, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC) for AT Vehicles.>
P0065 Air assist injector solenoid valve malfunction <Ref. to EN(H4)-322 DTC P0065 — AIR ASSIST INJECTOR
SOLENOID VALVE MALFUNCTION —, Diagnostic Procedure
with Diagnostic Trouble Code (DTC) for AT Vehicles.>
P0066 Air assist injector solenoid valve circuit low input <Ref. to EN(H4)-324 DTC P0066 — AIR ASSIST INJECTOR
SOLENOID VALVE CIRCUIT LOW INPUT —, Diagnostic Pro-
P0067 Air assist injector solenoid valve circuit high input <Ref. to EN(H4)-326 DTC P0067 — AIR ASSIST INJECTOR
SOLENOID VALVE CIRCUIT HIGH INPUT —, Diagnostic
Vehicles.>
P0106 Pressure sensor circuit range/performance prob- <Ref. to EN(H4)-328 DTC P0106 — PRESSURE SENSOR
lem (low input) CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW
INPUT) —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC) for AT Vehicles.>
P0107 Pressure sensor circuit low input <Ref. to EN(H4)-332 DTC P0107 — PRESSURE SENSOR
CIRCUIT LOW INPUT —, Diagnostic Procedure with Diag-
P0108 Pressure sensor circuit high input <Ref. to EN(H4)-336 DTC P0108 — PRESSURE SENSOR
P0111 Intake air temperature sensor circuit range/ <Ref. to EN(H4)-340 DTC P0111 — INTAKE AIR TEMPERA-
performance problem TURE SENSOR CIRCUIT RANGE/PERFORMANCE PROB-
(DTC) for AT Vehicles.>
P0112 Intake air temperature sensor circuit low input <Ref. to EN(H4)-342 DTC P0112 — INTAKE AIR TEMPERA-
TURE SENSOR CIRCUIT LOW INPUT —, Diagnostic Proce-
P0113 Intake air temperature sensor circuit high input <Ref. to EN(H4)-344 DTC P0113 — INTAKE AIR TEMPERA-
TURE SENSOR CIRCUIT HIGH INPUT —, Diagnostic Proce-
P0117 Engine coolant temperature sensor circuit low <Ref. to EN(H4)-348 DTC P0117 — ENGINE COOLANT
input TEMPERATURE SENSOR CIRCUIT LOW INPUT —, Diag-
nostic Procedure with Diagnostic Trouble Code (DTC) for AT
Vehicles.>
P0118 Engine coolant temperature sensor circuit high <Ref. to EN(H4)-350 DTC P0118 — ENGINE COOLANT
input TEMPERATURE SENSOR CIRCUIT HIGH INPUT —, Diag-
Vehicles.>
EN(H4)-301
DTC
Item Index
No.
Trouble Code (DTC) for AT Vehicles.>
P0122 Throttle position sensor circuit low input <Ref. to EN(H4)-356 DTC P0122 — THROTTLE POSITION
SENSOR CIRCUIT LOW INPUT —, Diagnostic Procedure
P0123 Throttle position sensor circuit high input <Ref. to EN(H4)-360 DTC P0123 — THROTTLE POSITION
SENSOR CIRCUIT HIGH INPUT —, Diagnostic Procedure
P0125 Insufficient coolant temperature for closed loop <Ref. to EN(H4)-362 DTC P0125 — INSUFFICIENT COOL-
fuel control ANT TEMPERATURE FOR CLOSED LOOP FUEL CON-
TROL -, Diagnostic Procedure with Diagnostic Trouble Code
P0128 Thermostat malfunction <Ref. to EN(H4)-364 DTC P0128 — THERMOSTAT MAL-
FUNCTION —, Diagnostic Procedure with Diagnostic Trouble
performance problem (Lean) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM
(LEAN) —, Diagnostic Procedure with Diagnostic Trouble
(open circuit) SENSOR CIRCUIT MALFUNCTION (OPEN CIRCUIT) —,
AT Vehicles.>
(short circuit) SENSOR CIRCUIT MALFUNCTION (SHORT CIRCUIT) —,
AT Vehicles.>
P0133 Front oxygen (A/F) sensor circuit slow response <Ref. to EN(H4)-374 DTC P0133 — FRONT OXYGEN (A/F)
SENSOR CIRCUIT SLOW RESPONSE —, Diagnostic Proce-
P0136 Rear oxygen sensor circuit malfunction <Ref. to EN(H4)-376 DTC P0136 — REAR OXYGEN SEN-
SOR CIRCUIT MALFUNCTION —, Diagnostic Procedure
P0139 Rear oxygen sensor circuit slow response <Ref. to EN(H4)-380 DTC P0139 — REAR OXYGEN SEN-
SOR CIRCUIT SLOW RESPONSE —, Diagnostic Procedure
P0170 Fuel trim malfunction <Ref. to EN(H4)-382 DTC P0170 — FUEL TRIM MALFUNC-
P0181 Fuel temperature sensor A circuit range/ <Ref. to EN(H4)-384 DTC P0181 — FUEL TEMPERATURE
performance problem SENSOR A CIRCUIT RANGE/PERFORMANCE PROBLEM
—, Diagnostic Procedure with Diagnostic Trouble Code
P0182 Fuel temperature sensor A circuit low input <Ref. to EN(H4)-386 DTC P0182 — FUEL TEMPERATURE
SENSOR A CIRCUIT LOW INPUT —, Diagnostic Procedure
P0183 Fuel temperature sensor A circuit high input <Ref. to EN(H4)-388 DTC P0183 — FUEL TEMPERATURE
SENSOR A CIRCUIT HIGH INPUT —, Diagnostic Procedure
EN(H4)-302
DTC
Item Index
No.
P0327 Knock sensor circuit low input <Ref. to EN(H4)-400 DTC P0327 — KNOCK SENSOR CIR-
P0328 Knock sensor circuit high input <Ref. to EN(H4)-402 DTC P0328 — KNOCK SENSOR CIR-
P0335 Crankshaft position sensor circuit malfunction <Ref. to EN(H4)-404 DTC P0335 — CRANKSHAFT POSI-
TION SENSOR CIRCUIT MALFUNCTION —, Diagnostic Pro-
P0336 Crankshaft position sensor circuit range/ <Ref. to EN(H4)-406 DTC P0336 — CRANKSHAFT POSI-
performance problem TION SENSOR CIRCUIT RANGE/PERFORMANCE PROB-
P0340 Camshaft position sensor circuit malfunction <Ref. to EN(H4)-408 DTC P0340 — CAMSHAFT POSITION
P0341 Camshaft position sensor circuit range/ <Ref. to EN(H4)-410 DTC P0341 — CAMSHAFT POSITION
performance problem SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM —,
AT Vehicles.>
P0420 Catalyst system efficiency below threshold <Ref. to EN(H4)-414 DTC P0420 — CATALYST SYSTEM
EFFICIENCY BELOW THRESHOLD —, Diagnostic Proce-
Vehicles.>
trol valve circuit low input SION CONTROL SYSTEM PURGE CONTROL VALVE CIR-
trol valve circuit high input SION CONTROL SYSTEM PURGE CONTROL VALVE CIR-
low input SION CONTROL SYSTEM VENT CONTROL LOW INPUT
high input SION CONTROL SYSTEM VENT CONTROL HIGH INPUT
sensor range/performance problem SION CONTROL SYSTEM PRESSURE SENSOR RANGE/
PERFORMANCE PROBLEM —, Diagnostic Procedure with
Diagnostic Trouble Code (DTC) for AT Vehicles.>
sensor low input SION CONTROL SYSTEM PRESSURE SENSOR LOW
INPUT —, Diagnostic Procedure with Diagnostic Trouble
EN(H4)-303
DTC
Item Index
No.
sensor high input SION CONTROL SYSTEM PRESSURE SENSOR HIGH
Vehicles.>
lem CIRCUIT RANGE/PERFORMANCE PROBLEM —, Diagnos-
tic Procedure with Diagnostic Trouble Code (DTC) for AT
Vehicles.>
P0462 Fuel level sensor circuit low input <Ref. to EN(H4)-448 DTC P0462 — FUEL LEVEL SENSOR
P0463 Fuel level sensor circuit high input <Ref. to EN(H4)-452 DTC P0463 — FUEL LEVEL SENSOR
P0464 Fuel level sensor intermittent input <Ref. to EN(H4)-456 DTC P0464 — FUEL LEVEL SENSOR
INTERMITTENT INPUT —, Diagnostic Procedure with Diag-
P0480 Cooling fan relay 1 circuit low input <Ref. to EN(H4)-458 DTC P0480 — COOLING FAN RELAY
1 CIRCUIT LOW INPUT —, Diagnostic Procedure with Diag-
P0483 Cooling fan function problem <Ref. to EN(H4)-462 DTC P0483 — COOLING FAN FUNC-
TION PROBLEM —, Diagnostic Procedure with Diagnostic
P0500 Vehicle speed sensor malfunction <Ref. to EN(H4)-466 DTC P0500 — VEHICLE SPEED SEN-
SOR MALFUNCTION —, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC) for AT Vehicles.>
P0506 Idle control system RPM lower than expected <Ref. to EN(H4)-468 DTC P0506 — IDLE CONTROL SYS-
TEM RPM LOWER THAN EXPECTED —, Diagnostic Proce-
P0507 Idle control system RPM higher than expected <Ref. to EN(H4)-470 DTC P0507 — IDLE CONTROL SYS-
TEM RPM HIGHER THAN EXPECTED —, Diagnostic Proce-
P0512 Starter switch circuit high input <Ref. to EN(H4)-472 DTC P0512 — STARTER SWITCH
P0604 Internal control module memory check sum error <Ref. to EN(H4)-474 DTC P0604 — INTERNAL CONTROL
MODULE MEMORY CHECK SUM ERROR —, Diagnostic
Vehicles.>
P0703 Brake switch input malfunction <Ref. to EN(H4)-476 DTC P0703 — BRAKE SWITCH INPUT
MALFUNCTION —, Diagnostic Procedure with Diagnostic
P0705 Transmission range sensor circuit malfunction <Ref. to EN(H4)-478 DTC P0705 — TRANSMISSION
RANGE SENSOR CIRCUIT MALFUNCTION —, Diagnostic
Vehicles.>
P0710 Transmission fluid temperature sensor circuit <Ref. to EN(H4)-478 DTC P0710 — TRANSMISSION FLUID
malfunction TEMPERATURE SENSOR CIRCUIT MALFUNCTION —,
AT Vehicles.>
EN(H4)-304
DTC
Item Index
No.
P0715 Torque converter turbine speed sensor circuit <Ref. to EN(H4)-478 DTC P0715 — TORQUE CONVERTER
malfunction TURBINE SPEED SENSOR CIRCUIT MALFUNCTION —,
AT Vehicles.>
P0720 Output speed sensor (vehicle speed sensor 2) <Ref. to EN(H4)-479 DTC P0720 — OUTPUT SPEED SEN-
circuit malfunction SOR (VEHICLE SPEED SENSOR 2) CIRCUIT MALFUNC-
TION -, Diagnostic Procedure with Diagnostic Trouble Code
P0725 Engine speed input circuit malfunction <Ref. to EN(H4)-479 DTC P0725 — ENGINE SPEED INPUT
CIRCUIT MALFUNCTION —, Diagnostic Procedure with
RATIO —, Diagnostic Procedure with Diagnostic Trouble
P0741 Torque converter clutch system malfunction <Ref. to EN(H4)-482 DTC P0741 — TORQUE CONVERTER
CLUTCH SYSTEM MALFUNCTION —, Diagnostic Procedure
P0743 Torque converter clutch system (Lock-up duty <Ref. to EN(H4)-484 DTC P0743 — TORQUE CONVERTER
solenoid) electrical CLUTCH SYSTEM (LOCK-UP DUTY SOLENOID) ELECTRI-
P0748 Pressure control solenoid (Line pressure duty <Ref. to EN(H4)-484 DTC P0748 — PRESSURE CONTROL
solenoid) electrical SOLENOID (LINE PRESSURE DUTY SOLENOID) ELECTRI-
P0753 Shift solenoid A (Shift solenoid 1) electrical <Ref. to EN(H4)-484 DTC P0753 — SHIFT SOLENOID A
(SHIFT SOLENOID 1) ELECTRICAL —, Diagnostic Proce-
P0758 Shift solenoid B (Shift solenoid 2) electrical <Ref. to EN(H4)-485 DTC P0758 — SHIFT SOLENOID B
(SHIFT SOLENOID 2) ELECTRICAL —, Diagnostic Proce-
P0778 2-4 brake pressure control solenoid valve circuit <Ref. to EN(H4)-485 DTC P0778 — 2-4 BRAKE PRESSURE
AT Vehicles.>
P0785 2-4 brake timing control solenoid valve circuit <Ref. to EN(H4)-485 DTC P0785 — 2-4 BRAKE TIMING
AT Vehicles.>
P1110 Atmospheric pressure sensor low input <Ref. to EN(H4)-486 DTC P1110 — ATMOSPHERIC PRES-
SURE SENSOR CIRCUIT LOW INPUT —, Diagnostic Proce-
P1111 Atmospheric pressure sensor high input <Ref. to EN(H4)-490 DTC P1111 — ATMOSPHERIC PRES-
SURE SENSOR CIRCUIT HIGH INPUT —, Diagnostic Pro-
EN(H4)-305
DTC
Item Index
No.
P1112 Atmospheric pressure sensor range/performance <Ref. to EN(H4)-494 DTC P1112 — ATMOSPHERIC PRES-
problem SURE SENSOR CIRCUIT RANGE/PERFORMANCE PROB-
perfomance problem SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM —,
AT Vehicles.>
P1146 Pressure sensor circuit range/performance prob- <Ref. to EN(H4)-502 DTC P1146 — PRESSURE SENSOR
lem (high input) CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH
INPUT) —, Diagnostic Procedure with Diagnostic Trouble
P1400 Fuel tank pressure control solenoid valve circuit <Ref. to EN(H4)-506 DTC P1400 — FUEL TANK PRES-
low input SURE CONTROL SOLENOID VALVE CIRCUIT LOW INPUT
P1420 Fuel tank pressure control solenoid valve circuit <Ref. to EN(H4)-510 DTC P1420 — FUEL TANK PRES-
high input SURE CONTROL SOLENOID VALVE CIRCUIT HIGH INPUT
lem 2 CIRCUIT RANGE/PERFORMANCE PROBLEM 2 —, Diag-
Vehicles.>
function problem SION CONTROL SYSTEM VENT CONTROL FUNCTION
P1480 Cooling fan relay 1 circuit high input <Ref. to EN(H4)-516 DTC P1480 — COOLING FAN RELAY
1 CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diag-
P1507 Idle control system malfunction (fail-safe) <Ref. to EN(H4)-520 DTC P1507 — IDLE CONTROL SYS-
TEM MALFUNCTION (FAIL-SAFE) —, Diagnostic Procedure
P1510 Idle air control solenoid valve signal 1 circuit low <Ref. to EN(H4)-522 DTC P1510 — IDLE AIR CONTROL
input SOLENOID VALVE SIGNAL 1 CIRCUIT LOW INPUT —,
AT Vehicles.>
P1511 Idle air control solenoid valve signal 1 circuit high <Ref. to EN(H4)-522 DTC P1511 — IDLE AIR CONTROL
input SOLENOID VALVE SIGNAL 1 CIRCUIT HIGH INPUT —,
AT Vehicles.>
AT Vehicles.>
AT Vehicles.>
EN(H4)-306
DTC
Item Index
No.
AT Vehicles.>
AT Vehicles.>
AT Vehicles.>
AT Vehicles.>
P1518 Starter switch circuit low input <Ref. to EN(H4)-530 DTC P1518 — STARTER SWITCH
P1540 Vehicle speed sensor malfunction 2 <Ref. to EN(H4)-532 DTC P1540 — VEHICLE SPEED SEN-
SOR MALFUNCTION 2 —, Diagnostic Procedure with Diag-
P1560 Back-up voltage circuit malfunction <Ref. to EN(H4)-534 DTC P1560 — BACK-UP VOLTAGE
CIRCUIT MALFUNCTION —, Diagnostic Procedure with
P1590 Neutral position switch circuit high input <Ref. to EN(H4)-536 DTC P1590 — NEUTRAL POSITION
SWITCH CIRCUIT HIGH INPUT —, Diagnostic Procedure
P1591 Neutral position switch circuit low input <Ref. to EN(H4)-540 DTC P1591 — NEUTRAL POSITION
SWITCH CIRCUIT LOW INPUT —, Diagnostic Procedure
P1594 Automatic transmission diagnosis input signal <Ref. to EN(H4)-542 DTC P1594 — AUTOMATIC TRANS-
circuit malfunction MISSION DIAGNOSIS INPUT SIGNAL CIRCUIT MALFUNC-
circuit low input MISSION DIAGNOSIS INPUT SIGNAL CIRCUIT LOW INPUT
circuit high input MISSION DIAGNOSIS INPUT SIGNAL CIRCUIT HIGH
P1698 Engine torque control cut signal circuit low input <Ref. to EN(H4)-548 DTC P1698 — ENGINE TORQUE
CONTROL CUT SIGNAL CIRCUIT LOW INPUT —, Diagnos-
Vehicles.>
P1699 Engine torque control cut signal circuit high input <Ref. to EN(H4)-550 DTC P1699 — ENGINE TORQUE
CONTROL CUT SIGNAL CIRCUIT HIGH INPUT —, Diagnos-
Vehicles.>
P1700 Throttle position sensor circuit malfunction for <Ref. to EN(H4)-552 DTC P1700 — THROTTLE POSITION
automatic transmission SENSOR CIRCUIT MALFUNCTION FOR AUTOMATIC
EN(H4)-307
DTC
Item Index
No.
P1701 Cruise control set signal circuit malfunction for <Ref. to EN(H4)-554 DTC P1701 — CRUISE CONTROL
automatic transmission SET SIGNAL CIRCUIT MALFUNCTION FOR AUTOMATIC
P1703 Low clutch timing control solenoid valve circuit <Ref. to EN(H4)-556 DTC P1703 — LOW CLUTCH TIMING
AT Vehicles.>
P1711 Engine torque control signal 1 circuit malfunction <Ref. to EN(H4)-558 DTC P1711 — ENGINE TORQUE
CONTROL SIGNAL 1 CIRCUIT MALFUNCTION —, Diagnos-
Vehicles.>
P1712 Engine torque control signal 2 circuit malfunction <Ref. to EN(H4)-560 DTC P1712 — ENGINE TORQUE
CONTROL SIGNAL 2 CIRCUIT MALFUNCTION —, Diagnos-
Vehicles.>
EN(H4)-308
MEMO:
EN(H4)-309
AT VEHICLES
20. Diagnostic Procedure with Diagnostic Trouble Code (DTC) for

AT Vehicles S008602
A: DTC P0031 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT LOW

INPUT — S008602F83

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3948
EN(H4)-310
AT VEHICLES

same time?
2 CHECK POWER SUPPLY TO FRONT OXY- Is the voltage more than 10 Go to step 3. Repair power sup-
GEN (A/F) SENSOR. V? ply line.
2) Disconnect connector from front oxygen In this case,
(A/F) sensor. repair the follow-
4) Measure voltage between front oxygen 쐌 Open circuit in
(A/F) sensor connector and engine ground. harness between
(B18) No. 2 (+) — Engine ground (−): front oxygen (A/F)
sensor connector
쐌 Poor contact in
front oxygen (A/F)
sensor connector
쐌 Poor contact in
main relay con-
nector
Measure resistance of harness between ECM 5 Ω? and connector.
connector and chassis ground. NOTE:
ing:
쐌 Open circuit in
harness between
ECM and engine
ground terminal
쐌 Poor contact in
ECM connector
Poor contact in
coupling connec-
tor (B22)
4 CHECK GROUND CIRCUIT OF ECM. Is there resistance less Go to step 5. Repair harness
1) Measure resistance of harness between than 5 Ω? and connector.
ECM connector and chassis ground. NOTE:
ing:
쐌 Open circuit in
harness between
ECM and engine
ground terminal
쐌 Poor contact in
ECM connector
Poor contact in
coupling connec-
tor (B22)
EN(H4)-311
AT VEHICLES

5 CHECK CURRENT DATA. Is the value more than 0.2 Repair poor con- Go to step 6.
1) Start engine A? tact in connector.
2) Read data of front oxygen (A/F) sensor NOTE:
heater current using Subaru Select Monitor or In this case,
NOTE: ing:
For detailed operation procedure, refer to the front oxygen (A/F)
“READ CURRENT DATA FOR ENGINE”. sensor connector
쐌 OBD-II scan tool ECM connector
and chassis ground.
(−):
(−):
and chassis ground.
(−):
(−):
10 CHECK FRONT OXYGEN (A/F) SENSOR. Is the resistance less than Repair harness Replace front oxy-
1) Turn ignition switch to OFF. 10 Ω? and connector. gen (A/F) sensor.
2) Measure resistance between front oxygen NOTE: <Ref. to
(A/F) sensor connector terminals. In this case, EC(H4)-63 Front
Terminals repair the follow- Oxygen (A/F)
No. 2 — No. 5: ing: Sensor.>
쐌 Open or ground
short circuit in
harness between
front oxygen (A/F)
sensor and ECM
connector
쐌 Poor contact in
front oxygen (A/F)
sensor connector
쐌 Poor contact in
ECM connector
EN(H4)-312
AT VEHICLES
MEMO:
EN(H4)-313
AT VEHICLES
B: DTC P0032 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT HIGH

INPUT — S008602F84

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3948
EN(H4)-314
AT VEHICLES

and chassis ground.
(−):
and chassis ground.
(−):
3 CHECK FRONT OXYGEN (A/F) SENSOR Is the value more than 2.3 Replace ECM. END
HEATER CURRENT. A? <Ref. to
1) Turn ignition switch to OFF. FU(H4)-67 Engine
2) Repair battery short circuit in harness Control Module.>
between ECM and front oxygen (A/F) sensor
connector.
heater current using Subaru Select Monitor or
the OBD-II general scan tool.
NOTE:
4 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Repair battery Go to step 5.
5 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Repair battery END
EN(H4)-315
AT VEHICLES
C: DTC P0037 — REAR OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION

— S008602F85

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3949
EN(H4)-316
AT VEHICLES

1 CHECK GROUND CIRCUIT OF ECM. Is the resistance less than Go to step 3. Go to step 2.
1) Turn ignition switch to OFF. 5 Ω?
1) Repair harness and connector. 5 Ω? and connector.
NOTE: NOTE:
쐌 Poor contact in
coupling connec-
tor (B22)
3 CHECK CURRENT DATA. Is the value more than 0.2 Repair connector. Go to step 4.
1) Start engine. A? NOTE:
2) Read data of rear oxygen sensor heater In this case,
current using Subaru Select Monitor or OBD-II repair the follow-
general scan tool. ing:
NOTE: 쐌 Poor contact in
쐌 Subaru Select Monitor rear oxygen sen-
For detailed operation procedure, refer to the sor connector
“READ CURRENT DATA FOR ENGINE”. 쐌 Poor contact in
<Ref. to EN(H4)-52 Subaru Select Monitor.> rear oxygen sen-
쐌 OBD-II scan tool sor connecting
For detailed operation procedures, refer to the harness connector
ECM connector
and chassis ground.
(−):
(−):
6 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1.0 Replace ECM. Repair battery
1) Disconnect connector from rear oxygen V? <Ref. to short circuit in
sensor. FU(H4)-67 Engine harness between
2) Measure voltage between ECM connector Control Module.> ECM and rear
and chassis ground. oxygen sensor
Connector & terminal connector. After
(B134) No. 21 (+) — Chassis ground repair, replace
(−): ECM. <Ref. to
FU(H4)-67 Engine
Control Module.>
EN(H4)-317
AT VEHICLES

7 CHECK POWER SUPPLY TO REAR OXY- Is the voltage more than 10 Go to step 8. Repair power sup-
GEN SENSOR. V? ply line.
2) Disconnect connector from rear oxygen In this case,
sensor. repair the follow-
4) Measure voltage between rear oxygen sen- 쐌 Open circuit in
sor connector and engine ground or chassis harness between
ground. main relay and
Connector & terminal rear oxygen sen-
(T6) No. 2 (+) — Chassis ground (−): sor connector
쐌 Poor contact in
rear oxygen sen-
sor connector
쐌 Poor contact in
coupling connec-
tor (T5)
8 CHECK REAR OXYGEN SENSOR. Is the resistance less than Repair harness Replace rear oxy-
1) Turn ignition switch to OFF. 30 Ω? and connector. gen sensor. <Ref.
2) Measure resistance between rear oxygen NOTE: to FU(H4)-65
sensor connector terminals. In this case, Rear Oxygen
Terminals repair the follow- Sensor.>
No. 1 — No. 2: ing:
쐌 Open circuit in
harness between
rear oxygen sen-
sor and ECM con-
nector
쐌 Poor contact in
rear oxygen sen-
sor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (T5)
EN(H4)-318
AT VEHICLES
MEMO:
EN(H4)-319
AT VEHICLES
D: DTC P0038 — REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT —

S008602F86

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3949

and chassis ground.
(−):
EN(H4)-320
AT VEHICLES

2 CHECK CURRENT DATA. Is the value more than 7 Replace ECM. END
1) Turn ignition switch to OFF. A? <Ref. to
2) Repair battery short circuit in harness FU(H4)-67 Engine
between ECM and rear oxygen sensor con- Control Module.>
nector.
4) Read data of rear oxygen sensor heater
current using Subaru Select Monitor or the
NOTE:
3 CHECK POOR CONTACT. Is there poor contact in Repair poor con- END
Check poor contact in ECM connector. ECM connector? tact in ECM con-
nector.
EN(H4)-321
AT VEHICLES
E: DTC P0065 — AIR ASSIST INJECTOR SOLENOID VALVE MALFUNCTION

— S008602F87

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3961
EN(H4)-322
AT VEHICLES

nostic Trouble
Code (DTC) for
AT Vehicles”.
<Ref. to EN(H4)-
301 List of Diag-
nostic Trouble
Code (DTC) for
AT Vehicles.>
2 CHECK AIR ASSIST INJECTOR SOLENOID Does air assist injector Go to step 3. Replace air assist
VALVE OPERATION. solenoid valve operating injector solenoid
1) Turn ignition switch to OFF. sound? valve. <Ref. to
2) Connect test mode connector at the lower FU(H4)-55 Air
portion of instrument panel (on the driver’s Assist Injector
side), to the side of the center console box. Solenoid Valve.>
4) Operate air assist injector solenoid valve.
NOTE:
Air assist injector solenoid valve operation
can also be executed using Subaru Select
Monitor. For the procedure, refer to the “Com-
Check Mode.>
3 CHECK AIR BY-PASS HOSES. Is air by-pass hose dam- Repair or replace Go to step 4.
Use your mouth to blow through air by-pass aged? air by-pass hoses.
hose to make sure that there is a smooth air
flow (no clogging).
4 CHECK FUEL INJECTOR. Is fuel injector clogged? Replace fuel Replace air assist
1) Turn ignition switch to OFF. injector. <Ref. to injector solenoid
2) Remove fuel injector. <Ref. to FU(H4)-56 FU(H4)-60 valve. <Ref. to
REMOVAL, Fuel Injector.> INSTALLATION, FU(H4)-55 Air
3) Check for clogged fuel injectors. Fuel Injector.> Assist Injector
Solenoid Valve.>
EN(H4)-323
AT VEHICLES
F: DTC P0066 — AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT LOW

INPUT — S008602F88

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3961
EN(H4)-324
AT VEHICLES

1) Turn ignition switch to ON. V? tact in ECM con-
sis ground.
(−):
2 CHECK POWER SUPPLY TO AIR ASSIST Is the voltage more than 10 Go to step 3. Repair harness
INJECTOR SOLENOID VALVE. V? and connector.
2) Disconnect connector from air assist injec- In this case,
tor solenoid valve. repair the follow-
4) Measure voltage between air assist injector 쐌 Open circuit in
solenoid valve and engine ground. harness between
Connector & terminal air assist injector
and main relay
connector
쐌 Poor contact in
coupling connec-
tor (B22)
AIR ASSIST INJECTOR SOLENOID VALVE 1 Ω? and connector.
CONNECTOR. NOTE:
ECM and air assist injector solenoid valve 쐌 Open circuit in
connector. harness between
Connector & terminal ECM and air
(B134) No. 24 — (E42) No. 1: assist injector
solenoid valve
connector
쐌 Poor contact in
coupling connec-
tor (B22)
AIR ASSIST INJECTOR SOLENOID VALVE 10 Ω? short circuit in
Measure resistance of harness between ECM ECM and air
and chassis ground. assist injector
Connector & terminal solenoid valve
(B134) No. 24 — Chassis ground: connector.
5 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace air assist
Check poor contact in ECM and air assist ECM and air assist injector tact in ECM and injector solenoid
injector solenoid valve connectors. solenoid valve connectors? air assist injector valve. <Ref. to
solenoid valve FU(H4)-55 Air
connectors. Assist Injector
Solenoid Valve.>
EN(H4)-325
AT VEHICLES
G: DTC P0067 — AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT HIGH

INPUT — S008602F89

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3961
EN(H4)-326
AT VEHICLES

sis ground.
(−):
2 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 Repair battery Replace air assist
1) Turn ignition switch to OFF. V? short circuit in injector solenoid
2) Disconnect connector from air assist injec- harness between valve <Ref. to
tor solenoid valve. ECM and air FU(H4)-55 Air
3) Turn ignition switch to ON. assist injector Assist Injector
4) Measure voltage between ECM and chas- solenoid valve Solenoid Valve.>
sis ground. connector. After and ECM <Ref. to
Connector & terminal repair, replace FU(H4)-67 Engine
(B134) No. 24 (+) — Chassis ground ECM. <Ref. to Control Module.>
(−): FU(H4)-67 Engine
Control Module.>
3 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Repair battery Contact with SOA
Measure voltage between ECM and chassis more than 10 V by shaking short circuit in service.
ground. harness and connector of harness between NOTE:
Connector & terminal ECM while monitoring the ECM and air Insepction by
(B134) No. 24 (+) — Chassis ground value with voltage meter? assist injector DTM is required,
(−): solenoid valve because probable
connector. After cause is deterio-
repair, replace ration of multiple
ECM. <Ref. to parts.
FU(H4)-67 Engine
Control Module.>
EN(H4)-327
AT VEHICLES
H: DTC P0106 — PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (LOW INPUT) — S008602F90

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3946
EN(H4)-328
AT VEHICLES

NOTE: Monitor or OBD-II general P0107, P0108 or
In this case, it is not necessary to inspect scan tool indicate DTC P1112 using “19.
DTC P0106. P0107, P0108 or P1112? List of Diagnostic
Trouble Code
(DTC) for AT
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
air intake system?
3 CHECK PRESSURE SENSOR. Is the value within the Go to step 4. Replace intake air
1) Start the engine and warm-up engine until specifications? temperature sen-
coolant temperature is greater than 60°C sor and pressure
(140°F). sensor. <Ref. to
2) Place the shift lever in the selector lever in FU(H4)-51 Intake
“N” or “P” position. Air Temperature
3) Turn A/C switch to OFF. and Pressure
4) Turn all accessory switches to OFF. 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)
4 CHECK THROTTLE POSITION. Is throttle positioning ratio Go to step 5. Adjust or replace
Read data of throttle position signal using equal to or less than 5% throttle position
Subaru Select Monitor or OBD-II general scan when throttle is fully sensor. <Ref. to
tool. closed? FU(H4)-45
NOTE: Throttle Position
쐌 Subaru Select Monitor Sensor.>
EN(H4)-329
AT VEHICLES

5 CHECK THROTTLE POSITION. Is throttle positioning ratio Replace intake air Replace throttle
equal to or more than 85% temperature and position sensor.
when throttle is fully open? pressure sensor. <Ref. to
<Ref. to FU(H4)-45
FU(H4)-51 Intake Throttle Position
Air Temperature Sensor.>
and Pressure
Sensor.>
EN(H4)-330
AT VEHICLES
MEMO:
EN(H4)-331
AT VEHICLES
I: DTC P0107 — PRESSURE SENSOR CIRCUIT LOW INPUT — S008602B12

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3946
EN(H4)-332
AT VEHICLES

1 CHECK CURRENT DATA. Is the value less than 13.3 Go to step 3. Go to step 2.
NOTE:
sensor connector. connector? pressure sensor returned to a nor-
connector. mal condition at
this time.
and chassis ground.
(−):
cause is deterio-
ration of multiple
parts.
ground.
INTAKE AIR TEMPERATURE AND PRES- 4.5 V? cuit in harness
SURE SENSOR CONNECTOR. between ECM
1) Turn ignition switch to OFF. and intake air
2) Disconnect connector from intake air tem- temperature and
perature and pressure sensor. pressure sensor
3) Turn ignition switch to ON. connector.
4) Measure voltage between intake air tem-
perature sensor and pressure sensor connec-
tor and engine ground.
EN(H4)-333
AT VEHICLES

INTAKE AIR TEMPERATURE AND PRES- 1 Ω? cuit in harness
2) Disconnect connector from ECM. temperature and
3) Measure resistance of harness between pressure sensor
ECM and intake air temperature and pressure connector.
sensor connector.
(B136) No. 16 — (E21) No. 1:
INTAKE AIR TEMPERATURE AND PRES- 500 kΩ? short circuit in
SURE SENSOR CONNECTOR. harness between
Measure resistance of harness between ECM and intake
intake air temperature and pressure sensor air temperature
connector and engine ground. and pressure sen-
Connector & terminal sor connector.
10 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace intake air
Check poor contact in intake manifold pres- intake manifold pressure tact in intake air temperature and
sure sensor connector. sensor connector? temperature and pressure sensor.
pressure sensor <Ref. to
connector. FU(H4)-51 Intake
Air Temperature
and Pressure
Sensor.>
EN(H4)-334
AT VEHICLES
MEMO:
EN(H4)-335
AT VEHICLES
J: DTC P0108 — PRESSURE SENSOR CIRCUIT HIGH INPUT — S008602B13

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3946
EN(H4)-336
AT VEHICLES

1 CHECK CURRENT DATA. Is the value more than Go to step 10. Go to step 2.
1) Start engine. 119.5 kPa (896.5 mmHg,
2) Read the data of intake manifold absolute 35.29 inHg)?
NOTE:
and chassis ground.
(−):
cause is deterio-
ration of multiple
parts.
and chassis ground.
INTAKE AIR TEMPERATURE AND PRES- 4.5 V? cuit in harness
2) Disconnect connector from intake air tem- temperature and
3) Turn ignition switch to ON. connector.
4) Measure voltage between intake air tem-
perature and pressure sensor connector and
engine ground.
EN(H4)-337
AT VEHICLES

2) Disconnect connector from ECM. temperature and
3) Measure resistance of harness between pressure sensor
ECM and intake air temperature and pressure connector.
sensor connector.
(B136) No. 5 — (E21) No. 4:
Measure resistance of harness between ECM and intake air
and intake air temperature and pressure sen- temperature and
sor connector. pressure sensor
(B136) No. 16 — (E21) No. 1:
9 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace intake air
Check poor contact in intake air temperature intake manifold pressure tact in intake airtemperature and
and pressure sensor connector. sensor connector? temperature and pressure sensor.
pressure sensor <Ref. to
connector. FU(H4)-51 Intake
Air Temperature
and Pressure
Sensor.>
10 CHECK HARNESS BETWEEN ECM AND Is the value more than Repair battery Replace intake air
INTAKE AIR TEMPERATURE AND PRES- 119.5 kPa (896.5 mmHg, short circuit in temperature and
SURE SENSOR CONNECTOR. 35.29 inHg)? harness between pressure sensor.
1) Turn ignition switch to OFF and Subaru ECM and intake <Ref. to
Select Monitor or the OBD-II general scan air temperature FU(H4)-51 Intake
tool switch to OFF. and pressure sen- Air Temperature
2) Disconnect connector from intake air tem- sor connector. and Pressure
perature and pressure sensor. Sensor.>
tool switch to ON.
4) Read data of intake manifold absolute
NOTE:
EN(H4)-338
AT VEHICLES
MEMO:
EN(H4)-339
AT VEHICLES
K: DTC P0111 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT RANGE/


CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3946
EN(H4)-340
AT VEHICLES

P0112, P0113, P0117, P0125 using “19.
Trouble Code
(DTC) for AT
EN-301 List of
Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0111.
2 CHECK ENGINE COOLANT TEMPERA- Is the engine coolant tem- Replace intake air Inspect DTC
TURE. perature between 75°C temperature and P0125 using “19.
1) Start the engine and warm it up completely. (167°F) and 95°C (203°F)? pressure sensor. List of Diagnostic
2) Measure engine coolant temperature using <Ref. to Trouble Code
Subaru Select Monitor or OBD-II general scan FU(H4)-51 Intake (DTC) for AT
tool. Air Temperature Vehicles”. <Ref. to
NOTE: and Pressure EN-301 List of
쐌 Subaru Select Monitor Sensor.> Diagnostic
For detailed operation procedure, refer to the Trouble Code
“READ CURRENT DATA FOR ENGINE”. (DTC) for AT
<Ref. to EN(H4)-52 Subaru Select Monitor.> Vehicles.>
EN(H4)-341
AT VEHICLES
L: DTC P0112 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW INPUT

— S008602B15

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3946
EN(H4)-342
AT VEHICLES

NOTE: ing:
“READ CURRENT DATA FOR ENGINE”. perature and
<Ref. to EN(H4)-52 Subaru Select Monitor.> pressure sensor
For detailed operation procedure, refer to the ECM
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
2 CHECK HARNESS BETWEEN INTAKE AIR Is the value less than Replace intake air Repair ground
TEMPERATURE AND PRESSURE SENSOR −40°C (−40°F)? temperature and short circuit in
AND ECM CONNECTOR. pressure sensor. harness between
1) Turn ignition switch to OFF. <Ref. to intake air tem-
2) Disconnect connector from intake air tem- FU(H4)-51 Intake perature sensor
perature and pressure sensor. Air Temperature and ECM connec-
3) Turn ignition switch to ON. and Pressure tor.
4) Read data of intake air temperature sensor Sensor.>
NOTE:
EN(H4)-343
AT VEHICLES
M: DTC P0113 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH

INPUT — S008602B16

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3946
EN(H4)-344
AT VEHICLES

NOTE: ing:
“READ CURRENT DATA FOR ENGINE”. perature and
<Ref. to EN(H4)-52 Subaru Select Monitor.> pressure sensor
For detailed operation procedure, refer to the ECM
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
TEMPERATURE AND PRESSURE SENSOR V? short circuit in
1) Turn ignition switch to OFF. intake air tem-
2) Disconnect connector from intake air temperature and
3) Measure voltage between intake air tem- and ECM connec-
perature and pressure sensor connector and tor.
engine ground.
TEMPERATURE AND PRESSURE SENSOR V? short circuit in
1) Turn ignition switch to ON. intake air tem-
2) Measure voltage between intake air temperature and
perature and pressure sensor connector and pressure sensor
engine ground. and ECM connec-
Connector & terminal tor.
EN(H4)-345
AT VEHICLES

4 CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 3 Go to step 5. Repair harness
TEMPERATURE AND PRESSURE SENSOR V? and connector.
Measure voltage between intake air tempera- In this case,
ture and pressure sensor connector and repair the follow-
engine ground. ing:
intake air tem-
perature and
pressure sensor
and ECM connec-
tor
쐌 Poor contact in
intake air tem-
perature and
pressure sensor
쐌 Poor contact in
ECM
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
5 CHECK HARNESS BETWEEN INTAKE AIR Is the resistance less than Replace intake air Repair harness
TEMPERATURE AND PRESSURE SENSOR 5 Ω? temperature and and connector.
AND ECM CONNECTOR. pressure sensor. NOTE:
1) Turn ignition switch to OFF. <Ref. to In this case,
2) Measure resistance of harness between FU(H4)-51 Intake repair the follow-
intake air temperature and pressure sensor Air Temperature ing:
connector and engine ground. and Pressure 쐌 Open circuit in
Connector & terminal Sensor.> harness between
(E21) No. 1 — Engine ground: intake air tem-
perature and
pressure sensor
and ECM connec-
tor
쐌 Poor contact in
intake air tem-
perature and
pressure sensor
쐌 Poor contact in
ECM
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
EN(H4)-346
AT VEHICLES
MEMO:
EN(H4)-347
AT VEHICLES
N: DTC P0117 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW

INPUT — S008602F91

쐌 Hard to start
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3925
EN(H4)-348
AT VEHICLES

NOTE: ing:
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
2 CHECK HARNESS BETWEEN ENGINE Is the value less than Replace engine Repair ground
COOLANT TEMPERATURE SENSOR AND −40°C (−40°F)? coolant tempera- short circuit in
ECM CONNECTOR. ture sensor. <Ref. harness between
1) Turn ignition switch to OFF. to FU(H4)-40 engine coolant
2) Disconnect connector from engine coolant Engine Coolant temperature sen-
temperature sensor. Temperature Sen- sor and ECM con-
3) Turn ignition switch to ON. sor.> nector.
4) Read data of engine coolant temperature
sensor signal using Subaru Select Monitor or
NOTE:
EN(H4)-349
AT VEHICLES
O: DTC P0118 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT

HIGH INPUT — S008602F92

쐌 Hard to start
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3925
EN(H4)-350
AT VEHICLES

NOTE: ing:
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
1) Turn ignition switch to OFF. ECM and engine
2) Disconnect connector from engine coolant coolant tempera-
temperature sensor. ture sensor con-
3) Measure voltage between engine coolant nector.
temperature sensor connector and engine
ground.
1) Turn ignition switch to ON. ECM and engine
2) Measure voltage between engine coolant coolant tempera-
temperature sensor connector and engine ture sensor con-
ground. nector.
EN(H4)-351
AT VEHICLES

4 CHECK HARNESS BETWEEN ENGINE Is the voltage more than 4 Go to step 5. Repair harness
COOLANT TEMPERATURE SENSOR AND V? and connector.
ECM CONNECTOR. NOTE:
Measure voltage between engine coolant tem- In this case,
perature sensor connector and engine repair the follow-
ground. ing:
ECM and engine
coolant tempera-
ture sensor con-
nector
쐌 Poor contact in
engine coolant
temperature sen-
sor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
5 CHECK HARNESS BETWEEN ENGINE Is the resistance less than Replace engine Repair harness
COOLANT TEMPERATURE SENSOR AND 5 Ω? coolant tempera- and connector.
ECM CONNECTOR. ture sensor. <Ref. NOTE:
1) Turn ignition switch to OFF. to FU(H4)-40 In this case,
2) Measure resistance of harness between Engine Coolant repair the follow-
engine coolant temperature sensor connector Temperature Sen- ing:
and engine ground. sor.> 쐌 Open circuit in
(E8) No. 2 — Engine ground: ECM and engine
coolant tempera-
ture sensor con-
nector
쐌 Poor contact in
engine coolant
temperature sen-
sor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
EN(H4)-352
AT VEHICLES
MEMO:
EN(H4)-353
AT VEHICLES
P: DTC P0121 — THROTTLE POSITION SENSOR CIRCUIT


쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3926
EN(H4)-354
AT VEHICLES

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace throttle
Monitor or OBD-II general P0122 or P0123 position sensor.
P0122 or P0123? Diagnostic FU(H4)-45
Trouble Code Throttle Position
(DTC) for AT Sensor.>
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0121.
EN(H4)-355
AT VEHICLES
Q: DTC P0122 — THROTTLE POSITION SENSOR CIRCUIT LOW INPUT —

S008602B20

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3926
EN(H4)-356
AT VEHICLES

1 CHECK CURRENT DATA. Is the value less than 0.1 Go to step 2. Even if MIL lights
쐌 Poor contact in
throttle position
sensor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
and chassis ground while throttle valve is fully
closed.
(−):
cause is deterio-
ration of multiple
parts.
and chassis ground.
(−):
5 CHECK INPUT SIGNAL FOR ECM. (USING Does the voltage change Repair poor con- Go to step 6.
SUBARU SELECT MONITOR.) more than 0.1 V by shaking tact in ECM con-
Measure voltage between ECM connector harness and connector of nector.
and chassis ground. ECM while monitoring the
value with Subaru Select
Monitor?
EN(H4)-357
AT VEHICLES

THROTTLE POSITION SENSOR CONNEC- 4.5 V? and connector.
TOR. NOTE:
2) Disconnect connectors from throttle posi- repair the follow-
tion sensor. ing:
4) Measure voltage between throttle position harness between
sensor connector and engine ground. throttle position
(E13) No. 4 (+) — Engine ground (−): connector
쐌 Poor contact in
throttle position
sensor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
THROTTLE POSITION SENSOR CONNEC- 1 Ω? and connector.
TOR. NOTE:
ECM connector and throttle position sensor ing:
connector. 쐌 Open circuit in
(B136) No. 17 — (E13) No. 3: throttle position
sensor and ECM
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
throttle position
sensor connector
쐌 Poor contact in
coupling connec-
tor (B21)
THROTTLE POSITION SENSOR CONNEC- 10 Ω? short circuit in
Measure resistance of harness between throttle position
throttle position sensor connector and engine sensor and ECM
ground. connector.
9 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace throttle
Check poor contact in throttle position sensor throttle position sensor contact in throttle position sensor.
connector. nector? position sensor <Ref. to
connector. FU(H4)-45
Throttle Position
Sensor.>
EN(H4)-358
AT VEHICLES
MEMO:
EN(H4)-359
AT VEHICLES
R: DTC P0123 — THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT — S008602B21

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3926
EN(H4)-360
AT VEHICLES

1 CHECK CURRENT DATA. Is the value more than 4.9 Go to step 2. Even if MIL lights
쐌 Poor contact in
throttle position
sensor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
2 CHECK HARNESS BETWEEN THROTTLE Is the resistance less than Go to step 3. Repair harness
TOR. NOTE:
2) Disconnect connector from throttle position repair the follow-
sensor. ing:
throttle position sensor connector and engine harness between
ground. throttle position
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83)
3 CHECK HARNESS BETWEEN THROTTLE Is the voltage more than Repair battery Replace throttle
POSITION SENSOR AND ECM CONNEC- 4.9 V? short circuit in position sensor.
TOR. harness between <Ref. to
1) Turn ignition switch to ON. throttle position FU(H4)-45
2) Measure voltage between throttle position sensor and ECM Throttle Position
sensor connector and engine ground. connector. After Sensor.>
(E13) No. 3 (+) — Engine ground (−): ECM. <Ref. to
FU(H4)-67 Engine
Control Module.>
EN(H4)-361
AT VEHICLES
S: DTC P0125 — INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED

LOOP FUEL CONTROL — S008602B22

쐌 Engine would not return to idling.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3925
EN(H4)-362
AT VEHICLES

Trouble Code
(DTC) for AT
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0125.
2 CHECK THERMOSTAT. Does thermostat remain Replace thermo- Replace engine
opened? stat. <Ref. to coolant tempera-
EN(H4)-13 Ther- ture sensor. <Ref.
mostat.> to EN(H4)-40
Engine Coolant
Temperature Sen-
sor.>
EN(H4)-363
AT VEHICLES
T: DTC P0128 — THERMOSTAT MALFUNCTION — S008602F93

쐌 Thermostat remains open.
CAUTION:
tion Mode.>.
1 CHECK VEHICLE CONDITION. Has engine operated at idle In this case, it is Go to step 2.
or has vehicle been driven not necessary to
with part of engine sub- inspect DTC
merged under water? P1490.
2 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Go to step 3. Inspect DTC
scan tool indicate DTC P0302, P0303
P0125, P0301, P0302, and P0304 using
P0303 and P0304 at same “19. List of Diag-
time? nostic Trouble
Code (DTC) for
AT Vehicles”.
<Ref. to EN(H4)-
301 List of Diag-
nostic Trouble
Code (DTC) for
AT Vehicles.>
3 CHECK ENGINE COOLANT. Are coolant level and mix- Go to step 4. Replace engine
ture ratio of cooling water coolant. <Ref. to
to anti-freeze solution cor- CO(H4)-6
rect? REPLACEMENT,
Engine Coolant.>
4 CHECK RADIATOR FAN. Does radiator fan continu- Repair radiator Replace thermo-
1) Start the engine. ously rotate for more than fan circuit. <Ref. stat. <Ref. to
2) Check radiator fan operation. 3 minutes during idling? to CO(H4)-20 CO(H4)-13 Ther-
Radiator Main mostat.>
Fan and Fan
Motor.> and <Ref.
to CO(H4)-23
Radiator Sub Fan
and Fan Motor.>
EN(H4)-364
AT VEHICLES
MEMO:
EN(H4)-365
AT VEHICLES
U: DTC P0130 — FRONT OXYGEN (A/F) SENSOR CIRCUIT

RANGE/PERFORMANCE PROBLEM (LEAN) — S008602G44

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3948
EN(H4)-366
AT VEHICLES

P1133? Diagnostic
Trouble Code
(DTC) for AT
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
2 CHECK FRONT OXYGEN (A/F) SENSOR Is the value equal to or Go to step 3. Go to step 4.
70°C (160°F).
general scan tool.
NOTE:
3 CHECK FRONT OXYGEN (A/F) SENSOR Is the value more than 1.1 Go to step 6. Go to step 4.
DATA. for a moment?
Race engine at speeds from idling to 5,000
rpm for a total of 5 cycles.
NOTE:
To increase engine speed to 5,000 rpm,
FRONT OXYGEN (A/F) SENSOR. 5 Ω? cuit between ECM
1) Turn ignition switch to OFF. and front oxygen
2) Disconnect connector from ECM and front (A/F) sensor.
oxygen (A/F) sensor connector.
3) Measure resistance between ECM and
front oxygen (A/F) sensor.
Connector & terminals
(B136) No. 6 — (B18) No. 1:
(B136) No. 7 — (B18) No. 6:
(B136) No. 19 — (B18) No. 3:
(B136) No. 20 — (B18) No. 4:
EN(H4)-367
AT VEHICLES

FRONT OXYGEN (A/F) SENSOR. 1 MΩ? short circuit
Measure resistance between ECM and chas- between ECM
sis ground. and front oxygen
Connector & terminals (A/F) sensor.
NOTE: <Ref. to
sensor
EN(H4)-368
AT VEHICLES
MEMO:
EN(H4)-369
AT VEHICLES
V: DTC P0131 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION

(OPEN CIRCUIT) — S008602G45

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3948
EN(H4)-370
AT VEHICLES

TOR. NOTE:
2) Disconnect connectors from ECM and front repair the follow-
oxygen (A/F) sensor connector. ing:
ECM and front oxygen (A/F) sensor connec- harness between
tor. ECM and front
Connector & terminal oxygen (A/F) sen-
(B136) No. 6 — (E18) No. 1: sor connector
(B136) No. 7 — (B18) No. 6: 쐌 Poor contact in
(B136) No. 19 — (B18) No. 3: front oxygen (A/F)
(B136) No. 20 — (B18) No. 4: sensor connector
쐌 Poor contact in
ECM connector
Check poor contact in front oxygen (A/F) sen- front oxygen (A/F) sensor tact in front oxygen (A/F) sensor.
sor connector. connector? gen (A/F) sensor <Ref. to
connector. FU(H4)-63 Front
Oxygen (A/F)
Sensor.>
EN(H4)-371
AT VEHICLES
W: DTC P0132 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION

(SHORT CIRCUIT) — S008602G46

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3948
EN(H4)-372
AT VEHICLES

1 CHECK HARNESS BETWEEN ECM AND Is the resistance more than Replace front oxy- Repair ground
FRONT OXYGEN (A/F) SENSOR CONNEC- 10 Ω? gen (A/F) sensor. short circuit in
TOR. <Ref. to harness between
1) Turn ignition switch to OFF. FU(H4)-63 Front ECM and front
2) Disconnect connector from ECM. Oxygen (A/F) oxygen (A/F) sen-
3) Measure resistance of harness between Sensor.> sor connector.
EN(H4)-373
AT VEHICLES
X: DTC P0133 — FRONT OXYGEN (A/F) SENSOR CIRCUIT SLOW

RESPONSE — S008602B26

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3948
EN(H4)-374
AT VEHICLES

P1133? Diagnostic
Trouble Code
(DTC) for AT
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0133.
2 CHECK EXHAUST SYSTEM. Is there a fault in exhaust Repair exhaust Replace front oxy-
NOTE: system? system. gen (A/F) sensor.
쐌 Loose installation of front portion of exhaust FU(H4)-63 Front
pipe onto cylinder heads Oxygen (A/F)
쐌 Loose connection between front exhaust Sensor.>
pipe and front catalytic converter
쐌 Damage of exhaust pipe resulting in a hole
EN(H4)-375
AT VEHICLES
Y: DTC P0136 — REAR OXYGEN SENSOR CIRCUIT MALFUNCTION — S008602B28

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3949

P0131 or P0132?
EN(H4)-376
AT VEHICLES

2 CHECK FAILURE CAUSE OF P0131 or Is the failure cause of Check fuel sys- Go to step 3.
P0132. P0131 or P0132 in the fuel tem.
Inspect DTC P0131 or P0132 using “19. List system? NOTE:
of Diagnostic Trouble Code (DTC) for AT In this case, it is
Vehicles”. <Ref. to EN(H4)-301 List of Diag- not necessary to
nostic Trouble Code (DTC) for AT Vehicles.> inspect DTC
P0136.
3 CHECK REAR OXYGEN SENSOR DATA. Does the value fluctuate? Go to step 7. Go to step 4.
1) Warm-up the engine until engine coolant
temperature is above 70°C (158°F), and keep
the engine speed at 2,000 rpm to 3,000 rpm
for two minutes.
2) Read data of rear oxygen sensor signal
using Subaru Select Monitor or OBD-II gen-
eral scan tool.
NOTE:
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”. <Ref. to EN(H4)-52
4 CHECK REAR OXYGEN SENSOR DATA. Is the value fixed between Go to step 5. Replace rear oxy-
Read data of rear oxygen sensor signal using 0.2 and 0.4 V? gen sensor. <Ref.
Subaru Select Monitor or OBD-II General to FU(H4)-65
Scan Tool. Rear Oxygen
Sensor.>
5 CHECK HARNESS BETWEEN ECM AND Is the resistance more than Repair open cir- Go to step 6.
2) Disconnect connectors from ECM and rear and rear oxygen
oxygen sensor. sensor connector.
(B136) No. 16 — (T6) No. 3:
6 CHECK HARNESS BETWEEN REAR OXY- Is the voltage more than Replace rear oxy- Repair harness
GEN SENSOR AND ECM CONNECTOR. 0.2 V? gen sensor. <Ref. and connector.
1) Turn ignition switch to OFF. to FU(H4)-65 NOTE:
2) Disconnect connector from rear oxygen Rear Oxygen In this case,
sensor. Sensor.> repair the follow-
4) Measure voltage between rear oxygen sen- 쐌 Open circuit in
sor harness connector and engine ground or harness between
chassis ground. rear oxygen sen-
Connector & terminal sor and ECM con-
(T6) No. 4 (+) — Engine ground (−): nector
쐌 Poor contact in
rear oxygen sen-
sor connector
쐌 Poor contact in
ECM connector
EN(H4)-377
AT VEHICLES

7 CHECK EXHAUST SYSTEM. Is there a fault in exhaust Repair or replace Replace rear oxy-
Check exhaust system parts. system? faulty parts. gen sensor. <Ref.
NOTE: to FU(H4)-65
Check the following items. Rear Oxygen
쐌 Loose installation of portions Sensor.>
쐌 Damage (crack, hole etc.) of parts
sensor
EN(H4)-378
AT VEHICLES
MEMO:
EN(H4)-379
AT VEHICLES
Z: DTC P0139 — REAR OXYGEN SENSOR CIRCUIT SLOW RESPONSE — S008602B29

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3949
EN(H4)-380
AT VEHICLES

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace rear oxy-
Monitor or OBD-II general P0136 using “19. gen sensor. <Ref.
scan tool indicate DTC List of Diagnostic to FU(H4)-65
P0136? Trouble Code Rear Oxygen
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0139.
EN(H4)-381
AT VEHICLES
AA: DTC P0170 — FUEL TRIM MALFUNCTION — S008602B31

쐌 Engine stalls.
CAUTION:
tion Mode.>.
1 CHECK EXHAUST SYSTEM. Are there holes or loose Repair exhaust Go to step 2.
bolts on exhaust system? system.
air intake system?
WARNING: 284 and 314 kPa (2.9 — ing items.
쐌 Place “NO FIRE” signs near the working 3.2 kg/cm2, 41 — 46 psi)? Fuel pressure
area. too high
쐌 Be careful not to spill fuel on the floor. 쐌 Clogged fuel
1) Release fuel pressure. return line or bent
(1) Disconnect connector from fuel pump hose
relay. Fuel pressure
(2) Start the engine and run it until it stalls. too low
(3) After the engine stalls, crank it for five 쐌 Improper fuel
more seconds. pump discharge
(4) Turn ignition switch to OFF. 쐌 Clogged fuel
2) Connect connector to fuel pump relay. supply line
3) Disconnect fuel delivery hose from fuel
filter, and connect fuel pressure gauge.
5) Start the engine and idle while gear posi-
tion is neutral.
pressure regulator vacuum hose from intake
manifold.
WARNING:
Before removing fuel pressure gauge,
release fuel pressure.
NOTE:
If fuel pressure does not increase, squeeze
fuel return hose 2 to 3 times, then measure
fuel pressure again.
EN(H4)-382
AT VEHICLES

After connecting pressure regulator vacuum 206 and 235 kPa (2.1 — ing items.
hose, measure fuel pressure. 2.4 kg/cm2, 30 — 34 psi)? Fuel pressure
WARNING: too high
Before removing fuel pressure gauge, 쐌 Faulty pressure
release fuel pressure. regulator
NOTE: 쐌 Clogged fuel
쐌 If fuel pressure does not increase, squeeze return line or bent
fuel return hose 2 to 3 times, then measure hose
fuel pressure again. Fuel pressure
쐌 If out of specification as measured at this too low
step, check or replace pressure regulator and 쐌 Faulty pressure
pressure regulator vacuum hose. regulator
쐌 Improper fuel
pump discharge
쐌 Clogged fuel
supply line
5 CHECK ENGINE COOLANT TEMPERA- Is temperature between Go to step 6. Replace engine
TURE SENSOR. 70°C (158°F) and 100°C coolant tempera-
1) Start the engine and warm-up completely. (212°F)? ture sensor. <Ref.
2) Read data of engine coolant temperature to FU(H4)-40
sensor signal using Subaru Select Monitor or Engine Coolant
OBD-II general scan tool. Temperature Sen-
NOTE: sor.>
6 CHECK INTAKE MANIFOLD PRESSURE Is the voltage within the Contact with SOA Replace intake air
SENSOR SIGNAL. specifications? service. temperature and
1) Start the engine and warm-up engine until NOTE: pressure sensor.
coolant temperature is greater than 60°C Inspection by <Ref. to
(140°F). DTM is required, FU(H4)-51 Intake
2) Place the selector lever in “N” or “P” posi- because probable Air Temperature
tion. cause is deterio- and Pressure
3) Turn A/C switch to OFF. ration of multiple Sensor.>
4) Turn all accessory switches to OFF. parts.
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(H4)-383
AT VEHICLES
AB: DTC P0181 — FUEL TEMPERATURE SENSOR A CIRCUIT


CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3929
EN(H4)-384
AT VEHICLES

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace fuel tem-
Monitor or OBD-II general P0182 or P0183 perature sensor.
P0182 or P0183? Diagnostic EC(H4)-10 Fuel
Trouble Code Temperature Sen-
(DTC) for AT sor.>
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0181.
EN(H4)-385
AT VEHICLES
AC: DTC P0182 — FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT —

S008602B35

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3929
EN(H4)-386
AT VEHICLES

1 CHECK CURRENT DATA. Is the value greater than Go to step 2. Even if MIL lights
1) Start engine. 150°C (302°F)? up, the circuit has
2) Read data of fuel temperature sensor sig- returned to a nor-
nal using Subaru Select Monitor or OBD-II mal condition at
general scan tool. this time.
NOTE:
2 CHECK CURRENT DATA. Is the value less than Replace fuel tem- Repair ground
1) Turn ignition switch to OFF. −40°C (−40°F)? perature sensor. short circuit in
2) Remove access hole lid. <Ref. to harness between
3) Disconnect connector from fuel pump. EC(H4)-10 Fuel fuel pump and
4) Turn ignition switch to ON. Temperature Sen- ECM connector.
5) Read data of fuel temperature sensor sig- sor.>
general scan tool.
NOTE:
EN(H4)-387
AT VEHICLES
AD: DTC P0183 — FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT

— S008602B36

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3929
EN(H4)-388
AT VEHICLES

2) Read data of fuel temperature sensor sig- NOTE:
nal using Subaru Select Monitor or OBD-II In this case,
general scan tool. repair the follow-
NOTE: ing:
For detailed operation procedure, refer to the fuel pump con-
“READ CURRENT DATA FOR ENGINE”. nector
쐌 OBD-II general scan tool ECM connector
For detailed operation procedures, refer to the 쐌 Poor contact in
tors (B22, B99
and R57)
쐌 Poor contact in
joint connector
(B83)
2) Remove access hole lid. pump connector.
4) Measure voltage between fuel pump con-
1) Turn ignition switch to ON. ECM and fuel
2) Measure voltage between fuel pump con- pump connector.
4 CHECK HARNESS BETWEEN FUEL TEM- Is the voltage more than 4 Go to step 5. Repair harness
PERATURE SENSOR AND ECM CONNEC- V? and connector.
TOR. NOTE:
Measure voltage between fuel pump connec- In this case,
tor and chassis ground. repair the follow-
harness between
ECM and fuel
pump connector
쐌 Poor contact in
fuel pump con-
nector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tors (B99 and
R57)
EN(H4)-389
AT VEHICLES

5 CHECK HARNESS BETWEEN FUEL TEM- Is the resistance less than Replace fuel tem- Repair harness
PERATURE SENSOR AND ECM CONNEC- 5 Ω? perature sensor. and connector.
TOR. <Ref. to NOTE:
1) Turn ignition switch to OFF. EC(H4)-10 Fuel In this case,
2) Measure resistance of harness between Temperature Sen- repair the follow-
fuel pump connector and chassis ground. sor.> ing:
(R58) No. 5 — Chassis ground: harness between
ECM and fuel
pump connector
쐌 Poor contact in
fuel pump con-
nector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tors (B99 and
R57)
쐌 Poor contact in
joint connector
(B83)
EN(H4)-390
AT VEHICLES
AE: DTC P0301 — CYLINDER 1 MISFIRE DETECTED — S008602B37
NOTE:
FIRE DETECTED —, Diagnostic Procedure with Diagnostic Trouble Code (DTC) for AT Vehicles.>
AF: DTC P0302 — CYLINDER 2 MISFIRE DETECTED — S008602B38
NOTE:
AG: DTC P0303 — CYLINDER 3 MISFIRE DETECTED — S008602B39
NOTE:
EN(H4)-391
AT VEHICLES
AH: DTC P0304 — CYLINDER 4 MISFIRE DETECTED — S008602B40

쐌 Immediately at fault recognition (A misfire which could damage catalyst occurs.)
쐌 Engine stalls.
쐌 Rough driving
CAUTION:
tion Mode.>.
EN(H4)-392
AT VEHICLES
쐌 WIRING DIAGRAM:
B2M3966
EN(H4)-393
AT VEHICLES
B2M3967
EN(H4)-394
AT VEHICLES

P0106, P0107, P0108, P0117 or P0125
P0116, P0117 or P0125? using “19. List of
Diagnostic
Trouble Code
(DTC) for AT
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0301, P0302,
P0303 and
P0304.
and chassis ground on faulty cylinders.
(−):
(−):
(−):
(−):
3 CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance less than Repair ground Go to step 4.
TOR AND ECM CONNECTOR. 10 Ω? short circuit in
2) Disconnect connector from fuel injector on fuel injector and
faulty cylinders. ECM connector.
and engine ground on faulty cylinders.
4 CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance less than Go to step 5. Repair harness
TOR AND ECM CONNECTOR. 1 Ω? and connector.
Measure resistance of harness connector NOTE:
between ECM connector and fuel injector on In this case,
faulty cylinders. repair the follow-
#1 (B134) No. 4 — (E5) No. 1: 쐌 Open circuit in
#2 (B134) No. 13 — (E16) No. 1: harness between
#3 (B134) No. 14 — (E6) No. 1: ECM and fuel
#4 (B134) No. 15 — (E17) No. 1: injector connector
쐌 Poor contact in
coupling connec-
tor (B21)
EN(H4)-395
AT VEHICLES

5 CHECK FUEL INJECTOR. Is the resistance between 5 Go to step 6. Replace faulty
Measure resistance between fuel injector ter- and 20 Ω? fuel injector. <Ref.
minals on faulty cylinder. to FU(H4)-56 Fuel
Terminals Injector.>
No. 1 — No. 2:
6 CHECK POWER SUPPLY LINE. Is the voltage more than 10 Repair poor con- Repair harness
1) Turn ignition switch to ON. V? tact in all connec- and connector.
2) Measure voltage between fuel injector and tors in fuel injector NOTE:
engine ground on faulty cylinders. circuit. In this case,
#1 (E5) No. 2 (+) — Engine ground (−): ing:
#2 (E16) No. 2 (+) — Engine ground 쐌 Open circuit in
(−): harness between
#3 (E6) No. 2 (+) — Engine ground (−): main relay and
(−): nector on faulty
cylinders
쐌 Poor contact in
coupling connec-
tor
쐌 Poor contact in
main relay con-
nector
쐌 Poor contact in
fuel injector con-
nector on faulty
cylinders
7 CHECK HARNESS BETWEEN FUEL INJEC- Is the voltage more than 10 Repair battery Go to step 8.
TOR AND ECM CONNECTOR. V? short circuit in
2) Disconnect connector from fuel injector on ECM and fuel
faulty cylinder. injector. After
3) Turn ignition switch to ON. repair, replace
4) Measure voltage between ECM connector ECM. <Ref. to
and chassis ground on faulty cylinders. FU(H4)-67 Engine
Connector & terminal Control Module.>
(−):
(−):
(−):
(−):
8 CHECK FUEL INJECTOR. Is the resistance less than Replace faulty Go to step 9.
1) Turn ignition switch to OFF. 1 Ω? fuel injector <Ref.
2) Measure resistance between fuel injector to FU(H4)-56 Fuel
terminals on faulty cylinder. Injector.> and
Terminals ECM <Ref. to
Control Module.>.
9 CHECK INSTALLATION OF CAMSHAFT Is camshaft position sensor Tighten camshaft Go to step 10.
POSITION SENSOR/CRANKSHAFT POSI- or crankshaft position sen- position sensor or
TION SENSOR. sor loosely installed? crankshaft posi-
tion sensor.
10 CHECK CRANKSHAFT SPROCKET. Is crankshaft sprocket Replace crank- Go to step 11.
Remove timing belt cover. rusted or does it have bro- shaft sprocket.
ken teeth? <Ref. to
ME(H4)-52 Crank-
shaft Sprocket.>
EN(H4)-396
AT VEHICLES

11 CHECK INSTALLATION CONDITION OF Is timing belt dislocated Repair installation Go to step 12.
TIMING BELT. from its proper position? condition of timing
Turn crankshaft using ST, and align alignment belt. <Ref. to
mark on crankshaft sprocket with alignment ME(H4)-46 Timing
mark on cylinder block. Belt Assembly.>
ST 499987500 CRANKSHAFT SOCKET
12 CHECK FUEL LEVEL. Is the fuel meter indication Go to step 13. Replenish fuel so
higher than the “Lower” fuel meter indica-
level? tion is higher than
the “Lower” level.
After replenishing
fuel, Go to step
13.
13 CHECK STATUS OF CHECK ENGINE MAL- Is the MIL coming on or Go to step 15. Go to step 14.
FUNCTION INDICATOR LAMP (MIL). blinking?
1) Clear memory using Subaru Select Moni-
tor.
<Ref. to EN(H4)-63 Clear Memory Mode.>
2) Start engine, and drive the vehicle more
than 10 minutes.
14 CHECK CAUSE OF MISFIRE DIAGNOSED. Was the cause of misfire Finish diagnostics Repair poor con-
diagnosed when the engine operation, if the tact.
is running? engine has no NOTE:
abnormality. In this case,
NOTE: repair the follow-
Ex. Remove spark ing:
plug cord, etc. 쐌 Poor contact in
ignitor connector
쐌 Poor contact in
ignition coil con-
nector
쐌 Poor contact in
fuel injector con-
nector on faulty
cylinders
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
15 CHECK AIR INTAKE SYSTEM. Is there a fault in air intake Repair air intake Go to step 16.
system? system.
NOTE:
Check the follow-
ing items:
쐌 Are there air
leaks or air suc-
tion caused by
loose or dislo-
cated nuts and
bolts?
쐌 Are there
cracks or any dis-
connection of
hoses?
EN(H4)-397
AT VEHICLES

16 CHECK MISFIRE SYMPTOM. Does the Subaru Select Go to step 21. Go to step 17.
1) Turn ignition switch to ON. Monitor or OBD-II general
2) Read diagnostic trouble code (DTC). scan tool indicate only one
쐌 Subaru Select Monitor DTC?
OBD-II General Scan Tool Operation Manual.
NOTE:
Perform diagnosis according to the items
listed below.
P0301 and P0302?
P0303 and P0304?
P0301 and P0303?
P0302 and P0304?
21 ONLY ONE CYLINDER Is there a fault in that cylin- Repair or replace Go to DTC
der? faulty parts. P0170. <Ref. to
NOTE: EN(H4)-382 DTC
Check the follow- P0170 — FUEL
ing items. TRIM MALFUNC-
쐌 Spark plug TION —, Diag-
쐌 Spark plug cord nostic Procedure
쐌 Fuel injector with Diagnostic
쐌 Compression Trouble Code
ratio (DTC) for AT
Vehicles.>
22 GROUP OF #1 AND #2 CYLINDERS Are there faults in #1 and Repair or replace Go to DTC
#2 cylinders? faulty parts. P0170. <Ref. to
쐌 Check the fol- P0170 — FUEL
lowing items. TRIM MALFUNC-
Spark plugs TION —, Diag-
Fuel injectors nostic Procedure
Ignition coil with Diagnostic
Compression ratio Trouble Code
쐌 If no abnormal (DTC) for AT
is discovered, Vehicles.>
check for “IGNI-
TION CONTROL
SYSTEM” of #1
and #2 cylinders
side. <Ref. to
EN(H4)-86 IGNI-
TION CONTROL
SYSTEM, Diag-
nostics for Engine
Starting Failure.>
EN(H4)-398
AT VEHICLES

쐌 Check the fol- P0170 — FUEL
lowing items. TRIM MALFUNC-
Spark plugs TION —, Diag-
Fuel injectors nostic Procedure
Ignition coil with Diagnostic
쐌 If no abnormal Trouble Code
is discovered, (DTC) for AT
check for “16. D: Vehicles.>
IGNITION CON-
TROL SYSTEM”
of #3 and #4 cyl-
inders side. <Ref.
to EN(H4)-86
IGNITION CON-
TROL SYSTEM,
Diagnostics for
Engine Starting
Failure.>
쐌 Spark plugs TION —, Diag-
쐌 Fuel injectors nostic Procedure
쐌 Skipping timing with Diagnostic
belt teeth Trouble Code
(DTC) for AT
Vehicles.>
쐌 Spark plugs TION —, Diag-
쐌 Fuel injectors nostic Procedure
쐌 Compression with Diagnostic
ratio Trouble Code
쐌 Skipping timing (DTC) for AT
belt teeth Vehicles.>
26 CYLINDER AT RANDOM Is the engine idle rough? Go to DTC Repair or replace
P0170. <Ref. to faulty parts.
EN(H4)-382 DTC NOTE:
P0170 — FUEL Check the follow-
TRIM MALFUNC- ing items.
TION —, Diag- 쐌 Spark plugs
nostic Procedure 쐌 Fuel injectors
with Diagnostic 쐌 Compression
Trouble Code ratio
(DTC) for AT
Vehicles.>
EN(H4)-399
AT VEHICLES
AI: DTC P0327 — KNOCK SENSOR CIRCUIT LOW INPUT — S008602F94

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3930
EN(H4)-400
AT VEHICLES

1 CHECK HARNESS BETWEEN KNOCK Is the resistance more than Go to step 2. Repair harness
SENSOR AND ECM CONNECTOR. 700 kΩ? and connector.
3) Measure resistance between ECM harness repair the follow-
connector and chassis ground. ing:
(B136) No. 4 — Chassis ground: harness between
knock sensor and
ECM connector
쐌 Poor contact in
knock sensor con-
nector
쐌 Poor contact in
coupling connec-
tor (B21)
2 CHECK KNOCK SENSOR. Is the resistance more than Go to step 3. Repair harness
1) Disconnect connector from knock sensor. 700 kΩ? and connector.
2) Measure resistance between knock sensor NOTE:
connector terminal and engine ground. In this case,
Terminal repair the follow-
No. 2 — Engine ground: ing:
쐌 Open circuit in
harness between
knock sensor and
ECM connector
쐌 Poor contact in
knock sensor con-
nector
쐌 Poor contact in
coupling connec-
tor (B21)
3 CHECK CONDITION OF KNOCK SENSOR Is the knock sensor instal- Replace knock Tighten knock
INSTALLATION. lation bolt tightened sensor. <Ref. to sensor installation
securely? FU(H4)-43 Knock bolt securely.
Sensor.>
EN(H4)-401
AT VEHICLES
AJ: DTC P0328 — KNOCK SENSOR CIRCUIT HIGH INPUT — S008602F95

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3930
EN(H4)-402
AT VEHICLES

1 CHECK HARNESS BETWEEN KNOCK Is the resistance less than Go to step 2. Go to step 3.
Measure resistance of harness between ECM
2 CHECK KNOCK SENSOR. Is the resistance less than Replace knock Repair ground
1) Disconnect connector from knock sensor. 400 kΩ? sensor. <Ref. to short circuit in
2) Measure resistance between knock sensor FU(H4)-43 Knock harness between
connector terminal and engine ground. Sensor.> knock sensor con-
Terminal nector and ECM
No. 2 — Engine ground: connector.
NOTE:
The harness
between both
connectors is
shielded. Repair
short circuit of
harness together
with shield.
3 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 2 Even if MIL lights Repair poor con-
1) Connect connectors to ECM and knock V? up, the circuit has tact in ECM con-
sensor. returned to a nor- nector.
2) Turn ignition switch to ON. mal condition at
3) Measure voltage between ECM and chas- this time.
sis ground. (However, the
Connector & terminal possibility of poor
(B136) No. 4 (+) — Chassis ground (−): contact still
remains.)
NOTE:
In this case,
repair the follow-
ing:
쐌 Poor contact in
knock sensor con-
nector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
EN(H4)-403
AT VEHICLES
AK: DTC P0335 — CRANKSHAFT POSITION SENSOR CIRCUIT


쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3931
EN(H4)-404
AT VEHICLES

1 CHECK HARNESS BETWEEN CRANK- Is the resistance more than Repair harness Go to step 2.
SHAFT POSITION SENSOR AND ECM 100 kΩ? and connector.
CONNECTOR. NOTE:
2) Disconnect connector from crankshaft posi- repair the follow-
tion sensor. ing:
crankshaft position sensor connector and harness between
engine ground. crankshaft posi-
Connector & terminal tion sensor and
(E10) No. 1 — Engine ground: ECM connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
2 CHECK HARNESS BETWEEN CRANK- Is the resistance less than Repair ground Go to step 3.
SHAFT POSITION SENSOR AND ECM 10 Ω? short circuit in
Measure resistance of harness between crankshaft posi-
crankshaft position sensor connector and tion sensor and
engine ground. ECM connector.
between both
connectors are
shielded. Repair
ground short cir-
cuit in harness
together with
shield.
3 CHECK HARNESS BETWEEN CRANK- Is the resistance less than Go to step 4. Repair harness
SHAFT POSITION SENSOR AND ECM 5 Ω? and connector.
CONNECTOR. NOTE:
crankshaft position sensor connector and repair the follow-
engine ground. ing:
crankshaft posi-
tion sensor and
ECM connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
securely.
5 CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1 Repair poor con- Replace crank-
1) Remove crankshaft position sensor. and 4 kΩ? tact in crankshaft shaft position sen-
2) Measure resistance between connector position sensor sor. <Ref. to
terminals of crankshaft position sensor. connector. FU(H4)-41 Crank-
EN(H4)-405
AT VEHICLES
AL: DTC P0336 — CRANKSHAFT POSITION SENSOR CIRCUIT


쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3931
EN(H4)-406
AT VEHICLES

P0335? Trouble Code
(DTC) for AT
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
securely.
3 CHECK CRANKSHAFT SPROCKET. Are crankshaft sprocket Replace crank- Go to step 4.
Remove front belt cover. teeth cracked or damaged? shaft sprocket.
<Ref. to
ME(H4)-52 Crank-
shaft Sprocket.>
4 CHECK INSTALLATION CONDITION OF Is timing belt dislocated Repair installation Replace crank-
TIMING BELT. from its proper position? condition of timing shaft position sen-
Turn crankshaft using ST, and align alignment belt. <Ref. to sor. <Ref. to
mark on crankshaft sprocket with alignment ME(H4)-46 Timing FU(H4)-41 Crank-
mark on cylinder block. Belt Assembly.> shaft Position
ST 499987500 CRANKSHAFT SOCKET Sensor.>
EN(H4)-407
AT VEHICLES
AM: DTC P0340 — CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

— S008602B44

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3932
EN(H4)-408
AT VEHICLES

TOR. NOTE:
tion sensor. ing:
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
ground. connector.
between both
connectors are
shielded. Repair
ground short cir-
cuit in harness
together with
shield.
TOR. NOTE:
ground. ing:
camshaft position
sensor and ECM
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
securely.
5 CHECK CAMSHAFT POSITION SENSOR. Is the resistance between 1 Repair poor con- Replace camshaft
1) Remove camshaft position sensor. and 4 kΩ? tact in camshaft position sensor.
2) Measure resistance between connector position sensor <Ref. to
terminals of camshaft position sensor. connector. FU(H4)-42 Cam-
EN(H4)-409
AT VEHICLES
AN: DTC P0341 — CAMSHAFT POSITION SENSOR CIRCUIT


쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3932
EN(H4)-410
AT VEHICLES

P0340 using “19.
List of Diagnostic
P0340? Trouble Code
(DTC) for AT
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
TOR. NOTE:
tion sensor. ing:
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
ground. connector.
between both
connectors are
shielded. Repair
ground short cir-
cuit in harness
together with
shield.
TOR. NOTE:
ground. ing:
camshaft position
sensor and ECM
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
EN(H4)-411
AT VEHICLES

securely.
6 CHECK CAMSHAFT POSITION SENSOR. Is the resistance between 1 Go to step 7. Replace camshaft
1) Remove camshaft position sensor. and 4 kΩ? position sensor.
2) Measure resistance between connector <Ref. to
terminals of camshaft position sensor. FU(H4)-42 Cam-
securely.
8 CHECK CAMSHAFT SPROCKET. Are camshaft sprocket Replace camshaft Go to step 9.
Remove front belt cover. <Ref. to ME(H4)-45 teeth cracked or damaged? sprocket. <Ref. to
Belt Cover.> ME(H4)-51 Cam-
shaft Sprocket.>
9 CHECK INSTALLATION CONDITION OF Is timing belt dislocated Repair installation Replace camshaft
TIMING BELT. from its proper position? condition of timing position sensor.
Turn camshaft using ST, and align alignment belt. <Ref. to <Ref. to
mark on camshaft sprocket with alignment ME(H4)-46 Timing FU(H4)-42 Cam-
mark on timing belt cover LH. Belt Assembly.> shaft Position
ST 499207100 CAMSHAFT SPROCKET Sensor.>
WRENCH
EN(H4)-412
MEMO:
AT VEHICLES
AO: DTC P0420 — CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD

— S008602B46

쐌 Engine stalls.
쐌 Idle mixture is out of specifications.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3950
EN(H4)-414
AT VEHICLES

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect the rel- Go to step 2.
Monitor or OBD-II general evant DTC using
scan tool indicate DTC “19. List of Diag-
P0130, P0133, P0136, nostic Trouble
P0139, P0037, P0301, Code (DTC) for
P0302, P0303, P0304, AT Vehicles”.
P1130, P1131, P0031, <Ref. to EN(H4)-
P0032 and P0038? 301 List of Diag-
nostic Trouble
Code (DTC) for
AT Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0420.
2 CHECK EXHAUST SYSTEM. Is there a fault in exhaust Repair or replace Go to step 3.
Check for gas leaks or air suction caused by system? exhaust system.
loose or dislocated nuts and bolts, and open <Ref. to 2.>
hole at exhaust pipes.
NOTE:
Check the following positions.
쐌 Between cylinder head and front exhaust
pipe
쐌 Between front exhaust pipe and front cata-
lytic converter
쐌 Between front catalytic converter and rear
catalytic converter
3 CHECK REAR CATALYTIC CONVERTER. Is there damage at rear Replace front Go to step 4.
Separate rear catalytic converter from rear face of rear catalyst? catalytic converter
exhaust pipe. <Ref. to EC(H4)-3
Front Catalytic
Converter.> and
rear catalytic con-
verter <Ref. to
EC(H4)-6 Rear
Catalytic Con-
verter.>.
4 CHECK FRONT CATALYTIC CONVERTER. Is there damage at rear Replace front Contact with SOA
Remove front catalytic converter. face or front face of front catalytic con- service.
catalyst? verter. <Ref. to NOTE:
EC(H4)-3 Front Inspection by
Catalytic Con- DTM is required,
verter.> because probable
cause is deterio-
ration of multiple
parts.
EN(H4)-415
AT VEHICLES
AP: DTC P0442 — EVAPORATIVE EMISSION CONTROL SYSTEM


쐌 Gasoline smell
CAUTION:
tion Mode.>.
EN(H4)-416
AT VEHICLES
쐌 WIRING DIAGRAM:
B2M3882
EN(H4)-417
AT VEHICLES

nostic Trouble
Code (DTC) for
AT Vehicles”.
<Ref. to EN(H4)-
301 List of Diag-
nostic Trouble
Code (DTC) for
AT Vehicles.>
NOTE:
<Ref. to
FU(H4)-82 Fuel
Filler Pipe.>
NOTE:
Check Mode.>
Check Mode.>
Delivery, Return
and Evaporation
Lines.>
EN(H4)-418
AT VEHICLES

ter.>
Tank.>
TROUBLE IN EVAPORATIVE EMISSION than 1.0 mm (0.04 in) dia., hoses or pipes. service.
CONTROL SYSTEM. cracks, clogging or discon- NOTE:
nections of hoses or pipes Inspection by
in evaporative emission DTM is required,
control system? because probable
cause is deterio-
ration of multiple
parts.
EN(H4)-419
AT VEHICLES
AQ: DTC P0444 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE

CONTROL VALVE CIRCUIT LOW INPUT — S008602G47

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3935
EN(H4)-420
AT VEHICLES

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 Even if MIL lights Go to step 2.
1) Turn ignition switch to ON. V? up, the circuit has
2) Measure voltage between ECM and chas- returned to a nor-
Connector & terminal this time. Contact
(B134) No. 2 (+) — Chassis ground (−): with SOA service.
NOTE:
Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
2 CHECK HARNESS BETWEEN PURGE Is the resistance less than Repair ground Go to step 3.
CONTROL SOLENOID VALVE AND ECM 10 Ω? short circuit in
2) Disconnect connectors from purge control control solenoid
solenoid valve and ECM. valve connector.
purge control solenoid valve connector and
engine ground.
3 CHECK HARNESS BETWEEN PURGE Is the resistance less than Go to step 4. Repair open cir-
CONTROL SOLENOID VALVE AND ECM 1 Ω? cuit in harness
Measure resistance of harness between ECM and purge control
and purge control solenoid valve of harness solenoid valve
connector. connector.
(B134) No. 2 — (E4) No. 2: In this case,
repair the follow-
ing:
쐌 Open circuit in
harness between
ECM and purge
control solenoid
valve connector
쐌 Poor contact in
coupling connec-
tor (B22)
4 CHECK PURGE CONTROL SOLENOID Is the resistance between Go to step 5. Replace purge
VALVE. 10 and 100 Ω? control solenoid
1) Remove purge control solenoid valve. valve. <Ref. to
Terminals Valve.>
No. 1 — No. 2:
5 CHECK POWER SUPPLY TO PURGE CON- Is the voltage more than 10 Go to step 6. Repair open cir-
TROL SOLENOID VALVE. V? cuit in harness
1) Turn ignition switch to ON. between main
2) Measure voltage between purge control relay and purge
solenoid valve and engine ground. control solenoid
EN(H4)-421
AT VEHICLES

Check poor contact in purge control solenoid purge control solenoid tact in purge con- service.
valve connector. valve connector? trol solenoid valve NOTE:
connector. Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(H4)-422
AT VEHICLES
MEMO:
EN(H4)-423
AT VEHICLES
AR: DTC P0445 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE

CONTROL VALVE CIRCUIT HIGH INPUT — S008602G48

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3935
EN(H4)-424
AT VEHICLES

4) While operating purge control solenoid contact in ECM
valve, measure voltage between ECM and connector.
chassis ground.
NOTE:
Purge control solenoid valve operation can be
sis ground.
Control Module.>
4 CHECK HARNESS BETWEEN PURGE Is the voltage more than 10 Repair battery Go to step 5.
CONTROL SOLENOID VALVE AND ECM V? short circuit in
2) Disconnect connector from purge control control solenoid
4) Measure voltage between ECM and chas- replace ECM.
sis ground. <Ref. to
(B134) No. 2 (+) — Chassis ground (−): Control Module.>
5 CHECK PURGE CONTROL SOLENOID Is the resistance less than Replace purge Go to step 6.
VALVE. 1 Ω? control solenoid
1) Turn ignition switch to OFF. valve <Ref. to
Terminals Valve.> and ECM
No. 1 — No. 2: <Ref. to
FU(H4)-67 Engine
Control Module.>
Control Module.>
EN(H4)-425
AT VEHICLES
AS: DTC P0447 — EVAPORATIVE EMISSION CONTROL SYSTEM VENT

CONTROL LOW INPUT — S008602F98

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3936
EN(H4)-426
AT VEHICLES

sis ground.
(−):
Check poor contact in ECM connector. ECM connector? tact in ECM con- up, the circuit has
nector. returned to a nor-
mal condition at
this time.
(However, the
possibility of poor
contact still
remains.)
NOTE:
In this case,
repair the follow-
ing:
쐌 Poor contact in
drain valve con-
nector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tors (B97 and
B99)
3 CHECK HARNESS BETWEEN DRAIN Is the resistance less than Repair ground Go to step 4.
VALVE AND ECM CONNECTOR. 10 Ω? short circuit in
2) Disconnect connectors from drain valve ECM and drain
and ECM. valve connector.
drain valve connector and chassis ground.
4 CHECK HARNESS BETWEEN DRAIN Is the voltage less than 1 Go to step 5. Repair harness
VALVE AND ECM CONNECTOR. Ω? and connector.
and drain valve connector. In this case,
(B134) No. 10 — (R69) No. 2: ing:
쐌 Open circuit in
harness between
ECM and drain
valve connector
쐌 Poor contact in
coupling connec-
tors (B99)
5 CHECK DRAIN VALVE. Is the resistance between Go to step 6. Replace drain
Measure resistance between drain valve ter- 10 and 100 Ω? valve. <Ref. to
minals. EC(H4)-17 Drain
Terminals Valve.>
No. 1 — No. 2:
EN(H4)-427
AT VEHICLES

6 CHECK POWER SUPPLY TO DRAIN Is the voltage more than 10 Go to step 7. Repair harness
VALVE. V? and connector.
2) Measure voltage between drain valve and In this case,
chassis ground. repair the follow-
harness between
main relay and
drain valve
쐌 Poor contact in
coupling connec-
tors (B97)
쐌 Poor contact in
main relay con-
nector
Check poor contact in drain valve connector. drain valve connector? tact in drain valve service.
connector. NOTE:
Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(H4)-428
AT VEHICLES
MEMO:
EN(H4)-429
AT VEHICLES
AT: DTC P0448 — EVAPORATIVE EMISSION CONTROL SYSTEM VENT

CONTROL HIGH INPUT — S008602F99

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3936
EN(H4)-430
AT VEHICLES

4) While operating drain valve, measure volt- contact in ECM
age between ECM and chassis ground. connector.
NOTE:
Drain valve operation can be excecuted using
Subaru Select Monitor. For procedure, refer to
“Compulsory Valve Operation Check Mode”.
<Ref. to EN(H4)-64 Compulsory Valve Opera-
tion Check Mode.>
(−):
sis ground.
(−):
Control Module.>
4 CHECK HARNESS BETWEEN DRAIN Is the voltage more than 10 Repair battery Go to step 5.
VALVE AND ECM CONNECTOR. V? short circuit in
2) Disconnect connector from drain valve. ECM and drain
(B134) No. 10 (+) — Chassis ground FU(H4)-67 Engine
(−): Control Module.>
5 CHECK DRAIN VALVE. Is the resistance less than Replace drain Go to step 6.
1) Turn ignition switch to OFF. 1 Ω? valve <Ref. to
2) Measure resistance between drain valve EC(H4)-17 Drain
terminals. Valve.> and ECM
Terminals <Ref. to
Control Module.>
Control Module.>
EN(H4)-431
AT VEHICLES
AU: DTC P0451 — EVAPORATIVE EMISSION CONTROL SYSTEM

PRESSURE SENSOR RANGE/PERFORMANCE PROBLEM — S008602B51

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3937
EN(H4)-432
AT VEHICLES

1 CHECK ANY OTHER DTC ON DISPLAY. Is there any DTC on dis- Inspect the rel- Go to step 2.
play? evant DTC using
nostic Trouble
Code (DTC) for
AT Vehicles”.
<Ref. to EN(H4)-
301 List of Diag-
nostic Trouble
Code (DTC) for
AT Vehicles.>
2) Open the fuel flap.
3 CHECK PRESSURE/VACUUM LINE. Is there a fault in pressure/ Repair or replace Replace fuel tank
NOTE: vacuum line? hoses and pipes. pressure sensor.
쐌 Disconnection, leakage and clogging of the EC(H4)-12 Fuel
vacuum hoses and pipes between fuel tank Tank Pressure
pressure sensor and fuel tank Sensor.>
쐌 Disconnection, leakage and clogging of air
ventilation hoses and pipes between fuel filler
pipe and fuel tank
EN(H4)-433
AT VEHICLES
AV: DTC P0452 — EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE

SENSOR LOW INPUT — S008602B52

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3937
EN(H4)-434
AT VEHICLES

1 CHECK CURRENT DATA. Is the value less than −2.8 Go to step 2. Even if MIL lights
1) Turn ignition switch to OFF. kPa (−21.0 mmHg, −0.827 up, the circuit has
2) Remove fuel filler cap. inHg)? returned to a nor-
3) Install fuel filler cap. mal condition at
4) Turn ignition switch to ON. this time.
5) Read the data of fuel tank pressure sensor
NOTE:
and chassis ground.
(−):
3 CHECK POWER SUPPLY TO FUEL TANK Does the voltage change Repair poor con- Contact with SOA
PRESSURE SENSOR. more than 4.5 V by shaking tact in ECM con- service.
Measure voltage between ECM connector harness and connector of nector. NOTE:
and chassis ground. ECM while monitoring the Inspection by
Connector & terminal value with voltage meter? DTM is required,
(B136) No. 15 (+) — Chassis ground because probable
(−): cause is deterio-
ration of multiple
parts.
ground.
(−):
EN(H4)-435
AT VEHICLES

HARNESS. NOTE:
tor (B99)
HARNESS. NOTE:
wiring harness
connector (R134)
쐌 Poor contact in
coupling connec-
tor (B99)
쐌 Poor contact in
joint connector
(B83)
COUPLING CONNECTOR IN REAR WIRING 500 kΩ? short circuit in
sure sensor. cord.
(R135) No. 5 — (R47) No. 3:
(R135) No. 3 — (R47) No. 1:
Measure resistance of harness between fuel 500 kΩ? short circuit in fuel
tank pressure sensor connector and chassis tank cord.
ground.
Tank Pressure
Sensor.>
EN(H4)-436
AT VEHICLES
MEMO:
EN(H4)-437
AT VEHICLES
AW: DTC P0453 — EVAPORATIVE EMISSION CONTROL SYSTEM

PRESSURE SENSOR HIGH INPUT — S008602B53

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3937
EN(H4)-438
AT VEHICLES

1 CHECK CURRENT DATA. Is the value more than 2.8 Go to step 12. Go to step 2.
1) Turn ignition switch to OFF. kPa (21.0 mmHg, 0.827
2) Remove fuel filler cap. inHg)?
nal using Subaru Select Monitor or OBD-II
general scan tool.
NOTE:
and chassis ground.
(−):
3 CHECK POWER SUPPLY TO FUEL TANK Does the voltage change Repair poor con- Replace ECM.
PRESSURE SENSOR. more than 4.5 V by shaking tact in ECM con- <Ref. to
Measure voltage between ECM connector harness and connector of nector. FU(H4)-67 Engine
and chassis ground. ECM while monitoring the Control Module.>
Connector & terminal value with voltage meter?
(−):
ground.
(−):
HARNESS. NOTE:
tor (B99)
EN(H4)-439
AT VEHICLES

HARNESS. NOTE:
wiring harness
connector (R134)
쐌 Poor contact in
coupling connec-
tor (B99)
8 CHECK HARNESS BETWEEN ECM AND Is the resistance less than Go to step 9. Repair ground
COUPLING CONNECTOR IN REAR WIRING 1 Ω? short circuit in
(B136) No. 16 — (R134) No. 3:
sure sensor. cord.
(R135) No. 6 — (R47) No. 2:
(R135) No. 3 — (R47) No. 1:
connector. FU(H4)-12 Fuel
Tank Pressure
Sensor.>
12 CHECK HARNESS BETWEEN ECM AND Is the value more than 2.8 Repair battery Replace fuel tank
FUEL TANK PRESSURE SENSOR CON- kPa (21.0 mmHg, 0.827 short circuit in pressure sensor.
NECTOR. inHg)? harness between <Ref. to
1) Turn ignition switch to OFF. ECM and fuel FU(H4)-12 Fuel
2) Disconnect connector from fuel tank pres- tank pressure Tank Pressure
sure sensor. sensor connector. Sensor.>
general scan tool.
NOTE:
EN(H4)-440
AT VEHICLES
MEMO:
EN(H4)-441
AT VEHICLES
AX: DTC P0456 — EVAPORATIVE EMISSION CONTROL SYSTEM

MALFUNCTION — S008602G00

쐌 Gasoline smell
CAUTION:
tion Mode.>.
EN(H4)-442
AT VEHICLES
쐌 WIRING DIAGRAM:
B2M3882
EN(H4)-443
AT VEHICLES

nostic Trouble
Code (DTC) for
AT Vehicles”.
<Ref. to EN(H4)-
301 List of Diag-
nostic Trouble
Code (DTC) for
AT Vehicles.>
NOTE:
<Ref. to
FU(H4)-82 Fuel
Filler Pipe.>
NOTE:
Check Mode.>
Check Mode.>
Delivery, Return
and Evaporation
Lines.>
EN(H4)-444
AT VEHICLES

ter.>
Tank.>
TROUBLE IN EVAPORATIVE EMISSION than 0.5 mm (0.020 in) hoses or pipes. service.
CONTROL SYSTEM. dia., cracks, clogging or NOTE:
disconnections of hoses or Inspection by
pipes in evaporative emis- DTM is required,
sion control system? because probable
cause is deterio-
ration of multiple
parts.
EN(H4)-445
AT VEHICLES
AY: DTC P0461 — FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE


CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3938
EN(H4)-446
AT VEHICLES

Monitor or OBD-II general P0462 or P0463 sensor <Ref. to
scan tool indicate DTC using “19. List of EC(H4)-9 Main
P0462 or P0463? Diagnostic Fuel Level Sen-
Trouble Code sor.> and fuel sub
(DTC) for AT level sensor <Ref.
Vehicles”. <Ref. to to FU(H4)-94 Fuel
EN(H4)-301 List Sub Level Sen-
of Diagnostic sor.>.
Trouble Code
(DTC) for AT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect this
trouble.
EN(H4)-447
AT VEHICLES
AZ: DTC P0462 — FUEL LEVEL SENSOR CIRCUIT LOW INPUT — S008602B55

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3938

IDI-4 Combination
Meter System.>
EN(H4)-448
AT VEHICLES

2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than Go to step 6. Go to step 3.
1) Turn ignition switch to ON. (Engine OFF) 0.12 V?
and chassis ground.
(−):
3 CHECK INPUT SIGNAL FOR ECM. (USING Does the value change Repair poor con- Even if MIL lights
SUBARU SELECT MONITOR.) less than 0.12 V by shak- tact in ECM con- up, the circuit has
Read data of fuel level sensor signal using ing harness and connector nector. returned to a nor-
Subaru Select Monitor. of ECM while monitoring mal condition at
NOTE: the value with Subaru this time. A tem-
쐌 Subaru Select Monitor Select Monitor? porary poor con-
For detailed operation procedure, refer to the tact of the con-
“READ CURRENT DATA FOR ENGINE”. nector may be the
<Ref. to EN(H4)-52 Subaru Select Monitor.> cause.
NOTE:
In this case,
repair the follow-
ing:
쐌 Poor contact in
combination meter
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tors (B99)
4 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than Go to step 4. Go to step 7.
1) Turn ignition switch to OFF. 0.12 V?
2) Separate fuel tank cord connector (R57)
(−):
COMBINATION METER. 1 MΩ? short circuit in
2) Disconnect connector from connector (i10) ECM and combi-
and ECM connector. nation meter con-
3) Measure resistance between ECM and nector.
chassis ground.
6 CHECK HARNESS BETWEEN ECM AND Is the resistance less than Repair or replace Repair open cir-
COMBINATION METER. 10 Ω? combination cuit between ECM
Measure resistance between ECM and combi- meter. <Ref. to and combination
nation meter connector. IDI-4 Combination meter connector.
Connector & terminal Meter System.> NOTE:
(B136) No. 27 — (i10) No. 3: In this case,
repair the follow-
ing:
Poor contact in
coupling connec-
tor (R98)
EN(H4)-449
AT VEHICLES

1) Turn ignition switch to OFF. 1 MΩ? short circuit in fuel
2) Disconnect connector from fuel sub level tank cord.
sensor.
1) Disconnect connector from fuel pump 1 MΩ? short circuit in fuel
assembly. tank cord.
2) Measure resistance between fuel pump
assembly and chassis ground.
9 CHECK FUEL LEVEL SENSOR. Is the resistance between Go to step 10. Replace fuel level
WARNING: 0.5 and 2.5 Ω? sensor.
During work procedures, if fuel tank is
more than 3/4 full, be careful because fuel
may spill.
2) Measure resistance between fuel level sen-
sor and terminals with its float set to the full
position.
Terminals
No. 3 — No. 6:
10 CHECK FUEL SUB LEVLE SENSOR. Is the resistance between Repair poor con- Replace fuel sub
WARNING: 0.5 and 2.5 Ω? tact in harness level sensor.
During work procedures, if fuel tank is between ECM
more than 3/4 full, be careful because fuel and combination
may spill. meter connector.
1) Remove fuel sub level sensor. <Ref. to
sensor and terminals with its float set to the
full position.
Terminals
No. 1 — No. 2:
EN(H4)-450
AT VEHICLES
MEMO:
EN(H4)-451
AT VEHICLES
BA: DTC P0463 — FUEL LEVEL SENSOR CIRCUIT HIGH INPUT — S008602B56

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3938

IDI-4 Combination
Meter System.>
EN(H4)-452
AT VEHICLES

2 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than Go to step 3. Even if MIL lights
1) Turn ignition switch to ON. (Engine OFF) 4.75 V? up, the circuit has
2) Measure voltage between ECM connector returned to a nor-
and chassis ground. mal condition at
Connector & terminal this time. A tem-
(B136) No. 27 (+) — Chassis ground porary poor con-
(−): tact of the con-
nector may be the
cause.
NOTE:
In this case,
repair the follow-
ing:
쐌 Poor contact in
fuel pump con-
nector
쐌 Poor contact in
coupling connec-
tor (B22, R98 and
R57)
3 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than Go to step 4. Repair battery
1) Turn ignition switch to OFF. 4.75 V? short circuit
2) Disconnect combination meter connector between ECM
(i10) and ECM connector. and combination
3) Turn ignition switch to ON. meter connector.
and chassis ground.
(−):
FUEL TANK CORD. 5 Ω? cuit between ECM
1) Turn ignition switch to OFF. and fuel tank
2) Separate fuel tank cord connector (R57) cord.
3) Measure resistance between ECM and fuel
tank cord.
(B136) No. 27 — (R15) No. 6:
5 CHECK HARNESS BETWEEN FUEL TANK Is the resistance less than Go to step 6. Repair open cir-
CORD AND CHASSIS GROUND. 5 Ω? cuit between fuel
Measure resistance between fuel tank cord tank cord and
and chassis ground. chassis ground.
(R15) No. 5 — Chassis ground: In this case,
repair the follow-
ing:
Poor contact in
coupling connec-
tors (B22 and
B99)
1) Disconnect connector from fuel level sen- 10 Ω? cuit between cou-
sor. pling connector
2) Measure resistance between fuel level sen- and fuel level sen-
sor and coupling connector. sor.
(R57) No. 5 — (R58) No. 3:
EN(H4)-453
AT VEHICLES

1) Disconnect connector from fuel sub level 10 Ω? cuit between fuel
sensor. level sensor and
2) Measure resistance between fuel level sen- fuel sub level sen-
sor and fuel sub level sensor. sor.
(R58) No. 6 — (R59) No. 2:
Measure resistance between fuel sub level 10 Ω? cuit between cou-
sensor and coupling connector. pling connector
Connector & terminal and fuel sub level
(R57) No. 6 — (R59) No. 1: sensor.
9 CHECK FUEL LEVEL SENSOR. Is the resistance more than Replace fuel level Go to step 10.
WARNING: 54.5 Ω? sensor. <Ref. to
may spill.
down, measure resistance between fuel level
sensor terminals.
Terminals
No. 3 — No. 6:
10 CHECK FUEL SUB LEVEL SENSOR. Is the resistance more than Replace fuel sub Replace combina-
WARNING: 41.5 Ω? level sensor. tion meter. <Ref.
During work procedures, if fuel tank is <Ref. to to IDI-17 Combi-
more than 3/4 full, be careful because fuel FU(H4)-94 Fuel nation Meter
may spill. Sub Level Sen- Assembly.>
and down, measure resistance between fuel
sub level sensor terminals.
Terminals
No. 1 — No. 2:
EN(H4)-454
AT VEHICLES
MEMO:
EN(H4)-455
AT VEHICLES
BB: DTC P0464 — FUEL LEVEL SENSOR INTERMITTENT INPUT— S008602G01

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3938
EN(H4)-456
AT VEHICLES

Trouble Code
(DTC) for AT
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
2 CHECK FUEL LEVEL SENSOR. Does the resistance Go to step 3. Replace fuel level
WARNING: change smoothly? sensor. <Ref. to
may spill.
down, make sure that the resistance between
fuel level sensro terminals changes smoothly.
Terminals
No. 3 — No. 6:
3 CHECK FUEL SUB LEVEL SENSOR. Does the resistance Repair poor con- Replace fuel sub
WARNING: change smoothly? tact in ECM, com- level sensor.
During work procedures, if fuel tank is bination meter <Ref. to
more than 3/4 full, be careful because fuel and coupling con- FU(H4)-94 Fuel
may spill. nectors. Sub Level Sen-
and down, make sure that the resistance
between fuel level sensro terminals changes
smoothly.
Terminals
No. 1 — No. 2:
EN(H4)-457
AT VEHICLES
BC: DTC P0480 — COOLING FAN RELAY 1 CIRCUIT LOW INPUT — S008602B57

쐌 Overheating
CAUTION:
tion Mode.>.
EN(H4)-458
AT VEHICLES
쐌 WIRING DIAGRAM:
B2M3939
EN(H4)-459
AT VEHICLES

1 CHECK OUTPUT SIGNAL FROM ECM. Does voltage change Repair poor con- Go to step 2.
1) Turn ignition switch to OFF. between 0 and 10 V? tact in ECM con-
2) Connect test mode connector at the lower nector.
portion of instrument panel (on the driver’s
side), to the side of the center console box.
4) While operating radiator fan relay, measure
voltage between ECM terminal and ground.
NOTE:
Mode”. <Ref. to EN(H4)-52 Subaru Select
Monitor.>
2 CHECK GROUND SHORT CIRCUIT IN Is the resistance less than Repair ground Go to step 3.
RADIATOR FAN RELAY 1 CONTROL CIR- 10 Ω? short circuit in
CUIT. radiator fan relay
1) Turn ignition switch to OFF. 1 control circuit.
2) Disconnect connectors from ECM.
3 CHECK POWER SUPPLY FOR RELAY. Is the voltage more than 10 Go to step 4. Repair open cir-
1) Remove main fan relay from A/C relay V? cuit in harness
holder. between ignition
2) Turn ignition switch to ON. switch and fuse
3) Measure voltage between fuse and relay and relay box
box (F/B) connector and chassis ground. (F/B) connector.
4 CHECK MAIN FAN RELAY. Is the resistance between Go to step 5. Replace main fan
2) Measure resistance between main fan
relay terminals.
Terminal
No. 5 — No. 6:
5 CHECK OPEN CIRCUIT IN MAIN FAN Is the resistance less than Go to step 6. Repair harness
RELAY CONTROL CIRCUIT. 1 Ω? and connector.
and main fan relay connector. In this case,
(B134) No. 3 — (F66) No. 6: ing:
쐌 Open circuit in
harness between
ECM and main
fan relay connec-
tor
쐌 Poor contact in
coupling connec-
tor (F45)
Check poor contact in ECM or main fan relay ECM or main fan relay contact in ECM or service.
connector. nector? main fan relay
connector.
EN(H4)-460
AT VEHICLES
MEMO:
EN(H4)-461
AT VEHICLES
BD: DTC P0483 — COOLING FAN FUNCTION PROBLEM — S008602B58

쐌 Occurrence of noise
쐌 Overheating
CAUTION:
tion Mode.>.
NOTE:
If the vehicle, with the engine idling, is placed very close to a wall or another vehicle, preventing normal
cooling function, the OBD system may detect malfunction.
EN(H4)-462
AT VEHICLES
쐌 WIRING DIAGRAM:
B2M3939
EN(H4)-463
AT VEHICLES

1 CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on Inspect the rel- Check radiator fan
display? evant DTC using and fan motor.
“19. List of Diag- <Ref. to
nostic Trouble CO(H4)-22
AT Vehicles”. Radiator Main
<Ref. to EN(H4)- Fan and Fan
301 List of Diag- Motor.> and <Ref.
nostic Trouble to CO(H4)-24
AT Vehicles.> Radiator Sub Fan
and Fan Motor.>
EN(H4)-464
AT VEHICLES
MEMO:
EN(H4)-465
AT VEHICLES
BE: DTC P0500 — VEHICLE SPEED SENSOR MALFUNCTION — S008602B59

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3951
EN(H4)-466
AT VEHICLES

1 CHECK DTC P0720 ON DISPLAY. Does the Subaru Select Check front Go to step 2.
Monitor or OBD-II general vehicle speed
scan tool indicate DTC sensor signal cir-
P0720? cuit. <Ref. to
AT-56 TROUBLE
CODE 33 —
FRONT VEHICLE
SPEED SENSOR
—, Diagnostic
Procedure with
Trouble Code.>
speed sensor.
<Ref. to IDI-19
Speedometer.>
and <Ref. to
AT-31 Front and
Rear Vehicle
Speed Sensor,
Torque Converter
Turbine Speed
Sensor and Har-
ness Assembly.>
nation meter con-
nector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
combination meter
connector
쐌 Poor contact in
coupling connec-
tor (B36)
EN(H4)-467
AT VEHICLES
BF: DTC P0506 — IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED
— S008602B61

쐌 Engine is difficult to start.
쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3952
EN(H4)-468
AT VEHICLES

P1510, P1511, P1512, P1514, P1515,
P1513, P1514, P1515, P1516 or P1517
P1516 or P1517? using “19. List of
Diagnostic
Trouble Code
(DTC) for AT
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0506.
2 CHECK AIR BY-PASS LINE. Does air flow out? Replace idle air Replace throttle
1) Turn ignition switch to OFF. control solenoid body. <Ref. to
2) Remove idle air control solenoid valve from valve. <Ref. to FU(H4)-17 AT
throttle body. <Ref. to FU(H4)-53 AT FU(H4)-54 AT VEHICLES,
VEHICLES, REMOVAL, Idle Air Control Sole- VEHICLES, INSTALLATION,
noid Valve.> INSTALLATION, Throttle Body.>
3) Remove throttle body from intake manifold. Idle Air Control
<Ref. to FU(H4)-17 AT VEHICLES, Solenoid Valve.>
REMOVAL, Throttle Body.>
4) Using an air gun, force air into idle air con-
trol solenoid valve installation area. Confirm
that forced air subsequently escapes from
throttle body interior.
EN(H4)-469
AT VEHICLES
BG: DTC P0507 — IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED
— S008602B62

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3952
EN(H4)-470
AT VEHICLES

P1510, P1511, P1512, P1514, P1515,
P1513, P1514, P1515, P1516 or P1517
Diagnostic
Trouble Code
(DTC) for AT
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0507.
2 CHECK AIR INTAKE SYSTEM. Is there a fault in air intake Repair air suction Go to step 3.
1) Turn ignition switch to ON. system? and leaks.
2) Start engine, and idle it.
3) Check the following items.
쐌 Loose installation of intake manifold, idle air
control solenoid valve and throttle body
body gasket
SP(H4)-6
INSTALLATION,
Accelerator Con-
trol Cable.>
4 CHECK AIR BY-PASS LINE. Are foreign particles in by- Remove foreign Replace idle air
1) Turn ignition switch to OFF. pass air line? particles from by- control solenoid
2) Remove idle air control solenoid valve from pass air line. valve. <Ref. to
throttle body. <Ref. to FU(H4)-53 AT FU(H4)-53 Idle Air
VEHICLES, REMOVAL, Idle Air Control Sole- Control Solenoid
noid Valve.> Valve.>
3) Confirm that there are no foreign particles
in by-pass air line.
EN(H4)-471
AT VEHICLES
BH: DTC P0512 — STARTER SWITCH CIRCUIT HIGH INPUT — S008602G02

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3955
EN(H4)-472
AT VEHICLES

1 CHECK OPERATION OF STARTER MOTOR. Does starter motor operate Repair battery Check starter
NOTE: when ignition switch to short circuit in motor circuit.
Place the inhibitor switch in each position. “ON”? starter motor cir- <Ref. to
cuit. After repair, EC(H4)-77 Diag-
replace ECM. nostics for Engine
<Ref. to Starting Failure.>
FU(H4)-67 Engine
Control Module.>
EN(H4)-473
AT VEHICLES
BI: DTC P0604 — INTERNAL CONTROL MODULE MEMORY CHECK SUM

ERROR — S008602G03

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3953
EN(H4)-474
AT VEHICLES

EN(H4)-475
AT VEHICLES
BJ: DTC P0703 — BRAKE SWITCH INPUT MALFUNCTION — S008602B64

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3954

1 CHECK OPERATION OF BRAKE LIGHT. Does brake light come on Go to step 2. Repair or replace
when depressing the brake brake light circuit.
pedal?
EN(H4)-476
AT VEHICLES

2 CHECK HARNESS BETWEEN TCM AND Is the resistance less than Go to step 3. Repair or replace
BRAKE LIGHT SWITCH CONNECTOR. 1 Ω? harness and con-
1) Disconnect connectors from TCM and nector.
brake light switch. NOTE:
2) Measure resistance of harness between In this case,
TCM and brake light switch connector. repair the follow-
(B55) No. 24 — (B65) No. 3 (With harness between
cruise control): TCM and brake
light switch con-
nector
쐌 Poor contact in
TCM connector
쐌 Poor contact in
brake light switch
connector
3 CHECK HARNESS BETWEEN TCM AND Is the resistance more than Go to step 4. Repair ground
BRAKE LIGHT SWITCH CONNECTOR. 1 MΩ? short circuit in
Measure resistance of harness between TCM harness between
and chassis ground. TCM and brake
Connector & terminal light switch con-
(B55) No. 24 — Chassis ground: nector.
4 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V Go to step 5. Adjust or replace
1) Connect connectors to TCM and brake when releasing the brake brake light switch.
light switch. pedal? <Ref. to LI-19
2) Measure voltage between TCM and chas- STOP LIGHT
sis ground. SWITCH,
Connector & terminal INSPECTION,
(B55) No. 24 (+) — Chassis ground (−): Stop Light Sys-
tem.>
5 CHECK INPUT SIGNAL FOR TCM. Is the voltage more than 10 Go to step 6. Adjust or replace
Measure voltage between TCM and chassis V when depressing the brake light switch.
ground. brake pedal? <Ref. to LI-19
Connector & terminal STOP LIGHT
(B55) No. 24 (+) — Chassis ground (−): SWITCH,
INSPECTION,
Stop Light Sys-
tem.>
6 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace TCM.
Check poor contact in TCM connector. TCM connector? tact in TCM con- <Ref. to AT-42
nector. Transmission
Control Module.>
EN(H4)-477
AT VEHICLES
BK: DTC P0705 — TRANSMISSION RANGE SENSOR CIRCUIT


쐌 Starter does not rotate when selector lever is in “P” or “N” range.
쐌 Starter rotates when selector lever is in “R”, “D”, “3”, “2” or “1” range.
쐌 Engine brake is not effected when selector lever is in “3” range.
쐌 Shift characteristics are erroneous.
CAUTION:
tion Mode.>.
NOTE:
Check inhibitor switch circuit. <Ref. to AT-124 CHECK INHIBITOR SWITCH, Diagnostic Procedure for No-
Trouble Code.>
BL: DTC P0710 — TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT

쐌 No shift up to 4th speed (after engine warm-up)
쐌 No lock-up (after engine warm-up)
쐌 Excessive shift shock
CAUTION:
tion Mode.>.
NOTE:
Check ATF temperature sensor circuit. <Ref. to AT-44 TROUBLE CODE 27 — ATF TEMPERATURE SEN-
SOR —, Diagnostic Procedure with Trouble Code.>
BM: DTC P0715 — TORQUE CONVERTER TURBINE SPEED SENSOR

CAUTION:
tion Mode.>.
NOTE:
Check torque converter turbine speed sensor circuit. <Ref. to AT-62 TROUBLE CODE 36 — TORQUE
CONVERTER TURBINE SPEED SENSOR —, Diagnostic Procedure with Trouble Code.>
EN(H4)-478
AT VEHICLES
BN: DTC P0720 — OUTPUT SPEED SENSOR (VEHICLE SPEED SENSOR 2)


쐌 No shift or excessive tight corner “braking”
CAUTION:
tion Mode.>.
NOTE:
Check front vehicle speed sensor circuit. <Ref. to AT-56 TROUBLE CODE 33 — FRONT VEHICLE SPEED
SENSOR —, Diagnostic Procedure with Trouble Code.>
BO: DTC P0725 — ENGINE SPEED INPUT CIRCUIT MALFUNCTION — S008602B69

쐌 AT diagnostic indicator light (AT OIL TEMP indicator light) remains on when vehicle speed is “0”.
CAUTION:
tion Mode.>.
NOTE:
Check engine speed input signal circuit. <Ref. to AT-40 TROUBLE CODE 11 — ENGINE SPEED SIGNAL
—, Diagnostic Procedure with Trouble Code.>
BP: DTC P0731 — GEAR 1 INCORRECT RATIO — S008602B70
NOTE:
For the diagnostic procedure, refer to DTC P0734. <Ref. to EN(H4)-480 DTC P0734 — GEAR 4 INCOR-
RECT RATIO —, Diagnostic Procedure with Diagnostic Trouble Code (DTC) for AT Vehicles.>
BQ: DTC P0732 — GEAR 2 INCORRECT RATIO — S008602B71
NOTE:
BR: DTC P0733 — GEAR 3 INCORRECT RATIO — S008602B72
NOTE:
EN(H4)-479
AT VEHICLES
BS: DTC P0734 — GEAR 4 INCORRECT RATIO — S008602B73

쐌 Shift point too high or too low; engine brake not effected in “3” range; excessive shift shock; exces-
sive tight corner “braking”
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
1 CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on Inspect relevant Go to step 2.
display? DTC using “19.
List of Diagnostic
Trouble Code
(DTC) for AT
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
2 CHECK THROTTLE POSITION SENSOR Is there any trouble in Repair or replace Go to step 3.
CIRCUIT. throttle position sensor cir- throttle position
Check throttle position sensor circuit. <Ref. to cuit? sensor circuit.
AT-48 TROUBLE CODE 31 — THROTTLE
POSITION SENSOR —, Diagnostic Proce-
dure with Trouble Code.>
3 CHECK FRONT VEHICLE SPEED SENSOR Is there any trouble in Repair or replace Go to step 4.
CIRCUIT. vehicle speed sensor 2 cir- vehicle speed
Check front vehicle speed sensor circuit. cuit? sensor 2 circuit.
<Ref. to AT-56 TROUBLE CODE 33 —
FRONT VEHICLE SPEED SENSOR —, Diag-
nostic Procedure with Trouble Code.>
4 CHECK TORQUE CONVERTER TURBINE Is there any trouble in Repair or replace Go to step 5.
SPEED SENSOR CIRCUIT. torque converter turbine torque converter
Check torque converter turbine speed sensor speed sensor circuit? turbine speed
circuit. <Ref. to AT-62 TROUBLE CODE 36 — sensor circuit.
TORQUE CONVERTER TURBINE SPEED
SENSOR —, Diagnostic Procedure with
Trouble Code.>
Check poor contact in TCM connector. TCM connector? tact in TCM con-
nector.
6 CHECK MECHANICAL TROUBLE. Is there any mechanical Repair or replace Replace TCM.
Check mechanical trouble in automatic trans- trouble in automatic trans- automatic trans- <Ref. to AT-42
mission. mission? mission. <Ref. to Transmission
AT-11 Control Module
INSPECTION, (TCM).>
Road Test.>
EN(H4)-480
AT VEHICLES
MEMO:
EN(H4)-481
AT VEHICLES
BT: DTC P0741 — TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION

— S008602G04

쐌 No shift or excessive tight corner “braking”
CAUTION:
tion Mode.>.
nostic Trouble
Code (DTC) for
AT Vehicles”.
<Ref. to EN(H4)-
301 List of Diag-
nostic Trouble
Code (DTC) for
AT Vehicles.>
2 CHECK LOCK-UP DUTY SOLENOID CIR- Is there any trouble in Repair or replace Go to step 3.
CUIT. lock-up duty solenoid cir- lock-up duty sole-
Check lock-up duty solenoid circuit. <Ref. to cuit? noid circuit.
AT-102 TROUBLE CODE 77 — LOCK-UP
DUTY SOLENOID —, Diagnostic Procedure
with Trouble Code.>
3 CHECK THROTTLE POSITION SENSOR Is there any trouble in Repair or replace Go to step 4.
CIRCUIT. throttle position sensor cir- throttle position
Check throttle position sensor circuit. <Ref. to cuit? sensor circuit.
AT-48 TROUBLE CODE 31 — THROTTLE
POSITION SENSOR —, Diagnostic Proce-
4 CHECK TORQUE CONVERTER TURBINE Is there any trouble in Repair or replace Go to step 5.
SPEED SENSOR CIRCUIT. torque converter turbine torque converter
Check torque converter turbine speed sensor speed sensor circuit? turbine speed
circuit. <Ref. to AT-62 TROUBLE CODE 36 — sensor circuit.
TORQUE CONVERTER TURBINE SPEED
SENSOR —, Diagnostic Procedure with
Trouble Code.>
5 CHECK ENGINE SPEED INPUT CIRCUIT. Is there any trouble in Repair or replace Go to step 6.
Check engine speed input circuit. <Ref. to engine speed input circuit? engine speed
AT-40 TROUBLE CODE 11 — ENGINE input circuit.
SPEED SIGNAL —, Diagnostic Procedure
with Trouble Code.>
6 CHECK INHIBITOR SWITCH CIRCUIT. Is there any trouble in Repair or replace Go to step 7.
Check inhibitor switch circuit. <Ref. to AT-124 inhibitor switch circuit? inhibitor switch
CHECK INHIBITOR SWITCH, Diagnostic Pro- circuit.
cedure for No-trouble Code.>
7 CHECK BRAKE LIGHT SWITCH CIRCUIT. Is there any trouble in Repair or replace Go to step 8.
Check brake light switch circuit. <Ref. to brake light switch circuit? brake light switch
AT-122 CHECK BRAKE SWITCH, Diagnostic circuit.
Procedure for No-trouble Code.>
EN(H4)-482
AT VEHICLES

8 CHECK ATF TEMPERATURE SENSOR CIR- Is there any trouble in ATF Repair or replace Go to step 9.
CUIT. temperature sensor circuit? ATF temperature
Check ATF temperature sensor circuit. <Ref. sensor circuit.
to AT-44 TROUBLE CODE 27 — ATF TEM-
PERATURE SENSOR —, Diagnostic Proce-
Check poor contact in TCM connector. TCM connector? tact in TCM con-
nector.
10 CHECK MECHANICAL TROUBLE. Is there any mechanical Repair or replace Replace TCM.
Check mechanical trouble in automatic trans- trouble in automatic trans- automatic trans- <Ref. to AT-42
mission. mission? mission. <Ref. to Transmission
AT-11 Control Module
INSPECTION, (TCM).>
Road Test.>
EN(H4)-483
AT VEHICLES
BU: DTC P0743 — TORQUE CONVERTER CLUTCH SYSTEM (LOCK-UP


CAUTION:
tion Mode.>.
NOTE:
Check lock-up duty solenoid circuit. <Ref. to AT-102 TROUBLE CODE 77 — LOCK-UP DUTY SOLENOID
—, Diagnostic Procedure with Trouble Code.>
BV: DTC P0748 — PRESSURE CONTROL SOLENOID (LINE PRESSURE

CAUTION:
tion Mode.>.
NOTE:
Check line pressure duty solenoid circuit. <Ref. to AT-90 TROUBLE CODE 75 — LINE PRESSURE DUTY
SOLENOID —, Diagnostic Procedure with Trouble Code.>
BW: DTC P0753 — SHIFT SOLENOID A (SHIFT SOLENOID 1) ELECTRICAL
— S008602B77

쐌 No shift
CAUTION:
tion Mode.>.
NOTE:
Check shift solenoid 1 circuit. <Ref. to AT-74 TROUBLE CODE 71 — SHIFT SOLENOID 1 —, Diagnostic
Procedure with Trouble Code.>
EN(H4)-484
AT VEHICLES
BX: DTC P0758 — SHIFT SOLENOID B (SHIFT SOLENOID 2) ELECTRICAL —

S008602B78

쐌 No shift
CAUTION:
tion Mode.>.
NOTE:
Check shift solenoid 2 circuit. <Ref. to AT-78 TROUBLE CODE 72 — SHIFT SOLENOID 2 —, Diagnostic
Procedure with Trouble Code.>
BY: DTC P0778 — 2-4 BRAKE PRESSURE CONTROL SOLENOID VALVE
CIRCUIT MALFUNCTION — S008602G05

CAUTION:
tion Mode.>.
NOTE:
Check 2-4 brake pressure control solenoid valve circuit. <Ref. to AT-96 TROUBLE CODE 76 — 2-4 BRAKE
DUTY SOLENOID —, Diagnostic Procedure with Trouble Code.>
BZ: DTC P0785 — 2-4 BRAKE TIMING CONTROL SOLENOID VALVE

CAUTION:
tion Mode.>.
NOTE:
Check 2-4 brake timing control solenoid valve circuit. <Ref. to AT-86 TROUBLE CODE 74 — 2-4 BRAKE
TIMING SOLENOID —, Diagnostic Procedure with Trouble Code.>
EN(H4)-485
AT VEHICLES
CA: DTC P1110 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW

INPUT — S008602B84

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3959
EN(H4)-486
AT VEHICLES

1 CHECK CURRENT DATA. Is the value less than 0 Go to step 3. Go to step 2.
1) Start engine. kPa (0 mmHg, 0 inHg)?
2) Read the data of intake manifold absolute
NOTE:
sensor connector. connector? atmospheric pres- returned to a nor-
sure sensor con- mal condition at
nector. this time.
and chassis ground.
(−):
cause is deterio-
ration of multiple
parts.
ground.
(−):
SUBARU SELECT MONITOR.) more than 0 kPa (0 mmHg, tact in ECM con-
Read data of atmospheric absolute pressure 0 inHg) by shaking harness nector.
signal using Subaru Select Monitor. and connector of ECM
NOTE: while monitoring the value
쐌 Subaru Select Monitor with Subaru select moni-
For detailed operation procedure, refer to the tor?
EN(H4)-487
AT VEHICLES

ATMOSPHERIC PRESSURE SENSOR CON- 4.5 V? and connector.
NECTOR. NOTE:
2) Disconnect connector from atmospheric repair the follow-
pressure sensor. ing:
4) Measure voltage between atmospheric harness between
pressure sensor connector and engine ECM and atmo-
ground. spheric pressure
Connector & terminal sensor connector
(B2) No. 3 (+) — Engine ground (−): 쐌 Poor contact in
joint connector
(B83)
ATMOSPHERIC PRESSURE SENSOR CON- 1 Ω? and connector.
NECTOR. NOTE:
ECM and pressure sensor connector. 쐌 Open circuit in
(B136) No. 16 — (B2) No. 1: ECM and pres-
sure sensor con-
nector
ATMOSPHERIC PRESSURE SENSOR CON- 500 kΩ? short circuit in
Measure resistance of harness between pres- ECM and pres-
sure sensor connector and engine ground. sure sensor con-
(B2) No. 2 — Engine ground:
10 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace atmo-
Check poor contact in pressure sensor con- pressure sensor connec- tact in atmospheric pressure
nector. tor? spheric pressure sensor. <Ref. to
sensor connector. FU(H4)-52 Atmo-
spheric Pressure
Sensor.>
EN(H4)-488
AT VEHICLES
MEMO:
EN(H4)-489
AT VEHICLES
CB: DTC P1111 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH

INPUT — S008602B85

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3959
EN(H4)-490
AT VEHICLES

1 CHECK CURRENT DATA. Is the value more than 140 Go to step 10. Go to step 2.
1) Start engine. kPa (1,050 mmHg, 41.34
NOTE:
and chassis ground.
(−):
cause is deterio-
ration of multiple
parts.
and chassis ground.
(−):
SUBARU SELECT MONITOR.) more than 0 kPa (0 mmHg, tact in ECM con-
Read data of atmospheric absolute pressure 0 inHg) by shaking harness nector.
signal using Subaru Select Monitor. and connector of ECM
NOTE: while monitoring the value
쐌 Subaru Select Monitor with Subaru select moni-
For detailed operation procedure, refer to the tor?
PRESSURE SENSOR CONNECTOR. 4.5 V? and connector.
2) Disconnect connector from atmospheric In this case,
pressure sensor. repair the follow-
4) Measure voltage between atmospheric 쐌 Open circuit in
pressure sensor connector and engine harness between
ground. ECM and pres-
Connector & terminal sure sensor con-
(B2) No. 3 (+) — Engine ground (−): nector
쐌 Poor contact in
joint connector
(B83)
EN(H4)-491
AT VEHICLES

PRESSURE SENSOR CONNECTOR. 1 Ω? and connector.
ECM and pressure sensor connector. ing:
(B136) No. 29 — (B2) No. 2: harness between
ECM and pres-
sure sensor con-
nector
쐌 Poor contact in
joint connector
(B83)
PRESSURE SENSOR CONNECTOR. 1 Ω? and connector.
and pressure sensor connector. In this case,
(B136) No. 16 — (B2) No. 1: ing:
쐌 Open circuit in
harness between
ECM and pres-
sure sensor con-
nector
쐌 Poor contact in
joint connector
(B83)
9 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace atmo-
Check poor contact in pressure sensor con- pressure sensor connec- tact in atmospheric pressure
nector. tor? spheric pressure sensor. <Ref. to
sensor connector. FU(H4)-52 Atmo-
spheric Pressure
Sensor.>
10 CHECK CURRENT DATA. Is the value more than 140 Repair battery Replace atmo-
1) Turn ignition switch to OFF. kPa (1,050 mmHg, 41.34 short circuit in spheric pressure
2) Disconnect connector from atmospheric inHg)? harness between sensor. <Ref. to
pressure sensor. ECM and atmo- FU(H4)-52 Atmo-
3) Turn ignition switch to ON. spheric pressure spheric Pressure
4) Read data of intake manifold absolute sensor connector. Sensor.>
pressure signal using Subaru select monitor
NOTE:
EN(H4)-492
AT VEHICLES
MEMO:
EN(H4)-493
AT VEHICLES
CC: DTC P1112 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGE/


CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3959
EN(H4)-494
AT VEHICLES

NOTE: Monitor or OBD-II general P0106, P0107,
In this case, it is not necessary to inspect scan tool indicate DTC P0108, P1110 or
DTC P0106. P0106, P0107, P0108, P1111 using “19.
Trouble Code
(DTC) for AT
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
2 CHECK ATMOSPHERIC PRESSURE SEN- Is atmospheric pressure Replace atmo- Go to step 3.
SOR FILTER. sensor filter non-functional? spheric pressure
1) Turn ignition switch to OFF. (Check for contamination, sensor filter.
2) Disconnect connector from atmospheric damage, water leakage,
pressure sensor. etc.)
3) Remove atmospheric pressure sensor.
4) Check atmospheric pressure sensor filter.
3 CHECK CURRENT DATA. Is the value between 73.3 Replace atmo- Replace intake air
1) Turn ignition switch to ON. kPa (550 mmHg, 21.65 spheric pressure temperature and
2) Read data of intake manifold absolute inHg) and 106.6 kPa (800 sensor. <Ref. to pressure sensor.
pressure signal using Subaru Select Monitor mmHg, 31.50 inHg)? FU(H4)-52 Atmo- <Ref. to
or OBD-II general scan tool. spheric Pressure FU(H4)-51 Intake
NOTE: Sensor.> Air Temperature
쐌 Subaru Select Monitor and Pressure
For detailed operation procedure, refer to the Sensor.>
EN(H4)-495
AT VEHICLES
CD: DTC P1137 — FRONT OXYGEN (A/F) SENSOR CIRCUIT

RANGE/PERFORMANCE PROBLEM — S008602G49

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3948
EN(H4)-496
AT VEHICLES

P1133? Diagnostic
Trouble Code
(DTC) for AT
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
2 CHECK FRONT OXYGEN (A/F) SENSOR Is the value equal to or Go to step 3. Go to step 4.
70°C (160°F).
general scan tool.
NOTE:
3 CHECK FRONT OXYGEN (A/F) SENSOR Is the value more than 1.1 Go to step 6. Go to step 4.
DATA. for a moment?
Race engine at speeds from idling to 5,000
rpm for a total of 5 cycles.
NOTE:
To increase engine speed to 5,000 rpm,
FRONT OXYGEN (A/F) SENSOR. 5 Ω? cuit between ECM
1) Turn ignition switch to OFF. and front oxygen
2) Disconnect connector from ECM and front (A/F) sensor.
oxygen (A/F) sensor connector.
3) Measure resistance between ECM and
front oxygen (A/F) sensor.
Connector & terminals
(B136) No. 6 — (B18) No. 1:
(B136) No. 7 — (B18) No. 6:
(B136) No. 19 — (B18) No. 3:
(B136) No. 20 — (B18) No. 4:
EN(H4)-497
AT VEHICLES

FRONT OXYGEN (A/F) SENSOR. 1 MΩ? short circuit
Measure resistance between ECM and chas- between ECM
sis ground. and front oxygen
Connector & terminals (A/F) sensor.
NOTE: <Ref. to
sensor
EN(H4)-498
AT VEHICLES
MEMO:
EN(H4)-499
AT VEHICLES
CE: DTC P1142 — THROTTLE POSITION SENSOR CIRCUIT


쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3947
EN(H4)-500
AT VEHICLES

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace throttle
Monitor or OBD-II general P0122 or P0123 position sensor.
P0122 or P0123? Diagnostic FU(H4)-45
Trouble Code Throttle Position
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1142.
EN(H4)-501
AT VEHICLES
CF: DTC P1146 — PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (HIGH INPUT) — S008602G07

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3946
EN(H4)-502
AT VEHICLES

NOTE: Monitor or OBD-II general P0107, P0108 or
In this case, it is not necessary to inspect scan tool indicate DTC P1112 using “19.
DTC P0106. P0107, P0108 or P1112? List of Diagnostic
Trouble Code
(DTC) for AT
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
air intake system?
3 CHECK PRESSURE SENSOR. Is the value within the Go to step 4. Replace intake air
1) Start the engine and warm-up engine until specifications? temperature sen-
coolant temperature is greater than 60°C sor and pressure
(140°F). sensor. <Ref. to
2) Place the shift lever in the selector lever in FU(H4)-51 Intake
“N” or “P” position. Air Temperature
3) Turn A/C switch to OFF. and Pressure
4) Turn all accessory switches to OFF. 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)
4 CHECK THROTTLE POSITION. Is throttle positioning ratio Go to step 5. Adjust or replace
Read data of throttle position signal using equal to or less than 5% throttle position
Subaru Select Monitor or OBD-II general scan when throttle is fully sensor. <Ref. to
tool. closed? FU(H4)-45
NOTE: Throttle Position
쐌 Subaru Select Monitor Sensor.>
EN(H4)-503
AT VEHICLES

5 CHECK THROTTLE POSITION. Is throttle positioning ratio Replace intake air Replace throttle
equal to or more than 85% temperature and position sensor.
when throttle is fully open? pressure sensor. <Ref. to
<Ref. to FU(H4)-45
FU(H4)-51 Intake Throttle Position
Air Temperature Sensor.>
and Pressure
Sensor.>
EN(H4)-504
AT VEHICLES
MEMO:
EN(H4)-505
AT VEHICLES
CG: DTC P1400 — FUEL TANK PRESSURE CONTROL SOLENOID VALVE


CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3944

sis ground.
EN(H4)-506
AT VEHICLES

nector. NOTE:
Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
3 CHECK HARNESS BETWEEN FUEL TANK Is the resistance less than Repair ground Go to step 4.
PRESSURE CONTROL SOLENOID VALVE 10 Ω? short circuit in
2) Disconnect connectors from fuel tank pres- tank pressure
sure control solenoid valve and ECM. control solenoid
3) Measure resistance of harness between valve connector.
fuel tank pressure control solenoid valve con-
4 CHECK HARNESS BETWEEN FUEL TANK Is the voltage less than 1 Go to step 5. Repair harness
PRESSURE CONTROL SOLENOID VALVE Ω? and connector.
and fuel tank pressure control solenoid valve repair the follow-
connector. ing:
(B134) No. 1 — (R68) No. 2: harness between
ECM and fuel
tank pressure
control solenoid
valve connector
쐌 Poor contact in
coupling connec-
tors (R134 and
B99)
5 CHECK FUEL TANK PRESSURE CONTROL Is the resistance between Go to step 6. Replace fuel tank
SOLENOID VALVE. 10 and 100 Ω? pressure control
Measure resistance between fuel tank pres- solenoid valve.
sure control solenoid valve terminals. <Ref. to
Terminals EC(H4)-13 Pres-
No. 1 — No. 2: sure Control Sole-
noid Valve.>
EN(H4)-507
AT VEHICLES

6 CHECK POWER SUPPLY TO FUEL TANK Is the voltage more than 10 Go to step 7. Repair harness
PRESSURE CONTROL SOLENOID VALVE. V? and connector.
2) Measure voltage between fuel tank pres- In this case,
sure control solenoid valve and chassis repair the follow-
ground. ing:
(R68) No. 1 (+) — Chassis ground (−): harness between
main relay and
fuel tank pressure
control solenoid
valve connector
쐌 Poor contact in
coupling connec-
tors (R134 and
B97)
쐌 Poor contact in
main relay con-
nector
7 CHECK POOR CONTACT. Is there poor contact in fuel Repair poor con- Contact with SOA
Check poor contact in fuel tank pressure con- tank pressure control sole- tact in fuel tank service.
trol solenoid valve connector. noid valve connector? pressure control NOTE:
solenoid valve Inspection by
connector. DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(H4)-508
AT VEHICLES
MEMO:
EN(H4)-509
AT VEHICLES
CH: P1420 — FUEL TANK PRESSURE CONTROL SOLENOID VALVE


CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3944
EN(H4)-510
AT VEHICLES

4) While operating fuel tank pressure control contact in ECM
solenoid valve, measure voltage between connector.
NOTE:
Fuel tank pressure control solenoid valve
operation can be executed using Subaru
Select Monitor. For procedure, refer to “Com-
Check Mode.>
sis ground.
Control Module.>
4 CHECK HARNESS BETWEEN FUEL TANK Is the voltage more than 10 Repair battery Go to step 5.
PRESSURE CONTROL SOLENOID VALVE V? short circuit in
2) Disconnect connector from fuel tank pres- tank pressure
sure control solenoid valve. control solenoid
(B134) No. 1 (+) — Chassis ground (−): FU(H4)-67 Engine
Control Module.>
5 CHECK FUEL TANK PRESSURE CONTROL Is the resistance less than Replace fuel tank Go to step 6.
SOLENOID VALVE. 1 Ω? pressure control
1) Turn ignition switch to OFF. solenoid valve
2) Measure resistance between fuel tank <Ref. to
pressure control solenoid valve terminals. EC(H4)-13 Pres-
Terminals sure Control Sole-
No. 1 — No. 2: noid Valve.> and
ECM <Ref. to
FU(H4)-67 Engine
Control Module.>
Control Module.>
EN(H4)-511
AT VEHICLES
CI: DTC P1442 — FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM 2 — S008602C11

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3938
EN(H4)-512
AT VEHICLES

Monitor or OBD-II general P0461, P0462 or sensor <Ref. to
scan tool indicate DTC P0463 using “19. FU(H4)-93 Fuel
P0461, P0462 or P0463? List of Diagnostic Level Sensor.>
Trouble Code and fuel sub level
(DTC) for AT sensor. <Ref. to
Vehicles”. <Ref. to FU(H4)-94 Fuel
EN(H4)-301 List Sub Level Sen-
of Diagnostic sor.>
Trouble Code
(DTC) for AT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect this
trouble.
EN(H4)-513
AT VEHICLES
CJ: DTC P1443 — EVAPORATIVE EMISSION CONTROL SYSTEM VENT

CONTROL FUNCTION PROBLEM — S008602C12

쐌 Improper fuel supply
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3936
EN(H4)-514
AT VEHICLES

nostic Trouble
Code (DTC) for
AT Vehicles”.
<Ref. to EN(H4)-
301 List of Diag-
nostic Trouble
Code (DTC) for
AT Vehicles.>
2 CHECK VENT LINE HOSES. Is there a fault in vent line? Repair or replace Go to step 3.
Check the following items. the faulty part.
쐌 Clogging of vent hoses between canister
and drain valve
쐌 Clogging of vent hose between drain valve
and air filter
쐌 Clogging of drain filter
3 CHECK DRAIN VALVE OPERATION. Does drain valve produce Contact with SOA Replace drain
1) Turn ignition switch to OFF. operating sound? service. valve. <Ref. to
2) Connect test mode connector at the lower NOTE: EC(H4)-17 Drain
portion of instrument panel (on the driver’s Inspection by Valve.>
side), to the side of the center console box. DTM is required,
3) Turn ignition switch to ON. because probable
4) Operate drain valve. cause is deterio-
NOTE: ration of multiple
Drain valve operation can also be executed parts.
procedure, refer to the “Compulsory Valve
EN(H4)-515
AT VEHICLES
CK: DTC P1480 — COOLING FAN RELAY 1 CIRCUIT HIGH INPUT — S008602G08

쐌 Overheating
CAUTION:
tion Mode.>.
EN(H4)-516
AT VEHICLES
쐌 WIRING DIAGRAM:
B2M3939
EN(H4)-517
AT VEHICLES

1 CHECK OUTPUT SIGNAL FROM ECM. Does voltage change Even if MIL lights Go to step 2.
4) While operating radiator fan relay, measure contact in ECM
voltage between ECM and chassis ground. connector.
NOTE:
Mode”. <Ref. to EN(H4)-64 Compulsory Valve
Operation Check Mode.>
2 CHECK SHORT CIRCUIT IN RADIATOR Is the voltage more than 10 Repair battery Go to step 3.
FAN RELAY CONTROL CIRCUIT. V? short circuit in
1) Turn ignition switch to OFF. radiator fan relay
2) Remove main fan relay and sub fan relay. control circuit.
(with A/C models) After repair,
3) Disconnect test mode connector. replace ECM.
4) Turn ignition switch to ON. <Ref. to
5) Measure voltage between ECM and chas- FU(H4)-67 Engine
sis ground. Control Module.>
3 CHECK MAIN FAN RELAY. Is the resistance less than Replace main fan Go to step 4.
1) Turn ignition switch to OFF. 1 Ω? relay and ECM.
2) Remove main fan relay. <Ref. to
3) Measure resistance between main fan FU(H4)-67 Engine
relay terminals. Control Module.>
Terminal
No. 1 — No. 3:
4 CHECK SUB FAN RELAY. Is the resistance less than Replace sub fan Go to step 5.
1) Remove sub fan relay. 1 Ω? relay and ECM.
2) Measure resistance between sub fan relay <Ref. to
terminals. FU(H4)-67 Engine
Terminal Control Module.>
No. 1 — No. 3
Control Module.>
EN(H4)-518
AT VEHICLES
MEMO:
EN(H4)-519
AT VEHICLES
CL: DTC P1507 — IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE) —

S008602C16

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3952
EN(H4)-520
AT VEHICLES

P1510, P1511, P1512, P1514, P1515,
P1513, P1514, P1515, P1516 or P1517
Diagnostic
Trouble Code
(DTC) for AT
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0507.
2 CHECK AIR INTAKE SYSTEM. Is there a fault in air intake Repair air suction Go to step 3.
1) Turn ignition switch to ON. system? and leaks.
2) Start engine, and idle it.
3) Check the following items.
쐌 Loose installation of intake manifold, idle air
control solenoid valve and throttle body
body gasket
SP(H4)-6
INSTALLATION,
Accelerator Con-
trol Cable.>
4 CHECK AIR BY-PASS LINE. Are foreign particles in by- Remove foreign Replace idle air
1) Turn ignition switch to OFF. pass air line? particles from by- control solenoid
2) Remove idle air control solenoid valve from pass air line. valve. <Ref. to
throttle body. <Ref. to FU(H4)-53 Idle Air Con- FU(H4)-53 Idle Air
trol Solenoid Valve.> Control Solenoid
3) Confirm that there are no foreign particles Valve.>
in by-pass air line.
EN(H4)-521
AT VEHICLES
CM: DTC P1510 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1

NOTE:
For the diagnostic procedure, refer to DTC P1516. <Ref. to EN(H4)-524 DTC 1516 — IDLE AIR CONTROL
SOLENOID VALVE SIGNAL 4 CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble
CN: DTC P1511 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1
NOTE:
SOLENOID VALVE SIGNAL 4 CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble
CO: DTC P1512 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 2
NOTE:
CP: DTC P1513 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 2
NOTE:
CQ: DTC P1514 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 3
NOTE:
CR: DTC P1515 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 3
NOTE:
EN(H4)-522
AT VEHICLES
MEMO:
EN(H4)-523
AT VEHICLES
CS: DTC P1516 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4


쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3952
EN(H4)-524
AT VEHICLES

2) Disconnect connector from idle air control In this case,
solenoid valve. repair the follow-
4) Measure voltage between idle air control 쐌 Open circuit in
solenoid valve connector and engine ground. harness between
Connector & terminal idle air control
and main relay
connector
쐌 Poor contact in
coupling connec-
tor (B22)
Measure voltage between idle air control sole- NOTE:
noid valve connector and engine ground. In this case,
(E7) No. 5 (+) — Engine ground (−): ing:
쐌 Open circuit in
harness between
idle air control
solenoid valve
and main relay
connector
쐌 Poor contact in
coupling connec-
tor (B22)
IDLE AIR CONTROL SOLENOID VALVE 1 Ω? and connector.
CONNECTOR. NOTE:
2) Measure resistance between ECM and idle repair the follow-
air control solenoid valve connector. ing:
DTC P1510; (B134) No. 5 — (E7) No. 3: harness between
DTC P1512; (B134) No. 6 — (E7) No. 1: ECM and idle air
DTC P1514; (B134) No. 19 — (E7) No. control solenoid
6: valve connector
DTC P1516; (B134) No. 20 — (E7) No. 쐌 Poor contact in
4: coupling connec-
tor (B21)
IDLE AIR CONTROL SOLENOID VALVE 10 Ω? short circuit in
1) Disconnect connector from ECM. ECM and idle air
2) Measure resistance between ECM connec- control solenoid
tor and chassis ground. valve connector.
DTC P1510; (B134) No. 5 — Chassis
ground:
ground:
ground:
ground:
EN(H4)-525
AT VEHICLES

5 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace idle air
Check poor contact in ECM connector and ECM connector or idle air tact in ECM con- control solenoid
idle air control solenoid valve connector. control solenoid valve connector or idle air valve. <Ref. to
nector? control solenoid FU(H4)-53 Idle Air
valve connector. Control Solenoid
Valve.>
EN(H4)-526
AT VEHICLES
MEMO:
EN(H4)-527
AT VEHICLES
CT: DTC P1517 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4


쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3952
EN(H4)-528
AT VEHICLES

P1511, P1513, P1515 and
P1517 at same time?
2 CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than Go to step 3. Repair harness
1) Turn ignition switch to OFF. 5 Ω? and connector.
2) Measure resistance between ECM connec- NOTE:
tor and chassis ground. In this case,
(B134) No. 7 — Chassis ground: ing:
쐌 Open circuit in
harness between
ECM connector
and engine
ground terminal
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B22)
3 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 10 Repair battery Replace ECM.
IDLE AIR CONTROL SOLENOID VALVE V? short circuit in <Ref. to
CONNECTOR. harness between FU(H4)-67 Engine
1) Turn ignition switch to OFF. ECM and idle air Control Module.>
2) Disconnect connector from idle air control control solenoid
4) Measure voltage between ECM connector replace ECM.
and chassis ground. <Ref. to
DTC P1511; (B134) No. 5 (+) — Chassis Control Module.>
ground (–):
DTC P1513; (B134) No. 6 (+) — Chassis
ground (–):
DTC P1515; (B134) No. 19 (+) — Chas-
sis ground (–):
DTC P1517; (B134) No. 20 (+) — Chas-
sis ground (–):
EN(H4)-529
AT VEHICLES
CU: DTC P1518 — STARTER SWITCH CIRCUIT LOW INPUT — S008602G09

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3955
EN(H4)-530
AT VEHICLES

1 CHECK OPERATION OF STARTER MOTOR. Does starter motor operate Repair harness Check starter
NOTE: when ignition switch to and connector. motor circuit.
Place the inhibitor switch in the “P” or “N” “ST”? NOTE: <Ref. to
position. In this case, EN(H4)-78
repair the follow- STARTER
ing: MOTOR CIRCUIT,
쐌 Open or ground Diagnostic for
short circuit in Engine Starting
harness between Failure.>
ECM and starter
motor connector.
쐌 Poor contact in
ECM connector.
EN(H4)-531
AT VEHICLES
CV: DTC P1540 — VEHICLE SPEED SENSOR MALFUNCTION 2 — S008602C26

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3951
EN(H4)-532
AT VEHICLES

1 CHECK DTC P0720 ON DISPLAY. Does the Subaru Select Check front Go to step 2.
Monitor or OBD-II general vehicle speed
scan tool indicate DTC sensor signal cir-
P0720? cuit. <Ref. to
AT-56 TROUBLE
CODE 33 —
FRONT VEHICLE
SPEED SENSOR
—, Diagnostic
Procedure with
Trouble Code.>
speed sensor.
<Ref. to IDI-19
Speedometer.>
nation meter con-
nector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
combination meter
connector
쐌 Poor contact in
coupling connec-
tor (i2)
EN(H4)-533
AT VEHICLES
CW: DTC P1560 — BACK-UP VOLTAGE CIRCUIT MALFUNCTION — S008602C27

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3945

1 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 Repair poor con- Go to step 2.
1) Turn ignition switch to OFF. V? tact in ECM con-
sis ground.
EN(H4)-534
AT VEHICLES

MAIN FUSE BOX CONNECTOR. 10 Ω? short circuit in
1) Disconnect connector from ECM. harness between
2) Measure resistance of harness between ECM connector
ECM and chassis ground. and battery termi-
Connector & terminal nal.
3 CHECK FUSE SBF-5. Is fuse blown? Replace fuse. Repair harness
and connector.
NOTE:
In this case,
repair the follow-
ing:
쐌 Open circuit in
harness between
ECM and battery
쐌 Poor contact in
ECM connector
쐌 Poor contact in
battery terminal
EN(H4)-535
AT VEHICLES
CX: DTC P1590 — NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT — S008602G10

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3956
EN(H4)-536
AT VEHICLES

1 CHECK DTC P0705 ON DISPLAY. Does the Subaru Select Inspect DTC Go to step 2.
P0705? Trouble Code
(DTC) for AT
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 1 Go to step 3. Go to step 5.
sis ground in selector lever “N” and “P” posi-
tions.
(−):
3 CHECK INPUT SIGNAL FOR ECM. Is the voltage between 4.5 Go to step 4. Go to step 5.
Measure voltage between ECM and chassis and 5.5 V?
ground in selector lever except for “N” and “P”
positions.
(−):
nector. NOTE:
Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
5 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 Repair battery Go to step 6.
Measure voltage between ECM and chassis V? short circuit in
ground. harness between
Connector & terminal ECM and inhibitor
(B135) No. 26 (+) — Chassis ground switch connector.
(−):
INHIBITOR SWITCH CONNECTOR. 1 Ω? and connector.
2) Disconnect connectors from ECM and In this case,
inhibitor switch. repair the follow-
ECM and inhibitor switch connector. 쐌 Open circuit in
(B135) No. 26 — (T7) No. 12: ECM and inhibitor
switch connector
쐌 Poor contact in
coupling connec-
tor (B12)
쐌 Poor contact in
inhibitor switch
connector
쐌 Poor contact in
ECM connector
EN(H4)-537
AT VEHICLES

7 CHECK INHIBITOR SWITCH GROUND Is the resistance less than Go to step 8. Repair open cir-
LINE. 5 Ω? cuit in harness
Measure resistance of harness between between inhibitor
inhibitor switch connector and engine ground. switch connector
Connector & terminal and starter motor
(T7) No. 7 — Engine ground: ground line.
NOTE:
In this case,
repair the follow-
ing:
쐌 Open circuit in
harness between
inhibitor switch
connector and
starter motor
ground line
쐌 Poor contact in
starter motor con-
nector
쐌 Poor contact in
starter motor
ground
쐌 Starter motor
8 CHECK INHIBITOR SWITCH. Is the resistance less than Go to step 9. Replace inhibitor
Measure resistance between inhibitor switch 1 Ω? switch. <Ref. to
connector receptacle’s terminals in selector AT-28 Inhibitor
lever “N” and “P” positions. Switch.>
Terminals
No. 7 — No. 12:
9 CHECK SELECTOR CABLE CONNECTION. Is there any fault in selec- Repair selector Contact with SOA
tor cable connection to cable connection. service.
inhibitor switch? <Ref. to CS-25 NOTE:
INSPECTION, Inspection by
Select Cable.> DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(H4)-538
AT VEHICLES
MEMO:
EN(H4)-539
AT VEHICLES
CY: DTC P1591 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT — S008602G11

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3956
EN(H4)-540
AT VEHICLES

1 CHECK DTC P0705 ON DISPLAY. Does the Subaru Select Inspect DTC Go to step 2.
P0705? Trouble Code
(DTC) for AT
EN(H4)-301 List
of Diagnostic
Trouble Code
(DTC) for AT
Vehicles.>
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage between 4.5 Even if MIL lights Go to step 3.
1) Turn ignition switch to ON. and 5.5 V at except “N” up, the circuit has
2) Measure voltage between ECM and chas- and “P” positions? returned to a nor-
Connector & terminal this time.
(−):
TRANSMISSION HARNESS CONNECTOR. 10 Ω? short circuit in
2) Disconnect connectors from ECM and ECM and trans-
transmission harness connector (T3). mission harness
3) Measure resistance of harness between connector.
4 CHECK TRANSMISSION HARNESS CON- Is the resistance less than Repair ground Go to step 5.
NECTOR. 10 Ω? short circuit in
1) Disconnect connector from inhibitor switch. harness between
2) Measure resistance of harness between transmission har-
transmission harness connector and engine ness and inhibitor
ground. switch connector.
(T3) No. 12 — Engine ground:
5 CHECK INHIBITOR SWITCH. Is the resistance more than Go to step 6. Replace inhibitor
Measure resistance between inhibitor switch 1 MΩ at except “N” and “P” switch. <Ref. to
connector receptacle’s terminals in selector positions? AT-28 Inhibitor
lever except for “N” position. Switch.>
Terminals
No. 7 — No. 12:
6 CHECK SELECTOR CABLE CONNECTION. Is there any fault in selec- Repair selector Contact with SOA
tor cable connection to cable connection. service.
inhibitor switch? <Ref. to CS-25 NOTE:
INSPECTION, Inspection by
Select Cable.> DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(H4)-541
AT VEHICLES
CZ: DTC P1594 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL


CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3963

1 CHECK DRIVING CONDITION. Is AT shift control function- Go to step 2. Replace TCM.
1) Start and warm-up the engine until the ing properly? <Ref. to AT-42
radiator fan makes one complete rotation. Transmission
2) Drive the vehicle. Control Module
(TCM).>
EN(H4)-542
AT VEHICLES

2 CHECK ACCESSORY. Are car phone and/or CB Repair grounding Replace TCM.
installed on vehicle? line of car phone <Ref. to AT-42
or CB system. Transmission
Control Module
(TCM).>
EN(H4)-543
AT VEHICLES
DA: DTC P1595 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT LOW INPUT — S008602G13

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3963
EN(H4)-544
AT VEHICLES

1 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 1 Go to step 2. Even if MIL lights
TCM CONNECTOR. V? up, the circuit has
1) Turn ignition switch to ON. returned to a nor-
2) Measure voltage between ECM and chas- mal condition at
sis ground. this time.
(B135) No. 4 (+) — Chassis ground (−): In this case,
repair the follow-
ing:
쐌 Poor contact in
ECM connector
쐌 Poor contact in
TCM connector
TCM CONNECTOR. 10 Ω? short circuit in
2) Disconnect connector from ECM and TCM. ECM and TCM
3) Measure resistance of harness between connector.
3 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 5 Go to step 4. Repair poor con-
1) Connect connector to ECM. V? tact in ECM con-
2) Turn ignition switch to ON. nector.
sis ground.
4 CHECK TROUBLE CODE FOR AUTOMATIC Does trouble code appear Inspect trouble Replace TCM.
TRANSMISSION. for automatic transmission? code for auto- <Ref. to AT-42
Read trouble code for automatic transmission. matic transmis- Transmission
<Ref. to AT-26 Read Diagnostic Trouble sion. <Ref. to Control Module
Code.> AT-36 Diagnostic (TCM).>
Procedure with
Trouble Code.>
EN(H4)-545
AT VEHICLES
DB: DTC P1596 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT HIGH INPUT — S008602G14

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3963
EN(H4)-546
AT VEHICLES

1 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 10 Repair battery Go to step 2.
TCM CONNECTOR. V? short circuit in
1) Turn ignition switch to ON. harness between
2) Measure voltage between ECM and chas- ECM and TCM
sis ground. connector. After
(B135) No. 4 (+) — Chassis ground (−): ECM. <Ref. to
FU(H4)-67 Control
Module.>
2 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4 Go to step 5. Go to step 3.
TCM CONNECTOR. V?
and chassis ground.
3 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 1 Repair poor con- Go to step 4.
TCM CONNECTOR. V? tact in ECM con-
Measure voltage between ECM connector nector.
and chassis ground.
4 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Even if MIL lights Contact with SOA
Measure voltage between ECM and chassis from 1 V to 4 V while moni- up, the circuit has service.
ground. toring the value with volt- returned to a nor- NOTE:
Connector & terminal age meter? mal condition at Inspection by
(B135) No. 4 (+) — Chassis ground (−): this time. DTM is required,
NOTE: because probable
In this case, cause is deterio-
repair the follow- ration of multiple
ing: parts.
쐌 Poor contact in
ECM connector
쐌 Poor contact in
TCM connector
5 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4 Go to step 6. Repair open cir-
TCM CONNECTOR. V? cuit in harness
Measure voltage between TCM and chassis between ECM
ground. and TCM connec-
6 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Check TCM
Check poor contact in TCM connector. TCM connector? tact in TCM con- power supply line
nector. and grounding
line.
EN(H4)-547
AT VEHICLES
DC: DTC P1698 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW
INPUT — S008602G15

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3960
EN(H4)-548
AT VEHICLES

1) Start engine, and warm-up the engine. V? tact in ECM con-
2) Turn ignition switch to OFF. nector.
sis ground.
(−):
2) Disconnect connectors from ECM and ECM and TCM
TCM. connector.
3 CHECK HARNESS BETWEEN ECM AND Is the resistance less than Repair poor con- Repair open cir-
TCM CONNECTOR. 1 Ω? tact in ECM or cuit in harness
Measure resistance of harness betwee ECM TCM connector. between ECM
and TCM connector. and TCM connec-
(B134) No. 31 — (B54) No. 2:
EN(H4)-549
AT VEHICLES
DD: DTC P1699 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH
INPUT — S008602G16

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3960
EN(H4)-550
AT VEHICLES

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 3 Go to step 2. Repair battery
1) Start engine, and warm-up the engine. V? short circuit in
2) Turn ignition swtich to OFF. harness between
3) Disconnect connector from TCM. ECM and TCM
4) Turn ignition switch to ON. connector. After
5) Measure voltage between ECM and chas- repair, replace
sis ground. ECM. <Ref. to
(B134) No. 31 (+) — Chassis ground Control Module.>
(−):
2 CHECK HARNESS BETWEEN ECM AND Does the voltage change Repair battery Contact with SOA
TCM CONNECTOR. more than 10 V by shaking short circuit in service.
1) Turn ignition switch to OFF. harness and connector of harness between NOTE:
2) Measure voltage between ECM and chas- ECM while monitoring the ECM and TCM Inspection by
sis ground. value with voltage meter? connector. After DTM is required,
Connector & terminal repair, replace because probable
(B134) No. 31 (+) — Chassis ground ECM. <Ref. to cause is deterio-
(−): FU(H4)-67 Engine ration of multiple
Control Module.> parts.
EN(H4)-551
AT VEHICLES
DE: DTC P1700 — THROTTLE POSITION SENSOR CIRCUIT MALFUNCTION


쐌 Shift point too high or too low; engine brake not effected in “3” range; excessive shift shock; exces-
sive tight corner “braking”
CAUTION:
tion Mode.>.
NOTE:
Check throttle position sensor circuit. <Ref. to AT-48 TROUBLE CODE 31 — THROTTLE POSITION SEN-
SOR —, Diagnostic Procedure with Trouble Code.>
EN(H4)-552
AT VEHICLES
MEMO:
EN(H4)-553
AT VEHICLES
DF: DTC P1701 — CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION


CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3962
EN(H4)-554
AT VEHICLES

1 CHECK HARNESS BETWEEN TCM AND Is the resistance less than Go to step 2. Repair open cir-
CCM CONNECTOR. 1 Ω? cuit in harness
2) Disconnect connectors from TCM and CCM connector.
CCM.
TCM and CCM connector.
(B54) No. 11 — (B94) No. 3:
2 CHECK HARNESS BETWEEN TCM AND Is the resistance less than Repair short cir- Go to step 3.
CCM CONNECTOR. 10 Ω? cuit in harness
Measure resistance of harness between TCM between TCM and
and chassis ground. CCM connector.
3 CHECK INPUT SIGNAL FOR TCM. Is the resistance less than Go to step 4. Check cruise con-
1) Connect connector to TCM and CCM. 1 V? trol command
2) Lift-up the vehicle or set the vehicle on free switch circuit.
rollers. <Ref. to CC-6
CAUTION: INSPECTION,
On AWD models, raise all wheels off Cruise Control
ground. Command
3) Start the engine. Switch.>
4) Cruise control main switch to ON.
5) Move selector lever to “D” and slowly
increase vehicle speed to 50 km/h (31 MPH).
6) Cruise control command switch to ON.
7) Measure voltage between TCM and chas-
sis ground.
Control Module
(TCM).>
EN(H4)-555
AT VEHICLES
DG: DTC P1703 — LOW CLUTCH TIMING CONTROL SOLENOID VALVE


CAUTION:
tion Mode.>.
NOTE:
Check low clutch timing control solenoid valve circuit. <Ref. to AT-82 TROUBLE CODE 73 — LOW CLUTCH
TIMING SOLENOID —, Diagnostic Procedure with Trouble Code.>
EN(H4)-556
AT VEHICLES
MEMO:
EN(H4)-557
AT VEHICLES
DH: DTC P1711 — ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT


CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3957
EN(H4)-558
AT VEHICLES

1) Turn ignition switch to ON. 4.5 V?
sis ground.
(−):
Connector & terminal ECM and TCM
(B135) No. 16 (+) — Chassis ground connector.
(−):
Control Module.>
TCM CONNECTOR. 1 Ω? cuit in harness
2) Disconnect connectors from ECM and and TCM connec-
TCM. tor.
ECM and TCM connector.
(B135) No. 16 — (B54) No. 13:
and chassis ground. ECM and TCM
Control Module
(TCM).>
EN(H4)-559
AT VEHICLES
DI: DTC P1712 — ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT


CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
B2M3958
EN(H4)-560
AT VEHICLES

1) Turn ignition switch to ON. 4.5 V?
sis ground.
(−):
Connector & terminal ECM and TCM
(B135) No. 17 (+) — Chassis ground connector.
(−):
Control Module.>
TCM CONNECTOR. 1 Ω? cuit in harness
2) Disconnect connectors from ECM and and TCM connec-
TCM. tor.
ECM and TCM connector.
(B135) No. 17 — (B54) No. 21:
and chassis ground. ECM and TCM
Control Module
(TCM).>
EN(H4)-561
21. General Diagnostic Table

S008257
1. ENGINE S008257A1001
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(H4)-86 Engine Trouble in Gen-
eral.>
Symptom Problem parts
1) Idle air control solenoid valve
2) Intake manifold pressure sensor
3) Intake air temperature sensor
4) Intake air temperature and pressure sensor
1. Engine stalls during idling. 5) Ignition parts (*1)
6) Engine coolant temperature sensor (*2)
7) Crankshaft position sensor (*3)
8) Camshaft position sensor (*3)
9) Fuel injection parts (*4)
6) Ignition parts (*1)
2. Rough idling 7) Air intake system (*5)
9) Throttle position sensor
12) Oxygen sensor
13) Fuel pump and fuel pump relay
2) Engine coolant temperature sensor
3) Accelerator cable (*6)
3. Engine does not return to idle. 4) Throttle position sensor
4. Poor acceleration
10) A/C switch and A/C cut relay
11) Engine torque control signal circuit
12) Ignition parts (*1)
EN(H4)-562
Symptom Problem parts

5. Engine stalls or engine sags or hesitates at 5) Crankshaft position sensor (*3)
acceleration. 6) Camshaft position sensor (*3)
7) Purge control solenoid valve
6. Surge 5) Crankshaft position sensor (*3)
7. Spark knock 4) Engine coolant temperature sensor
5) Knock sensor
8. After burning in exhaust system
*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 S008257A1002
NOTE:
Check general diagnostics table with non-conformity symptom for automatic transmission. <Ref. to AT-2
Basic Diagnostic Procedure.>
EN(H4)-563
MEMO:
EN(H4)-564
GENERAL DESCRIPTION
Cooling
Electric fan + Forced engine coolant circula-

Cooling system
tion system
MT: Approx. 6.0 (6.3, 5.3)
Total engine coolant capacity (US qt, Imp qt)
AT: Approx. 6.2 (6.6, 5.5)
Type Centrifugal impeller type
Discharge 20 (5.3 US gal, 4.4 Imp gal)/min.
Pump speed—total engine
Discharge performance I 760 rpm — 0.3 mAq (1.0 ftAq)
coolant head
Engine coolant temperature 85°C (185°F)
Discharge 100 (26.4 US gal, 22.0 Imp gal)/min.
Discharge performance II 3,000 rpm — 5.0 mAq (16.4 ftAq)
coolant head
Water pump Discharge 200 (52.8 US gal, 44.0 Imp gal)/min.
Discharge performance III 6,000 rpm — 23.0 mAq (75.5 ftAq)
coolant head
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 in)
Clearance between impeller Standard 0.5 — 0.7 mm (0.020 — 0.028 in)
and case Limit 1.0 mm (0.039 in)
“Thrust” runout of impeller end 0.5 mm (0.020 in)
Type Wax pellet type
Starts to open 76 — 80°C (169 — 176°F)
Thermostat Fully opened 91°C (196°F)
Valve lift 9.0 mm (0.354 in) or more
Valve bore 35 mm (1.38 in)
75 W (main fan)
Motor
75 W (sub fan)
Radiator fan
300 mm (11.81 in) × 5 (main fan)
Fan diameter × Blade
300 mm (11.81 in) × 4 (sub fan)
Type Down flow, pressure type
691.5 × 340 × 16 mm
Core dimensions
(27.22 × 13.39 × 0.63 in)
Radiator Above: 108±15 kPa
(1.1±0.15 kg/cm2, 16±2 psi)
Pressure range in which cap valve is open
Below: −1.0 to −4.9 kPa
(−0.01 to −0.05 kg/cm2, −0.1 to −0.7 psi)
Fins Corrugated fin type
Reservoir tank Capacity 0.45 (0.5 US qt, 0.4 Imp qt)
CO(H4)-2
墌 00.5.31/68j/1co4 墍
GENERAL DESCRIPTION
Cooling
1. WATER PUMP S106001A0501
H2M2354A
(1) Water pump ASSY (5) Gasket Tightening torque: N·m (kgf-m, ft-lb)
(2) Gasket (6) Thermostat cover
T1: First 12 (1.2, 8.7)
(3) Heater by-pass hose Second 12 (1.2, 8.7)
(4) Thermostat
T2: 6.4 (0.65, 4.7)
CO(H4)-3
墌 00.5.31/68j/1co4 墍
GENERAL DESCRIPTION
Cooling
2. RADIATOR AND RADIATOR FAN S106001A0502
B2M3700A
(1) Radiator lower cushion (12) Main fan shroud (19) ATF inlet hose B (AT vehicles
(2) Radiator (13) Radiator main fan and main fan only)
(3) Radiator upper cushion motor ASSY (20) Radiator outlet hose
(4) Radiator upper bracket (14) ATF hose clamp (AT vehicles (21) Radiator drain plug
(5) Clamp only) (22) O-ring
(6) Radiator inlet hose (15) ATF inlet hose A (AT vehicles (23) Radiator lower bracket
(7) Engine coolant reservoir tank only)
cap (16) ATF outlet hose A (AT vehicles Tightening torque: N·m (kgf-m, ft-lb)
(8) Over flow hose only) T1: 4.4 (0.45, 3.3)
(9) Engine coolant reservoir tank (17) ATF pipe (AT vehicles only) T2: 12 (1.2, 8.7)
(10) Sub fan shroud (18) ATF outlet hose B (AT vehicles T3: 18 (1.8, 13.0)
(11) Radiator sub fan and sub fan only) T4: 3.4 (0.35, 2.5)
motor ASSY T5: 4.9 (0.50, 3.6)
CO(H4)-4
墌 00.5.31/68j/1co4 墍
GENERAL DESCRIPTION
Cooling
C: CAUTION S106001A03 쐌 Be careful not to burn your hands, because each

쐌 Wear working clothing, including a cap, protec- 쐌 Be sure to tighten fasteners including bolts and
tion.
sion before removal, installation or disassembly. fied points.
쐌 Keep the disassembled parts in order and pro- 쐌 Before disconnecting electrical connectors of
tect them from dust or dirt. sensors or units, be sure to disconnect negative
쐌 Before removal, installation or disassembly, be terminal from battery.
ment.

499977100 CRANK PULLEY Used for stopping crankshaft pulley when
WRENCH loosening and tightening crankshaft pulley
bolts.
B2M3870
499207100 CAMSHAFT Used for removing and installing camshaft
SPROCKET WRENCH sprocket.
B2M3859
CO(H4)-5
墌 00.5.31/68j/1co4 墍
ENGINE COOLANT
Cooling
2. Engine Coolant S106060
1. DRAINING OF ENGINE COOLANT

S106060A2001

2) Remove under cover.
S2M0552A
3) Attach radiator cap and reservoir tank cap prop-

erly.
4) Warm-up engine completely for more than five
minutes at 2,000 to 3,000 rpm.
5) If engine coolant level drops in radiator, add
engine coolant to filler neck position.
6) If engine coolant level drops from upper level of
B2M2920
reservoir tank, add engine coolant to upper level.
3) Remove drain cock to drain engine coolant into 7) Attach radiator cap and reservoir tank cap prop-
container. erly.
NOTE: B: INSPECTION S106060A10
Remove radiator cap so that engine coolant will
drain faster. 1. RELATIONSHIP OF SUBARU COOLANT
CONCENTRATION AND FREEZING
TEMPERATURE S106060A1001
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.
B2M2921
2. FILLING OF ENGINE COOLANT S106060A2002
1) Fill engine coolant into radiator up to filler neck

position.
Coolant capacity (fill up to “FULL” level):
MT model;
Approx. 6.4 (6.8 US qt, 5.6 Imp qt)
AT model;
Approx. 6.3 (6.7 US qt, 5.5 Imp qt)
CAUTION:
The SUBARU Genuine Coolant containing anti-
freeze and anti-rust agents is especially made
for SUBARU engine, which has an aluminum
crankcase. Always use SUBARU Genuine
Coolant, since other coolant may cause corro-
sion.
2) Fill engine coolant into reservoir tank up to
upper level.
CO(H4)-6
墌 00.5.31/68j/1co4 墍
ENGINE COOLANT
Cooling
[Example] [Example]
If the coolant temperature is 25°C (77°F) and its Assume that the coolant concentration must be
specific gravity is 1.054, the concentration is 35% increased form 25% to 40%. Find point A, where
(point A), the safe operating temperature is −14°C the 25% line of coolant concentration intersects
(7°F) (point B), and the freezing temperature is with the 40% curve of the necessary coolant
−20°C (−4°F) (point C). concentration, and read the scale on the vertical
axis of the graph at height A. The quantity of cool-
ant 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 cool-
ant from the cooling system and add 2.1 liters (2.2
US qt, 1.8 Imp qt) of the undiluted solution of
SUBARU coolant.
If a coolant concentration of 50% is needed, drain
all the coolant and refill with the undiluted solution
only.
B2M3128A
2. PROCEDURE TO ADJUST THE

CONCENTRATION OF THE COOLANT
S106060A1002
To adjust the concentration of the coolant accord-

ing to temperature, find the proper fluid concentra-
tion in the above diagram and replace the neces- B2M3129A
sary 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.
CO(H4)-7
墌 00.5.31/68j/1co4 墍
WATER PUMP
Cooling
3. Water Pump S106061

5) Disconnect connectors from radiator main fan
(A) and sub fan (B) motors.
1) Disconnect ground cable from the battery.
B2M2923A
6) Disconnect radiator outlet hose and heater

G6M0095 hose from water pump.
B2M2924
7) Lower the vehicle.

B2M2920 8) Remove air intake duct.
4) Drain engine coolant completely.
<Ref. to CO(H4)-6 DRAINING OF ENGINE
COOLANT, REPLACEMENT, Engine Coolant.>
B2M2922
9) Disconnect over flow hose.
B2M2921
B2M2925
CO(H4)-8
墌 00.5.31/68j/1co4 墍
WATER PUMP
Cooling
10) Remove reservoir tank. 14) Remove automatic belt tension adjuster.
B2M2926 H2M2375
11) Remove radiator main fan and sub fan assem- 15) Remove belt idler No. 2.
blies. <Ref. to CO(H4)-20 REMOVAL, Radiator
Main Fan and Fan Motor.> and <Ref. to CO(H4)-23
REMOVAL, Radiator Sub Fan and Fan Motor.>
S2M0024
16) Remove left-hand camshaft sprocket by using

B2M2927
ST.
ST 499207100 CAMSHAFT SPROCKET
12) Remove V-belts. WRENCH
<Ref. to ME(H4)-43 REMOVAL, V-belt.>
B2M2039A
G2M0286
17) Remove left-hand belt cover No. 2.
13) Remove timing belt.
<Ref. to ME(H4)-46 TIMING BELT, REMOVAL,
Timing Belt Assembly.>
B2M2040
CO(H4)-9
墌 00.5.31/68j/1co4 墍
WATER PUMP
Cooling
18) Remove tensioner bracket. 2) Install left-hand belt cover No. 2.

Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
H2M2380
19) Disconnect heater hose from water pump.

20) Remove water pump. B2M2040
3) Install tensioner bracket.

Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B2M3894
H2M2380
1) Install water pump onto left-hand cylinder head.
CAUTION: 4) Install left-hand camshaft sprockets by using
쐌 Replace gasket with a new one. ST.
쐌 When installing water pump, tighten bolts in ST 4992707100 CAMSHAFT SPROCKET
two stages in alphabetical sequence as shown WRENCH
in figure. Tightening torque:
Tightening torque: 78 N·m (8.0 kgf-m, 57.9 ft-lb)
First:
12 N·m (1.2 kgf-m, 8.7 ft-lb)
Second:
12 N·m (1.2 kgf-m, 8.7 ft-lb)
B2M2039A
S2M0760A
CO(H4)-10
墌 00.5.31/68j/1co4 墍
WATER PUMP
Cooling
5) Install belt idler No. 2. 9) Install radiator main fan and sub fan motor
Tightening torque: assemblies. <Ref. to CO(H4)-21 INSTALLATION,
39 N·m (4.0 kgf-m, 28.9 ft-lb) Radiator Main Fan and Fan Motor.> and <Ref. to
CO(H4)-23 INSTALLATION, Radiator Sub Fan and
Fan Motor.>
S2M0024
6) Install automatic belt tension adjuster which B2M2927

tension rod is holded with pin. <Ref. to ME(H4)-47
AUTOMATIC BELT TENSION ADJUSTER 10) Install reservoir tank.
ASSEMBLY AND BELT IDLER, INSTALLATION,
B2M2926
11) Connect over flow hose.

H2M2384
7) Install timing belt. <Ref. to ME(H4)-48 TIMING

BELT, INSTALLATION, Timing Belt Assembly.>
8) Install V-belts. <Ref. to ME(H4)-43
INSTALLATION, V-belt.>
B2M2925
G2M0286
B2M2922
CO(H4)-11
墌 00.5.31/68j/1co4 墍
WATER PUMP
Cooling
14) Connect radiator outlet hose and heater hose C: INSPECTION S106061A10
to water pump.
1) Check water pump bearing for smooth rotation.
2) Check water pump pulley for abnormalities.
3) Using a dial gauge, measure impeller runout in
thrust direction while rotating the pulley.
“Thrust” runout limit:
0.5 mm (0.020 in)
B2M2924
15) Connect connectors to radiator main fan (A)

and sub fan (B) motors.
G2M0211
4) Check clearance between impeller and pump

case.
Clearance between impeller and pump case:
Standard
0.5 — 0.7 mm (0.020 — 0.028 in)
Limit
B2M2923A 1.0 mm (0.039 in)
16) Install under cover.
G2M0212
B2M2920 5) After water pump installation, check pulley shaft

for engine coolant leaks. If leaks are noted, replace
17) Lower the vehicle. water pump assembly.
G6M0095
19) Fill coolant. <Ref. to CO(H4)-6 FILLING OF

ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
CO(H4)-12
墌 00.5.31/68j/1co4 墍
THERMOSTAT
Cooling
4. Thermostat S106062
5) Remove thermostat cover and gasket, and pull
out the thermostat.

G2M0214
B2M2920
1) Install the thermostat in the water pump, and
3) Drain engine coolant completely. <Ref. to install the thermostat cover together with a gasket.
CO(H4)-6 DRAINING OF ENGINE COOLANT, CAUTION:
REPLACEMENT, Engine Coolant.> 쐌 When reinstalling the thermostat, use a new
gasket.
쐌 The thermostat must be installed with the
jiggle pin (A) facing to front side.
쐌 At this time, set the jiggle pin of thermostat
for front side.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
B2M2921
4) Disconnect radiator outlet hose from thermostat

cover.
S2M0026B

Coolant.>
B2M2929
CO(H4)-13
墌 00.5.31/68j/1co4 墍
THERMOSTAT
Cooling
Replace the thermostat if the valve does not close

completely at an ambient temperature or if the fol-
lowing 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:
76.0 — 80.0°C (169 — 176°F)
Fully opens:
91°C (196°F)
H2M2357A
(A) Thermometer
(B) Thermostat
CO(H4)-14
墌 00.5.31/68j/1co4 墍
RADIATOR
Cooling
5. Radiator S106058
5) Disconnect connectors of radiator main fan (A)
and sub fan (B) motor.
B2M2923A
6) Disconnect radiator outlet hose from thermostat

G6M0095 cover.
B2M2929
7) Disconnect ATF cooler hoses from radiator. (AT

B2M2920 vehicles only)
4) Drain engine coolant completely. <Ref. to
CO(H4)-6 DRAINING OF ENGINE COOLANT,
REPLACEMENT, Engine Coolant.>
B2M2928A

9) Remove air intake duct.
B2M2921
B2M2922
CO(H4)-15
墌 00.5.31/68j/1co4 墍
RADIATOR
Cooling
10) Disconnect over flow hose. 14) Detach power steering hose from the clip on
the radiator.
B2M2925
B2M2932
11) Remove reservoir tank.
15) While slightly lifting radiator, slide it to left.
16) Lift radiator up and away from vehicle.
B2M2926
12) Disconnect radiator inlet hose from engine. B2M2933
1) Attach radiator mounting cushions to holes on

the vehicle.
B2M2930
13) Remove radiator upper brackets.
B2M2934
B2M2931
CO(H4)-16
墌 00.5.31/68j/1co4 墍
RADIATOR
Cooling
2) Install radiator while fitting radiator pins to cush-

ions.
NOTE:
Fit pins on lower side of radiator into cushions on
body side.
B2M2930
6) Install reservoir tank.

Tightening torque:
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
B2M2933
3) Install radiator brackets and tighten bolts.

Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
B2M2926
B2M2931
4) Attach power steering hose to the radiator.
B2M2922

9) Connect ATF cooler hoses. (AT vehicles only)
B2M2932
5) Connect radiator inlet hose.
B2M2928A
10) Connect connectors to radiator main fan

motor and sub fan motor.
CO(H4)-17
墌 00.5.31/68j/1co4 墍
RADIATOR
Cooling
1) Remove radiator cap, top off radiator, and

attach tester to radiator in place of cap.
B2M2923A
11) Connect radiator outlet hose.
B2M3127
2) Apply a pressure of 157 kPa (1.6 kg/cm2, 23

psi) to radiator to check if:
(1) Engine coolant leaks at/around radiator.
(2) Engine coolant leaks at/around hoses or
connections.
CAUTION:
쐌 Engine should be off.
B2M2929 쐌 Wipe engine coolant from check points in
advance.
12) Install under cover. 쐌 Be careful to prevent engine coolant from
spurting out when removing tester.
쐌 Be careful also not to deform filler neck of
radiator when installing or removing tester.
B2M2920

G6M0095

Coolant.>
16) Check ATF level. <Ref. to AT-9
REPLACEMENT, Automatic Transmission Fluid.>
CO(H4)-18
墌 00.5.31/68j/1co4 墍
RADIATOR CAP
Cooling
6. Radiator Cap S106064
1) Attach radiator cap to tester.
G2M0223
2) Increase pressure until tester gauge pointer

stops. Radiator cap is functioning properly if it
holds the service limit pressure for five to six sec-
onds.
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 pres-
sure test will be incorrect.
CO(H4)-19
RADIATOR MAIN FAN AND FAN MOTOR
Cooling
7. Radiator Main Fan and Fan 5) Lower the vehicle.

Motor S106059
B2M2922
7) Disconnect over flow hose.
G6M0095

B2M2925
B2M2920
4) Disconnect connector of main fan motor.
B2M2926
9) Remove radiator main fan motor assembly.
B2M2935
B2M2927
CO(H4)-20
墌 00.5.31/68j/1co4 墍
Cooling
B: INSTALLATION S106059A11 2) Remove 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.
S2M0936
3) Remove bolts which install fan motor onto

shroud.
B2M2927
Tightening torque:
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
B2M3169

B2M2926 Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
1) Remove clip which holds motor connector onto

shroud.
B2M3169
S2M0937
CO(H4)-21
墌 00.5.31/68j/1co4 墍
Cooling
Tightening torque:
3.4 N·m (0.35 kgf-m, 2.5 ft-lb)
S2M0936
1) Connect battery positive (+) terminal to terminal

No. 2, and negative (−) terminal to terminal No. 1
of main fan motor connector.
2) Make sure the main fan motor operates prop-
erly. Replace it if it doesn’t.
B2M3319A
CO(H4)-22
墌 00.5.31/68j/1co4 墍
RADIATOR SUB FAN AND FAN MOTOR
Cooling
8. Radiator Sub Fan and Fan 5) Lower the vehicle.

Motor S106074
B2M2922
7) Remove bolts which hold sub fan shroud to

radiator.
8) Remove radiator sub fan shroud through the
G6M0095
under side of vehicle.
B2M2937
B2M2920 B: INSTALLATION S106074A11
4) Disconnect connector of sub fan motor. Install in the reverse order of removal.
Tightening torque:
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
B2M2936
B2M2937
CO(H4)-23
墌 00.5.31/68j/1co4 墍
RADIATOR SUB FAN AND FAN MOTOR
Cooling
1) Remove clip which holds motor harness onto Assemble in the reverse order of disasssembly.
shroud. Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
S2M0937
2) Remove nut which holds fan itself onto fan B2M3169
motor and shroud assembly.

Tightening torque:
3.4 N·m (0.35 kgf-m, 2.5 ft-lb)
B2M2938
3) Remove bolts which install fan motor onto B2M2938

shroud.
1) Connect battery positive (+) terminal to terminal

No. 2, and negative (−) terminal to terminal No. 1
of sub fan motor connector.
2) Make sure the sub-fan motor operates properly.
Replace it if it doesn’t.
B2M3169
B2M3330A
CO(H4)-24
墌 00.5.31/68j/1co4 墍
RESERVOIR TANK
Cooling
9. Reservoir Tank S106075
1) Disconnect over flow hose from radiator filler

neck position.
2) Remove bolts which install reservoir tank onto
radiator main fan shroud.
B2M2926

Tightening torque:
4.9N·m (0.50 kgf-m, 3.6 ft-lb)
B2M2926
Make sure the engine coolant level is between full

and low.
CO(H4)-25
ENGINE COOLING SYSTEM TROUBLE IN GENERAL
Cooling
10. Engine Cooling System

Trouble in General S106078
Trouble Corrective action

Replenish engine coolant, inspect for leakage, and
a. Insufficient engine coolant
repair.
b. Loose timing belt Repair or replace timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of water pump Replace.
f. Clogged engine coolant passage Clean.
Inspect and repair ignition control system.
g. Improper ignition timing <Ref. to EN(H4)-2 ENGINE, PROCEDURE, Basic
Diagnostic Procedure.>
h. Clogged or leaking radiator Clean or repair, or replace.
Over-heating i. Improper engine oil in engine coolant Replace engine coolant.
Inspect and repair fuel injection system.
j. Air/fuel mixture ratio too lean <Ref. to EN(H4)-2 ENGINE, 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 radiator fan relay, engine coolant temperature
q. Malfunction of electric fan
sensor or radiator motor and replace there.
a. Atmospheric temperature extremely low Partly cover radiator front area.
Over-cooling
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.
Engine coolant d. Leakage around cylinder head gasket Retighten cylinder head bolts or replace gasket.
leaks. e. Damaged or cracked cylinder head and crank-
Repair or replace.
case
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.
Noise
c. Defective water pump bearing Replace water pump.
d. Defective water pump mechanical seal Replace water pump.
CO(H4)-26
GENERAL DESCRIPTION
Emission Control (Aux. Emission Control Devices)

tion.
ment.
fied points.
EC(H4)-2
FRONT CATALYTIC CONVERTER
2. Front Catalytic Converter S110017

7) Separate center exhaust pipe from rear
exhaust pipe.
CAUTION:
1) Set the vehicle on the lift. Be careful, exhaust pipe is hot.
B2M3109
G6M0095
8) Remove bolts which hold front exhaust pipe
3) Disconnect front oxygen (A/F) sensor connec- onto cylinder heads.
tor.
B2M3200
B2M3439
9) Remove front exhaust pipe and center exhaust
4) Lift-up the vehicle. pipe from hanger bracket.
5) Remove under cover. CAUTION:
6) Disconnect connector from rear oxygen sensor Be careful not to pull down front exhaust pipe
connector. and center exhaust pipe.
B2M3440
B2M3111
EC(H4)-3
墌 00.5.31/68j/1ec4 墍
10) Separate front catalytic converter from front 3) Tighten bolts which hold front exhaust pipe onto
exhaust pipe. cylinder heads.
NOTE: Tightening torque:
The rear catalytic converter is integrated with front 30 N·m (3.1 kgf-m, 22.4 ft-lb)
catalytic converter. Therefore, the procedure for
removing rear catalytic converter is the same as
the description above.
B2M3200
4) Install center exhaust pipe to rear exhaust pipe.

S2M0923 Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
CAUTION:
Replace gaskets with new ones.
1) Install front catalytic converter to front exhaust
pipe.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
B2M3109
5) Tighten bolt which holds center exhaust pipe to

hanger bracket.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
S2M0923
2) Install front exhaust pipe and center exhaust

pipe. And temporarily tighten bolt which installs
center exhaust pipe to hanger bracket.
B2M3111
B2M3111
EC(H4)-4
墌 00.5.31/68j/1ec4 墍
6) Connect connector to rear oxygen sensor con-

nector.
B2M3440

9) Connect front oxygen (A/F) sensor connector.
B2M3439
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.
1) Make sure there are no exhaust leaks from con-

nections and welds.
2) Make sure there are no holes or rusting.
EC(H4)-5
墌 00.5.31/68j/1ec4 墍
REAR CATALYTIC CONVERTER
3. Rear Catalytic Converter S110036
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(H4)-3 REMOVAL, Front
Catalytic Converter.>
B2M3518A
(A) Front catalytic converter

(B) Rear catalytic converter
The front and rear catalytic converter and center

exhaust pipe are integrated into one unit.
Therefore, the removal and installation procedures
are the same as the ones described under front
catalytic converter. <Ref. to EC(H4)-4
INSTALLATION, Front Catalytic Converter.>
B2M3518A
(A) Front catalytic converter

(B) Rear catalytic converter

nections and welds.
EC(H4)-6
CANISTER
4. Canister S110037

2) Loosen two clamps which hold two canister
hoses, and disconnect evaporation three hoses
from canister.
B2M3519
3) Remove canister from body.
B2M3520

Tightening torque:
23 N·m (2.3 kgf-m, 17 ft-lb)
B2M3520A
Make sure the canister and canister hoses are not

cracked or loose.
EC(H4)-7
墌 00.5.31/68j/1ec4 墍
PURGE CONTROL SOLENOID VALVE
5. Purge Control Solenoid

Valve S110035
H2M2985
CAUTION:
Carefully connect the evaporation hoses.
G6M0095
2) Remove bolt which installs purge control sole-

noid valve onto intake manifold.
B2M1893A
Make sure hoses are not cracked or loose.
H2M2985
3) Take out purge control solenoid valve through

the bottom of the intake manifold.
4) Disconnect connector and hoses from purge
control solenoid valve.
H2M2986

Tightening torque:
16 N·m (1.6 kgf-m, 11.6 ft-lb)
EC(H4)-8
墌 00.5.31/68j/1ec4 墍
MAIN FUEL LEVEL SENSOR
6. Main Fuel Level Sensor S110038
For work procedures, refer to “FU” section. <Ref.

to FU(H4)-93 REMOVAL, Fuel Lever Sensor.>
For work procedures, refer to “FU” section. <Ref.

to FU(H4)-93 INSTALLATION, Fuel Lever Sen-
sor.>
EC(H4)-9
FUEL TEMPERATURE SENSOR
7. Fuel Temperature Sensor S110032
WARNING:
During work procedures, if fuel tank is more
than 3/4 full, be careful because fuel may spill.
NOTE:
Fuel temperature sensor is built in fuel pump
assembly.
B2M3738
FU(H4)-90 REMOVAL, Fuel Pump.>
2) Disconnect connector from fuel pump bracket.
B2M3521
3) Remove fuel temperature sensor.

NOTE:
When replacing fuel temperature sensor, also
replace fuel level sensor. <Ref. to FU(H4)-93
REMOVAL, Fuel Level Sensor.>
B2M3523

WARNING:
쐌 Ground cable must be connected.
쐌 Spark may occur and ignite if fuel is nearby.
EC(H4)-10
墌 00.5.31/68j/1ec4 墍
SUB FUEL LEVEL SENSOR
8. Sub Fuel Level Sensor S110029
For work procedures, refer to “FU(H4)” section.

<Ref. to FU(H4)-94 REMOVAL, Fuel Sub Lever
Sensor.>
For work procedures, refer to “FU(H4)” section.

<Ref. to FU(H4)-95 INSTALLATION, Fuel Sub
Lever Sensor.>
EC(H4)-11
FUEL TANK PRESSURE SENSOR
9. Fuel Tank Pressure Sensor 6) Disconnect pressure hose from fuel tank pres-
sure sensor.
S110030
1) Set the vehicle on the lift.

2) Open fuel flap lid, and remove fuel filler cap.
B2M3525
7) Remove fuel tank pressure sensor.
B2M3197
B2M3526

B2M1723
Tightening torque:
4) Lift-up the vehicle. 7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
5) Disconnect connector from fuel tank pressure
sensor.
B2M3526
B2M3524
1) Make sure that hoses are not cracked or loose.
EC(H4)-12
墌 00.5.31/68j/1ec4 墍
PRESSURE CONTROL SOLENOID VALVE
10. Pressure Control Solenoid 6) Remove pressure control solenoid valve from
bracket.
Valve S110031

B2M3529
B: INSTALLTION S110031A11

B2M1723
4) Disconnect connector from pressure control 1) Make sure that hoses are not cracked or loose.
solenoid valve.
B2M3527
5) Disconnect two evaporation hoses from pres-

sure control solenoid valve.
B2M3528
EC(H4)-13
墌 00.5.31/68j/1ec4 墍
DRAIN FILTER
11. Drain Filter S110567

7) Disconnect evaporation hoses, (a) and remove
drain filter (b).

B2M1791E
B2M1723
3) Lift-up the vehicle. Tightening torque:
4) Remove canister. <Ref. to EC(H4)-7 18 N·m (1.8 kgf-m, 13.0 ft-lb)
REMOVAL, Canister.>
5) Disconnect connector from drain valve.
B2M3655
B2M1788
6) Remove nut which installs drain filter and drain 1) Make sure that all hoses are installed correctly.
valve brackets on body, and remove them as a 2) Make sure that hoses are not cracked or loose.
unit.
B2M3655
EC(H4)-14
墌 00.5.31/68j/1ec4 墍
VENT VALVE
12. Vent Valve S110033
1) Remove fuel tank. <Ref. to FU(H4)-73

REMOVAL, Fuel Tank.>
2) Move clips, and disconnect hoses from vent
valve.
B2M3530
3) Remove nuts which install vent valve on fuel

tank.
B2M3531

CAUTION:
Replace rubber seat with a new one.
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
B2M3531
EC(H4)-15
墌 00.5.31/68j/1ec4 墍
SHUT VALVE
13. Shut Valve S110024
1) Drain fuel from fuel tank. <Ref. to FU(H4)-73

2) Remove fuel filler pipe. <Ref. to FU(H4)-82
REMOVAL, Fuel Filler Pipe.>
3) Disconnect evaporation hoses from shut valve.
B2M3532
4) Remove shut valve from fuel filler pipe.
B2M3533

Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
B2M3533
EC(H4)-16
DRAIN VALVE
14. Drain Valve S110088

7) Disconnect evaporation hose and remove drain
valve.

B2M1791D
B2M1723
3) Lift-up the vehicle. Tightening torque:
4) Remove canister. <Ref. to EC(H4)-7 18 N·m (1.8 kgf-m, 13.0 ft-lb)
REMOVAL, Canister.>
5) Disconnect connector from drain valve.
B2M3655
B2M1788
6) Remove bolt which installs air filter and drain 1) Make sure that all hoses are installed correctly.
valve brackets on body. 2) Make sure that hoses are not cracked or loose.
B2M3655
EC(H4)-17
墌 00.5.31/68j/1ec4 墍
DRAIN VALVE
MEMO:
EC(H4)-18
墌 00.5.31/68j/1ec4 墍
GENERAL DESCRIPTION
Exhaust
B2M3438A
EX(H4)-2
墌 00.5.31/68j/1ex4 墍
GENERAL DESCRIPTION
Exhaust
(1) Upper front exhaust pipe cover (10) Lower center exhaust pipe cover (21) Self-locking nut
CTR (11) Gasket (22) Protector
(2) Lower front exhaust pipe cover (12) Upper rear catalytic converter (23) Rear oxygen sensor
CTR cover
(3) Front exhaust pipe (13) Lower rear catalytic converter Tightening torque: N·m (kgf-m, ft-lb)
(4) Front oxygen (A/F) sensor cover T1: 13 (1.3, 9.4)
(5) Front catalytic converter (14) Rear catalytic converter T2: 18 (1.8, 13.0)
(6) Upper front catalytic converter (15) Center exhaust pipe T3: 30 (3.1, 22.4)
cover (16) Spring T4: 35 (3.6, 26.0)
(7) Lower front catalytic converter (17) Rear exhaust pipe T5: 48 (4.9, 35.4)
cover (18) Gasket
(8) Clamp (19) Cushion rubber
(9) Upper center exhaust pipe cover (20) Muffler
EX(H4)-3
墌 00.5.31/68j/1ex4 墍
GENERAL DESCRIPTION
Exhaust

tion.
ment.
fied points.
EX(H4)-4
墌 00.5.31/68j/1ex4 墍
FRONT EXHAUST PIPE
Exhaust
2. Front Exhaust Pipe S102065

5) Separate front and center exhaust pipe assem-
bly from rear exhaust pipe.
WARNING:
1) Disconnect battery ground cable. Be careful, exhaust pipe is hot.
G6M0095 B2M3109
2) Disconnect front oxygen (A/F) sensor connec- 6) Remove under cover.

tor.
B2M2920
B2M3439
7) Remove bolts which hold front exhaust pipe
3) Lift-up the vehicle. onto cylinder heads.
4) Disconnect rear oxygen sensor connector. CAUTION:
Be careful not to pull down front and center
exhaust pipe assembly.
B2M3440
B2M3200
EX(H4)-5
墌 00.5.31/68j/1ex4 墍
FRONT EXHAUST PIPE
Exhaust
8) Remove bolt which installs front and center B: INSTALLATION S102065A11

exhaust pipe assembly to hanger bracket.
1) Install front exhaust pipe to center exhaust
pipe.
CAUTION:
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
B2M3111
9) Remove front and center exhaust pipe assem-

bly from the vehicle.
CAUTION:
쐌 Be careful not to let front and center exhaust
pipe assembly fall off when removing as it is
quite heavy. S2M0923
쐌 After removing front and center exhaust

assembly, do not apply excessive pulling force 2) Install front and center exhaust pipe assembly
on rear exhaust pipe. to the vehicle.
3) Temporarily tighten bolt which installs front and
10) Separate front exhaust pipe from center center exhaust pipe assembly to hanger bracket.
exhaust pipe.
B2M3111
S2M0923
4) Tighten bolts which hold front exhaust pipe onto
cylinder heads.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
B2M3200
EX(H4)-6
墌 00.5.31/68j/1ex4 墍
FRONT EXHAUST PIPE
Exhaust
6) Tighten bolts which install front and center 9) Lower the vehicle.
exhaust pipe assembly to rear exhaust pipe. 10) Connect front oxygen (A/F) sensor connector.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
B2M3439

B2M3109
7) Tighten bolt which holds front and center

exhaust pipe assembly to hanger bracket.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
G6M0095

nections and welds.
B2M3111 2) Make sure there are no holes or rusting.
8) Connect rear oxygen sensor connector.
B2M3440
EX(H4)-7
墌 00.5.31/68j/1ex4 墍
CENTER EXHAUST PIPE
Exhaust
3. Center Exhaust Pipe S102067
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(H4)-5 REMOVAL, Front Exhaust Pipe.>
Install the center exhaust pipe and front exhaust

pipe as one unit. Refer to the procedure for install-
ing the front exhaust pipe. <Ref. to EX(H4)-6
INSTALLTION, Front Exhaust Pipe.>

nections and welds.
EX(H4)-8
REAR EXHAUST PIPE
Exhaust
4. Rear Exhaust Pipe S102068

2) Install rear exhaust pipe to center exhaust pipe.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
1) Separate rear exhaust pipe from center
exhaust pipe.
CAUTION:
Be careful, exhaust pipe is hot.
B2M3109

B2M3109
nections and welds.
2) Separate rear exhaust pipe from muffler. 2) Make sure there are no holes or rusting.
3) Make sure the cushion rubber is not worn or
CAUTION: cracked.
Be careful not to pull down rear exhaust pipe.
B2M3121
3) Remove rear exhaust pipe.
CAUTION:
1) Install rear exhaust pipe to muffler.
Tightening torque:
48 N·m (4.9 kgf-m, 35.4 ft-lb)
B2M3121
EX(H4)-9
MUFFLER
Exhaust
5. Muffler S102066
3) Remove front rubber cushion, and detach muf-
fler assembly.
NOTE:
1) Separate muffler from rear exhaust pipe. To facilitate removal, apply a coat of SUBARU
CRC to mating area of rubber cushion in advance.
CAUTION:
Be careful, exhaust pipe is hot. SUBARU CRC (Part No. 004301003)
B2M3117
B2M3121
2) Remove left and right rubber cushions.

CAUTION:
Be careful not to drop the muffler during
removal. CAUTION:
Replace gasket with a new one.
NOTE:
To facilitate removal, apply a coat of SUBARU Tightening torque:
CRC to mating area of rubber cushions in 48 N·m (4.9 kgf-m, 35.4 ft-lb)
advance.
SUBARU CRC (Part No. 004301003)
B2M3121
B2M3119 C: INSPECTIOIN S102066A10

nections and welds.
3) Make sure the cushion rubber is not worn or
cracked.
EX(H4)-10
墌 00.5.31/68j/1ex4 墍
GENERAL DESCRIPTION
Fuel Injection (Fuel Systems)
Model
Capacity 64 (16.9 US gal, 14.1 Imp gal)
Fuel tank
Location Under rear seat
Type Impeller
Shutoff discharge pressure 370 — 677 kPa (3.77 — 6.9 kg/cm2, 53.6 — 98 psi)
Fuel pump
More than 65 (17.2 US gal, 14.3 Imp gal)/h
Discharge flow
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
Fuel filter Cartridge type
FU(H4)-2
墌 00.5.31/68j/1fu4 墍
GENERAL DESCRIPTION
1. INTAKE MANIFOLD S105001A0501
B2M4151A
FU(H4)-3
墌 00.5.31/68j/1fu4 墍
GENERAL DESCRIPTION
(1) Intake manifold gasket RH (10) Purge control solenoid valve (19) Clip
(2) Guide pin (11) Nipple
(3) Insulator A (12) Intake manifold Tightening torque: N·m (kgf-m, ft-lb)
(4) Insulator B (13) Intake manifold gasket LH T1: 5.0 (0.51, 3.7)
(5) Fuel injector (14) Fuel pipe protector LH T2: 19 (1.9, 14)
(6) O-ring B (15) Fuel pipe protector RH T3: 22.5 (2.29, 16.6)
(7) O-ring A (16) Fuel pipe ASSY T4: 25 (2.5, 18.1)
(8) Plug (17) Fuel pipe protector LH
(9) PCV valve (18) Fuel hose
FU(H4)-4
墌 00.5.31/68j/1fu4 墍
GENERAL DESCRIPTION
B2M3454B
FU(H4)-5
墌 00.5.31/68j/1fu4 墍
GENERAL DESCRIPTION
(1) Intake manifold gasket RH (14) Intake air temperature and pres- (25) Atmospheric pressure sensor
(2) Fuel injector pipe sure sensor bracket
(3) Fuel injector (15) O-ring (26) Atmospheric pressure sensor
(4) O-ring (16) Fuel pipe protector LH
(5) O-ring (17) Fuel pipe protector RH Tightening torque: N·m (kgf-m, ft-lb)
(6) O-ring (18) Fuel pipe ASSY T1: 3.4 (0.35, 2.5)
(7) Plug (19) Fuel hose T2: 5.0 (0.51, 3.7)
(8) PCV valve (20) Clip T3: 6.4 (0.65, 4.7)
(9) Purge control solenoid valve (21) Clip T4: 19 (0.19, 1.4)
(10) Nipple (22) Air assist injector solenoid valve T5: 22.5 (2.29, 16.6)
(11) Intake manifold (23) Air assist injector solenoid valve
T6: 25 (2.6, 18.8)
(12) Intake manifold gasket LH bracket
(13) Fuel pipe protector LH (24) Guide pin
FU(H4)-6
墌 00.5.31/68j/1fu4 墍
GENERAL DESCRIPTION
2. AIR INTAKE SYSTEM S105001A0502
B2M2278B
(1) Gasket (5) Intake manifold pressure sensor Tightening torque: N·m (kgf-m, ft-lb)
(2) Throttle position sensor (6) Throttle body
T1: 1.6 (0.16, 1.2)
(3) Gasket
T2: 2.8 (0.29, 2.1)
(4) Idle air control solenoid valve
T3: 22 (2.2, 15.9)
FU(H4)-7
墌 00.5.31/68j/1fu4 墍
GENERAL DESCRIPTION
B2M3455B
(1) Gasket (4) Throttle body Tightening torque: N·m (kgf-m, ft-lb)
(2) Throttle position sensor
T1: 1.6 (0.16, 1.2)
(3) Idle air control solenoid valve
T2: 22 (2.2, 16)
FU(H4)-8
墌 00.5.31/68j/1fu4 墍
GENERAL DESCRIPTION
3. CRANKSHAFT POSITION, CAMSHAFT

POSITION AND KNOCK SENSORS S105001A0503
B2M2282B
(1) Crankangle position sensor (3) Camshaft position sensor Tightening torque: N·m (kgf-m, ft-lb)
(2) Knock sensor (4) Camshaft position sensor sup-
T1: 6.4 (0.65, 4.7)
port
T2: 23.5 (2.4, 17.4)
FU(H4)-9
墌 00.5.31/68j/1fu4 墍
GENERAL DESCRIPTION
4. FUEL TANK S105001A0504
B2M3662A
FU(H4)-10
墌 00.5.31/68j/1fu4 墍
GENERAL DESCRIPTION
(1) Heat sealed cover (18) Jet pump hose A (35) Fuel delivery tube
(2) Fuel tank band (19) Fuel return tube (36) Vent valve
(3) Protector LH (Front) (20) Retainer (37) Vent valve plate
(4) Protector RH (Front) (21) Quick connector (38) Vent valve gasket
(5) Fuel tank (22) Jet pump hose B (39) Evaporation tube
(6) Fuel pump plate (23) Fuel sub level sensor gasket (40) Evaporation hose D
(7) Fuel pump ASSY (24) Jet pump filter (41) Air vent hose
(8) Fuel level sensor (25) Fuel sub level sensor (42) Seal
(9) Cap (26) Protector LH (Rear) (43) Fuel pump holder
(10) Fuel pump (27) Protector RH (Rear) (44) Grommet
(11) Fuel cut valve gasket (28) Fuel filler hose
(12) Fuel cut valve (29) Fuel tank pressure sensor hose Tightening torque: N·m (kgf-m, ft-lb)
(13) Evaporation hose A (30) Clamp T1: 4.4 (0.45, 3.3)
(14) Clip (31) Gasket T2: 18 (1.8, 13.0)
(15) Evaporation hose C (32) Cap T3: 33 (3.4, 25)
(16) Joint pipe (33) Gasket T4: 5.9 (0.6, 4.3)
(17) Evaporation hose B (34) Fuel cut valve plate
FU(H4)-11
墌 00.5.31/68j/1fu4 墍
GENERAL DESCRIPTION
5. FUEL LINE S105001A0505
B2M4150A
FU(H4)-12
墌 00.5.31/68j/1fu4 墍
GENERAL DESCRIPTION
(1) Clamp (22) Air vent pipe (43) Drain filter

(2) Fuel delivery hose A (23) Evaporation hose J (44) Drain filter hose A
(3) Fuel filter bracket (24) Evaporation hose K (45) Drain valve hose
(4) Fuel filter holder (25) Evaporation hose L (46) Drain filter hose B
(5) Fuel filter cup (26) Fuel tank pressure sensor hose (47) Pressure control solenoid valve
(6) Fuel filter (27) Fuel filler hose (48) Evaporation hose O
(7) Evaporation hose F (28) Evaporation pipe B (49) Evaporation pipe C
(8) Clip (29) Fuel tank pressure sensor (50) Pipe protector
(9) Fuel delivery hose B (30) Fuel filler pipe (51) Evaporation hose P
(10) Fuel return hose (31) Ring A (52) Pressure control solenoid valve
(11) Fuel pipe ASSY (32) Fuel filler cap hose
(12) Fuel delivery hose C (33) Ring B (53) Canister front bracket
(13) Fuel return hose C (34) Packing
(14) Evaporation hose G (35) Shut valve Tightening torque: N·m (kgf-m, ft-lb)
(15) Clamp (36) Evaporation hose M T1: 4.5 (0.46, 3.3)
(16) Grommet (37) Evaporation hose N T2: 7.5 (0.76, 5.5)
(17) Fuel pipe ASSY (38) Canister T3: 18 (1.8, 13.0)
(18) Air vent hose A (39) Canister lower bracket T4: 23 (2.3, 16.6)
(19) Evaporation hose H (40) Cushion rubber T5: 33 (3.4, 25)
(20) Evaporation hose I (41) Canister upper bracket
(21) Air vent hose B (42) Drain valve
FU(H4)-13
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GENERAL DESCRIPTION
6. FUEL FILLER PIPE S105001A0506
B2M3664A
(1) Fuel filler pipe ASSY (5) Filler pipe protector Tightening torque: N·m (kgf-m, ft-lb)
(2) Filler pipe packing (6) Clip
T: 7.5 (0.75, 5.4)
(3) Filler ring (7) Ring A
(4) Filler cap (8) Ring B
FU(H4)-14
墌 00.5.31/68j/1fu4 墍
GENERAL DESCRIPTION

tion.
sure to clarify the failure. Avoid unnecessary 쐌 Place “NO FIRE” signs near the working area.
removal, installation, disassembly, and replace- 쐌 Be careful not to spill fuel on the floor.
ment.

24082AA150 CARTRIDGE
B2M3876
B2M3877
FU(H4)-15
墌 00.5.31/68j/1fu4 墍
THROTTLE BODY
2. Throttle Body S105010

5) Disconnect connectors from throttle position
sensor (A), idle air control solenoid valve (B) and
A: REMOVAL S105010A18 intake manifold pressure sensor (C).
6) Disconnect air by-pass hose (D) from idle air
B2M3658C
B2M1723
7) Disconnect engine coolant hoses from throttle
2) Remove air cleaner case. <Ref. to IN(H4)-6 body.
REMOVAL, Air Cleaner Case.>
B2M2299
H2M2947
8) Remove bolts which install throttle body to
3) Disconnect accelerator cable (A). intake manifold.
4) Disconnect cruise control cable (B). (With
cruise control model)
B2M2300
B2M2295A
FU(H4)-16
墌 00.5.31/68j/1fu4 墍
THROTTLE BODY
2. AT VEHICLES S105010A1802 5) Disconnect connectors from idle air control

solenoid valve, throttle position sensor.
6) Disconnect air by-pass hose from air assist
injector solenoid valve.
G6M0095
2) Remove air cleaner case. B2M3457A
(A) Throttle position sensor

(B) Idle air control solenoid valve
(C) Air by-pass hose from air assist injector solenoid
valve
7) Disconnect engine coolant hoses from throttle

body.
H2M2947
3) Disconnect accelerator cable (A).

cruise control model)
B2M3458
8) Remove bolts which install throttle body to

intake manifold.

CAUTION:
Always use a new gasket.
Tightening torque:
Throttle body;
22 N·m (2.2 kgf-m, 15.9 ft-lb)
Air cleaner case;
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)

CAUTION:
Always use a new gasket.
FU(H4)-17
墌 00.5.31/68j/1fu4 墍
THROTTLE BODY
Tightening torque:
Throttle body;
22 N·m (2.2 kgf-m, 15.9 ft-lb)
Air cleaner case;
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
FU(H4)-18
墌 00.5.31/68j/1fu4 墍
INTAKE MANIFOLD
3. Intake Manifold S105034

5) Disconnect accelerator cable (A).
A: REMOVAL S105034A18 cruise control model)
1) Release fuel pressure. <Ref. to FU(H4)-70
RELEASING OF FUEL PRESSURE,
OPERATION, Fuel.>
B2M3365A
7) Remove power steering pump and tank from

brackets.
(1) Remove resonator chamber.
B2M3135
B6M1237
(2) Remove V-belt covers.

G6M0095
4) Remove air intake duct and air cleaner assem-

bly. <Ref. to IN(H4)-7 REMOVAL, Air Intake Duct.>
and <Ref. to IN(H4)-6 REMOVAL, Air Cleaner
Case.>
B2M3106
(3) Loosen lock bolt and slider bolt, and remove

power steering pump drive V-belt.
B2M3101
G2M0286
FU(H4)-19
INTAKE MANIFOLD
(4) Remove bolts which hold power steering (7) Remove power steering tank from the
pipes onto intake manifild protector. bracket by pulling it upwards.
NOTE:
Do not disconnect power steering hose.
B2M3153
(8) Place power steering pump and tank on the

B2M3366 right side wheel apron.
(5) Remove bolts which install power steering
pump bracket.
B2M3154
8) Disconnect spark plug cords from spark plugs.

B2M3151 9) Disconnect PCV hose from intake manifold.
(6) Disconnect connector from power steering
pump switch.
H2M2953
B2M3152
FU(H4)-20
INTAKE MANIFOLD
10) Disconnect engine coolant hose from throttle 13) Disconnect connectors from engine coolant
body. temperature sensor.
B2M2299A S2M1658
14) Disconnect knock sensor connector.
B2M3458A
S2M1659
11) Disconnect brake booster hose.
15) Disconnect connector from crankshaft position
sensor.
B2M3156
12) Remove air cleaner case stay RH and engine B2M1252

harness bracket, and disconnect engine harness
connectors from bulkhead harness connectors. 16) Disconnect connector from oil pressure
switch.
H2M2955
B2M1253
FU(H4)-21
INTAKE MANIFOLD
17) Disconnect connector from camshaft position 20) Remove intake manifold.
sensor.
B2M0160
B2M2317
18) Disconnect fuel hoses from fuel pipes. B: INSTALLATION S105034A11
WARNING: 1) Install intake manifold onto cylinder heads.

쐌 Do not spill fuel. CAUTION:
쐌 Catch fuel from hoses in a container or cloth. Always use new gaskets.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
S2M0500F
(A) Fuel delivery hose

(B) Return hose B2M3368
(C) Evaporation hose
2) Connect fuel hoses.
19) Remove bolts which hold intake manifold onto
cylinder heads.
S2M0500F
B2M3368 (A) Fuel delivery hose

(B) Return hose
(C) Evaporation hose
FU(H4)-22
INTAKE MANIFOLD
3) Connect connector to camshaft position sensor. 7) Connect connectors to engine coolant tempera-
ture sensor.
B2M2317
S2M1658
4) Connect connector to oil pressure switch.
8) Install air cleaner case stay RH and engine har-
ness bracket, and connect engine harness con-
nectors to bulkhead connectors.
B2M1253
5) Connect connector to crankshaft position sen-

sor. H2M2955
9) Connect brake booster hose.
B2M1252
6) Connect knock sensor connector. B2M3156
S2M1659
FU(H4)-23
INTAKE MANIFOLD
10) Connect engine coolant hose to throttle body. (2) Connect connector to power steering pump
switch.
B2M2299A
B2M3152
(3) Tighten bolts which install power steering

pump on bracket.
Tightening torque:
20.1 N·m (2.05 kgf-m, 14.8 ft-lb)
B2M3458A
11) Connect PCV hose to intake manifold.
B2M3151
(4) Install power steering pipes onto right side

intake manifold protector.
H2M2953
12) Connect spark plug cords to spark plugs.

13) Install power steering pump and tank on
brackets.
(1) Install power steering tank on bracket.
B2M3366
(5) Install power steering pump drive V-belt.
B2M3153
G2M0286
FU(H4)-24
INTAKE MANIFOLD
(6) Adjust V-belt. <Ref. to ME(H4)-43 16) Install air intake duct and air cleaner assem-
REMOVAL, V-belt.> bly. <Ref. to IN(H4)-7 REMOVAL, Air Intake Duct.>
(7) Install V-belt covers. and <Ref. to IN(H4)-6 REMOVAL, Air Cleaner
Case.>
B2M3106
B2M3101
(8) Install resonator chamber.
Tightening torque: 17) Connect connector to fuel pump relay.
33 N·m (3.4 kgf-m, 24.6 ft-lb)
B2M3159
B6M1237 18) Connect battery ground cable.

14) Connect accelerator cable (A).
15) Connect cruise control cable (B). (With cruise
control models)
G6M0095
B2M3365A
FU(H4)-25
INTAKE MANIFOLD
C: DISASSEMBLY S105034A06 7) Remove throttle body.

1) Disconnect engine ground terminal from intake

manifold.
B2M2300
8) Disconnect pressure regulator vacuum hose

from intake manifold.
B2M2779
2) Disconnect connector from ignition coil and

ignitor assembly.
3) Remove ignition coil and ignitor assembly.
B2M3460
9) Remove fuel pipe protector LH.
B2M3459
4) Disconnect connectors from throttle position

sensor (A), idle air control solenoid valve (B) and
intake manifold pressure sensor (C).
5) Disconnect air by-pass hose (D) from idle air
6) Disconnect air by-pass hose (E) from intake
manifold. B2M3476
B2M3658A
B2M3815
FU(H4)-26
INTAKE MANIFOLD
10) Remove fuel pipe protector RH. 14) Remove engine harness from intake manifold.
15) Remove purge control solenoid valve.
B2M3814
H2M2964
11) Disconnect connectors from fuel injectors.
16) Remove bolt which installs injector pipe on
intake manifold as shown in figure.
B2M3371
12) Disconnect connector from purge control sole- B2M3464

noid valve.
17) Remove bolt which installs injector pipe on
intake manifold.
H2M2963
13) Remove harness bands (*) which hold engine B2M3465

harness onto intake manifold.
18) Remove two bolts which hold fuel pipes on the
left side of intake manifold.
B2M4146A
B2M3466
FU(H4)-27
INTAKE MANIFOLD
19) Remove fuel injector while lifting up fuel injec- 23) Remove fuel injector pipe.
tor pipe.
H2M2975
B2M3468
24) Remove bolt which installs fuel pipes on
20) Disconnect air by-pass hoses from intake intake manifold.
manifold.
B2M3470
B2M4147A
25) Remove fuel pipe assembly and pressure
21) Loosen clamp which holds front left side fuel
regulator, from intake manifold.
hose to injector pipe and remove the pipe from
clamp. 2. AT VEHICLES S105034A0602
1) Disconnect engine ground terminal from intake

manifold.
H2M2972
22) Loosen clamp which holds front right side fuel

hose to injector pipe and remove the pipe from B2M3471
clamp.
B2M3376
FU(H4)-28
INTAKE MANIFOLD
2) Disconnect connector from ignition coil and 6) Disconnect connectors from throttle position
ignitor assembly. sensor and idle air control solenoid valve.
B2M3472 B2M3479
3) Remove ignition coil and ignitor assembly. 7) Disconnect air by-pass hose from throttle body.
B2M3473 B2M3480
4) Disconnect connector from intake air tempera- 8) Remove throttle body.

ture and pressure sensor.
H2M2951
B2M3474
9) Disconnect connector from air assist injector
5) Remove intake air temperature and pressure solenoid valve.
sensor from intake manifold. 10) Disconnect air by-pass hoses from air assist
solenoid valve.
B2M3475
B2M3477
FU(H4)-29
INTAKE MANIFOLD
11) Remove air assist injector solenoid valve from 14) Remove fuel pipe protector RH.
intake manifold.
B2M3816
B2M3478
15) Disconnect connectors from fuel injectors.
12) Disconnect pressure regulator vacuum hose
from intake manifold.
B2M3484
H2M2961
16) Disconnect connector from purge control sole-
noid valve.
13) Remove fuel pipe protector LH.
B2M3485
B2M3476
17) Disconnect air by-pass hose from purge con-
trol solenoid valve.
18) Remove harness bands (*) which hold engine
harness onto intake manifold.
B2M3815
B2M4148A
FU(H4)-30
INTAKE MANIFOLD
19) Remove engine harness from intake manifold. 24) Remove fuel injectors.
20) Remove purge control solenoid valve. (1) Remove fuel injector securing clip.
B2M3487 B2M3488
21) Remove bolt which installs injector pipe on (2) Remove fuel injector while lifting up fuel
intake manifold as shown in figure. injector pipe.
H2M2965 H2M2970
22) Remove bolt which installs injector pipe on 25) Disconnect air by-pass hoses from intake
intake manifold. manifold.
H2M2966 B2M4149A
23) Remove two bolts which hold fuel pipes on the 26) Loosen clamp which holds front left side fuel
left side of intake manifold. hose to injector pipe and remove the pipe from
clamp.
H2M2968
B2M3489
FU(H4)-31
INTAKE MANIFOLD
27) Loosen clamp which holds front right side fuel 2) Tighten bolt which installs fuel pipes on intake
hose to injector pipe and remove the pipe from manifold.
clamp. Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M3376
28) Remove fuel injector pipe. B2M3470
3) Connect right side fuel hose to injector pipe,

and tighten clamp screw.
H2M2975
29) Remove bolt which installs fuel pipes on

intake manifold. B2M3376
4) Install fuel injector pipe.
B2M3491
H2M2975
30) Remove fuel pipe assembly and pressure
regulator, from intake manifold. 5) Connect left side fuel hose to injector pipe, and
tighten clamp screw.
1) Install fuel pipe assembly and pressure

regulator, etc. to intake manifold.
H2M2972
FU(H4)-32
INTAKE MANIFOLD
6) Connect air by-pass hoses. 9) Tighten two bolts which install fuel pipes on the
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M4147A
7) Install fuel injectors.

CAUTION: B2M3466
Always use new o-rings and insulators.
10) Tighten bolt which install injector pipe on
intake manifold.
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M3516A
(A) O-ring
(B) Fuel injector
(C) Insulator
B2M3465
8) Tighten bolt which installs injector pipe on
intake manifold. 11) Install purge control solenoid valve.
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
H2M2964
B2M3464
FU(H4)-33
INTAKE MANIFOLD
12) Connect hoses to purge control solenoid 17) Install fuel pipe protector LH.
valve. Tightening torque:
CAUTION: 19 N·m (1.9 kgf-m, 13.7 ft-lb)
B2M3481
B2M1893A
13) Install engine harness onto intake manifold.

14) Connect connectors to fuel injectors and
purge control solenoid valve.
15) Hold engine harness by harness band (*).
B2M3476
18) Connect pressure regulator vacuum hose to

intake manifold.
B2M4146A
NOTE:
Do not use harness band on harnesses where they
are supposed to be protected by the fuel pipe pro-
tector.
16) Install fuel pipe protector RH.
Tightening torque:
19 N·m (1.9 kgf-m, 13.7 ft-lb) B2M3460
B2M3462
FU(H4)-34
INTAKE MANIFOLD
19) Install throttle body to intake manifold. 24) Connect connector to ignition coil and ignitor
CAUTION: assembly.
Replace gasket with a new one. 25) Install engine ground terminal to intake mani-
fold.
Tightening torque:
22 N·m (2.2 kgf-m, 15.9 ft-lb)
B2M2779
B2M2300
20) Connect connectors to throttle position sensor 1) Install fuel pipe assembly and pressure
(A), idle air control solenoid valve (B) and intake regulator, etc. to intake manifold.
manifold pressure sensor (C). 2) Tighten bolt which installs fuel pipes on intake
21) Connect air by-pass hose (D) to idle air con- manifold.
trol solenoid valve.
22) Connect air by-pass hose (E) to intake mani- Tightening torque:
fold. 4.9 N·m (0.5 kgf-m, 3.6 ft-lb)
B2M3658A B2M3491
23) Install ignition coil and ignitor assembly. 3) Connect right side fuel hose to injector pipe,
and tighten clamp screw.
B2M3459
B2M3376
FU(H4)-35
INTAKE MANIFOLD
4) Install fuel injector pipe. NOTE:

Do not forget to install the fuel injector securing
clip.
H2M2975
5) Connect left side fuel hose to injector pipe, and B2M3488

tighten clamp screw.
8) Tighten bolt which installs injector pipe on
intake manifold.
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M3489
6) Connect air assist hoses.
H2M2965
9) Tighten two bolts which install fuel pipes on the

Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M4149A
7) Install fuel injectors.

CAUTION:
Always use new o-rings.
H2M2968
B2M3492A
(A) O-ring
(B) Fuel injector
FU(H4)-36
INTAKE MANIFOLD
10) Tighten bolt which install injector pipe on 13) Install engine harness onto intake manifold.
intake manifold. 14) Connect connectors to fuel injectors and
Tightening torque: purge control solenoid valve.
5.0 N·m (0.51 kgf-m, 3.7 ft-lb) 15) Hold engine harness by harness band (*).
B2M4148A
H2M2966
11) Install purge control solenoid valve. NOTE:

Do not use harness band on harnesses where they
are supposed to be protected by the fuel pipe pro-
tector.
16) Install fuel pipe protector RH.
Tightening torque:
19 N·m (1.9 kgf-m, 13.7 ft-lb)
B2M3487
12) Connect hoses to purge control solenoid

valve.
CAUTION:
B2M3483
B2M1893A
FU(H4)-37
INTAKE MANIFOLD
17) Install fuel pipe protector LH. 20) Connect air by-pass hoses to air assist sole-
Tightening torque: noid valve.
19 N·m (1.9 kgf-m, 13.7 ft-lb)
B2M3477
B2M3481 21) Connect connector to air assist solenoid

valve.
22) Install throttle body to intake manifold.
CAUTION:
Tightening torque:
22 N·m (2.2 kgf-m, 15.9 ft-lb)
B2M3476
18) Connect pressure regulator vacuum hose to

intake manifold.
H2M2951
23) Connect connector to throttle position sensor

and idle air control solenoid valve.
H2M2961
19) Install air assist injector solenoid valve to

bracket.
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M3479
B2M3478
FU(H4)-38
INTAKE MANIFOLD
24) Connect air by-pass hose to throttle body. 26) Connect connector to intake air temperature
and pressure sensor.
27) Install ignition coil and ignitor assembly.
B2M3480
25) Install intake air temperature and pressure B2M3473

sensor.
28) Connect connector to ignition coil and ignitor
Tightening torque: assembly.
3.4 N·m (0.35 kgf-m, 2.5 ft-lb) 29) Install engine ground terminal to intake mani-
fold.
B2M3475
B2M2779
CAUTION:
Replace O-ring with new one.
Make sure the fuel pipe and fuel hoses are not
cracked and that connections are tight.
H2M2999
FU(H4)-39
ENGINE COOLANT TEMPERATURE SENSOR
4. Engine Coolant Temperature B: INSTALLATION S105047A11

Tightening torque:
16 N·m (0.16 kgf-m, 1.2 ft-lb)
H2M3503
G6M0095

Case.>
B2M3101
3) Disconnect connector from engine coolant tem-

perature sensor.
S2M1658
4) Remove engine coolant temperature sensor.
FU(H4)-40
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CRANKSHAFT POSITION SENSOR
5. Crankshaft Position Sensor B: INSTALLATION S105043A11
S105043
A: REMOVAL S105043A18 Tightening torque:
T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
B2M1252B
G6M0095
2) Remove bolt which install crankshaft position

sensor to cylinder block.
G2M0408
3) Remove crankshaft position sensor, and dis-

connect connector from it.
G2M0409
FU(H4)-41
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CAMSHAFT POSITION SENSOR
6. Camshaft Position Sensor 4) Remove bolt which installs camshaft position

sensor support to camshaft cap LH.
S105041
B2M2321
5) Remove camshaft position sensor and cam-

shaft position sensor support as a unit.
G6M0095 6) Remove camshaft position sensor itself.
2) Disconnect connector from camshaft position

sensor.
B2M2322
B2M2317

3) Remove bolt which installs camshaft position
sensor to camshaft position sensor support. Tightening torque:
쐌 Camshaft position sensor support;
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
쐌 Camshaft position sensor;
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
B2M2375
FU(H4)-42
墌 00.5.31/68j/1fu4 墍
KNOCK SENSOR
7. Knock Sensor S105042 B: INSTALLATION S105042A11
1) Install knock sensor to cylinder block.
1) Disconnect battery ground cable from battery Tightening torque:

ground terminal. 24 N·m (2.4 kgf-m, 17.4 ft-lb)
NOTE:
The extraction area of the knock sensor cord must
be positioned at a 45° angle relative to the engine
rear.
G6M0095
2) Remove air cleaner case.
H2M3511A
2) Connect knock sensor connector.
H2M2947
3) Disconnect knock sensor connector.
S2M1659
3) Install air cleaner case.
S2M1659
4) Remove knock sensor from cylinder block.
H2M2947
S2M1673
FU(H4)-43
墌 00.5.31/68j/1fu4 墍
KNOCK SENSOR
G6M0095
FU(H4)-44
墌 00.5.31/68j/1fu4 墍
THROTTLE POSITION SENSOR
8. Throttle Position Sensor S105039


G6M0095
2) Disconnect connector from throttle position

sensor.
B2M1723
2) Disconnect connector from throttle position

sensor.
B2M3493
3) Remove throttle position sensor holding

screws, and remove it.
B2M3659
3) Remove throttle position sensor holding

screws, and remove throttle position sensor itself.
H2M2979
B2M2757
FU(H4)-45
墌 00.5.31/68j/1fu4 墍
B: INSTALLATION S105039A11 C: ADJUSTMENT S105039A01
1. MT VEHICLES S105039A1101 1. MT VEHICLES S105039A0101
Install in the reverse order of removal. 1) Turn ignition switch to OFF.

CAUTION: 2) Loosen throttle position sensor holding screws.
When installing throttle position sensor, adjust
the position to match with the specified data.
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
B2M3660
3) When using voltage meter;

(1) Take out ECM.
(2) Turn ignition switch to ON.
B2M2757 (3) Adjust throttle position sensor to the proper
position to allow the voltage signal to ECM to be
2. AT VEHICLES S105039A1102 in specification.
Install in the reverse order of removal. Connector & terminal / Specified voltage
Tightening torque: (B136) No. 15 — (B136) No. 17 / 0.45 —
1.6 N·m (0.16 kgf-m, 1.2 ft-lb) 0.55 V
[Fully closed.]
CAUTION:
When installing throttle position sensor, adjust
to the specified data.
B2M4131A
(4) Tighten throttle position sensor holding

H2M2979 screws.
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
B2M3660
FU(H4)-46
墌 00.5.31/68j/1fu4 墍
4) When using Subaru Select Monitor; (9) Tighten throttle position sensor holding
NOTE: screws.
For detailed operation procedures, refer to the Tightening torque:
Subaru Select Monitor Operation Manual. 1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
(1) Insert the cartridge to Subaru Select Moni-
tor.
B2M3660
S2M0286A 2. AT VEHICLES S105039A0102
(2) Connect Subaru Select Monitor to the data 1) Turn ignition switch to OFF.
link connector. 2) Loosen throttle position sensor holding screws.
B2M3148A B2M3765
(3) Turn ignition switch to ON, and Subaru 3) When using voltage meter;
Select Monitor switch to ON. (1) Take out ECM.
(4) Select {2. Each System Check} in Main (2) Turn ignition switch to ON.
Menu. (3) Adjust throttle position sensor to the proper
(5) Select {Engine Control System} in Selection position to allow the voltage signal to ECM to be
Menu. in specification.
(6) Select {1. Current Data Display & Save} in Connector & terminal / Specified voltage
EGI/EMPI Diagnosis. (B136) No. 15 — (B136) No. 17 / 0.45 —
(7) Select {1.12 Data Display} in Data Display 0.55 V
Menu. [Fully closed.]
(8) Adjust throttle position sensor to the proper
position to match with the following specifica-
tions.
Condition: Throttle fully closed
Throttle opening angle 0.00%
Throttle sensor voltage 0.50 V
B2M4131A
FU(H4)-47
墌 00.5.31/68j/1fu4 墍
(4) Tighten throttle position sensor holding (4) Connect Subaru Select Monitor to the data
screws. link connector.
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
B2M3148A
5) Turn ignition switch to ON, and Subaru Select

B2M3765 Monitor switch to ON.
6) Select {2. Each System Check} in Main Menu.
4) When using Subaru Select Monitor; 7) Select {Engine Control System} in Selection
(1) Turn ignition switch to OFF. Menu.
(2) Loosen throttle position sensor holding 8) Select {1. Current Data Display & Save} in
screws. Engine Control System Diagnosis.
9) Select {1.12 Data Display} in Data Display
Menu.
10) Adjust throttle position sensor to the proper
position to match with the following specifications.
Condition: Throttle fully closed
Throttle opening angle 0.00%
Throttle sensor voltage 0.50 V
11) Tighten throttle position sensor holding
screws.
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
NOTE:
Subaru Select Monitor Operation Manual.
(3) Insert the cartridge to Subaru Select Moni-
tor.
B2M3765
S2M0286A
FU(H4)-48
墌 00.5.31/68j/1fu4 墍
INTAKE MANIFOLD PRESSURE SENSOR
9. Intake Manifold Pressure 4) Remove intake manifold pressure sensor from

throttle body.
Sensor S105568
NOTE:
This sensor is installed on MT vehicles only.
B2M2373

CAUTION:
B2M1723 Replace gaskets for intake air pressure sensor
and idle air control solenoid valve with new
2) Remove idle air control solenoid valve. <Ref. to ones.
FU(H4)-53 MT VEHICLES, REMOVAL, Idle Air
Tightening torque:
Control Solenoid Valve.>
2.8 N·m (0.29 kgf-m, 2.1 ft-lb)
B2M2364
B2M2373
3) Disconnect connector from intake manifold

pressure sensor.
B2M2372
FU(H4)-49
墌 00.5.31/68j/1fu4 墍
INTAKE AIR TEMPERATURE SENSOR
10. Intake Air Temperature

Sensor S105569
NOTE:
This sensor is installed on MT vehicles only.
B2M1723
2) Disconnect connector from intake air tempera-

ture sensor.
B2M2285
3) Remove intake air temperature sensor from air

cleaner case.
B2M2374
FU(H4)-50
INTAKE AIR TEMPERATURE AND PRESSURE SENSOR
11. Intake Air Temperature and 4) Remove intake air temperature and pressure
sensor.
Pressure Sensor S105044
NOTE:
This sensor is installed on AT vehicles only.
B2M3497

Tightening torque:
G6M0095 3.4 N·m (0.35 kgf-m, 2.5 ft-lb)
2) Disconnect spark plug cord from ignition coil
and ignitor assembly.
B2M3497
CAUTION:
B2M3495 Replace O-ring with new one.
ture and pressure sensor.
H2M2999
B2M3496
FU(H4)-51
墌 00.5.31/68j/1fu4 墍
ATMOSPHERIC PRESSURE SENSOR
12. Atmospheric Pressure B: INSTALLATION S105045A11
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
NOTE:
This sensor is installed on AT vehicles only.
B2M3499
G6M0095
2) Disconnect connector from atmospheric pres-

sure sensor.
B2M3498
3) Remove atmospheric pressure sensor from

bracket.
B2M3499
FU(H4)-52
墌 00.5.31/68j/1fu4 墍
IDLE AIR CONTROL SOLENOID VALVE
13. Idle Air Control Solenoid 4) Remove idle air control solenoid valve from
throttle body.
Valve S105056
B2M2364

B2M1723
2) Disconnect connector from idle air control sole-

noid valve.
G6M0095
2) Disconnect connector from idle air control sole-

noid valve.
B2M2363
3) Disconnect air by-pass hose (A) from idle air

B2M3500
3) Remove idle air control solenoid valve from

throttle body.
B2M3661B
B2M3501
FU(H4)-53
墌 00.5.31/68j/1fu4 墍
IDLE AIR CONTROL SOLENOID VALVE

CAUTION:
Tightening torque:
2.8 N·m (0.29 kgf-m, 2.1 ft-lb)
B2M2364

CAUTION:
Always use new gasket.
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
B2M3501
FU(H4)-54
墌 00.5.31/68j/1fu4 墍
AIR ASSIST INJECTOR SOLENOID VALVE
14. Air Assist Injector Solenoid B: INSTALLATION S105570A11
Valve S105570 Install in the reverse order of removal.
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
NOTE:
This solenoid valve is used on AT vehicles only.
B2M3503
G6M0095
2) Disconnect connector from air assist injector

solenoid valve and disconnect air by-pass hoses.
B2M3502
3) Remove air assist injector solenoid valve from

intake manifold.
B2M3503
FU(H4)-55
墌 00.5.31/68j/1fu4 墍
FUEL INJECTOR
15. Fuel Injector S105051

5) Remove resonator chamber.
1. RH SIDE S105051A1801
1) Release fuel pressure.

<Ref. to FU(H4)-70 RELEASING OF FUEL
PRESSURE, Fuel.>
B6M1237
6) Remove spark plug cords from spark plugs (#1

and #3 cylinders).
B2M3135
B2M3374
7) Remove power steering pump and tank from

brackets.
(1) Remove V-belt covers.
G6M0095

Case.>
B2M3106

power steering pump drive V-belt.
B2M3101
G2M0286
FU(H4)-56
墌 00.5.31/68j/1fu4 墍
FUEL INJECTOR
(3) Remove bolts which hold power steering (7) Place power steering pump and tank on the
pipes onto intake manifold protector. right side wheel apron.
B2M3366 B2M3154
(4) Remove bolts which install power steering 8) Remove fuel pipe protector RH.
pump to bracket.
B2M3505
B2M3151
9) Disconnect connector from fuel injector.
(5) Disconnect connector from power steering
pump switch.
B2M3506
B2M3152
10) Remove bolt which holds injector pipe to
intake manifold.
(6) Remove power steering tank from the
bracket by pulling it upwards.
B2M4132
B2M3153
FU(H4)-57
墌 00.5.31/68j/1fu4 墍
FUEL INJECTOR
11) Remove bolt which install injector pipe to 2. LH SIDE S105051A1802
intake manifold.
OPERATION, Fuel.>
B2M3507
12) Remove fuel injector from intake manifold.

(1) Remove fuel injector securing clip. (AT
vehicle) B2M3135
B2M3508
(2) Remove fuel injector while lifting up fuel G6M0095
injector pipe.
4) Remove two bolts which install washer tank on
body.
B2M3509
B2M3139
FU(H4)-58
墌 00.5.31/68j/1fu4 墍
FUEL INJECTOR
5) Disconnect connector from front window 10) Remove fuel pipe protector LH.
washer motor.
6) Disconnect connector from rear gate glass
washer motor.
B2M3511
B6M0562
7) Disconnect rear window glass washer hose

from washer motor, then plug connection with a
suitable cap.
8) Move washer tank, and secure it away from
working area.
B2M3818
11) Disconnect connector from fuel injector.
B2M3140
9) Remove spark plug cords from spark plugs (#2

and #4 cylinders).
B2M3514
12) Remove bolt which holds injector pipe to

intake manifold.
B2M3377
B2M4133
FU(H4)-59
墌 00.5.31/68j/1fu4 墍
FUEL INJECTOR
13) Remove bolt which installs injector pipe to B: INSTALLATION S105051A11

intake manifold.
1. RH SIDE S105051A1101

CAUTION:
Replace O-rings and insulators with new ones.
H2M2994
14) Remove bolt which holds fuel pipe on the left

side intake manifold.
B2M3516A
H2M2995
15) Remove fuel injector from intake manifold.

(1) Remove fuel injector securing clip. (AT B2M3492A
vehicles)
(A) O-ring
(B) Fuel injector
(C) Insulator
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
H2M2997
(2) Remove fuel injector while lifting up fuel

injector pipe.
B2M3507
H2M3241
FU(H4)-60
墌 00.5.31/68j/1fu4 墍
FUEL INJECTOR
Tightening torque: 2. LH SIDE S105051A1102
19 N·m (0.19 kgf-m, 1.4 ft-lb)

CAUTION:
Replace O-rings and insulators with new ones.
B2M4132
Tightening torque:
19 N·m (0.19 kgf-m, 1.4 ft-lb) B2M3516A
B2M3505
B2M3492A
(A) O-ring
(B) Fuel injector
(C) Insulator
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
H2M2994
FU(H4)-61
墌 00.5.31/68j/1fu4 墍
FUEL INJECTOR
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
H2M2995
Tightening torque:
19 N·m (1.9 kgf-m, 13.7 ft-lb)
B2M4133
Tightening torque:
19 N·m (1.9 kgf-m, 13.7 ft-lb)
B2M3513
Tightening torque:
19 N·m (1.9 kgf-m, 13.7 ft-lb)
B2M3511
FU(H4)-62
墌 00.5.31/68j/1fu4 墍
FRONT OXYGEN (A/F) SENSOR
16. Front Oxygen (A/F) Sensor B: INSTALLATION S105642A11
S105642
1) Before installing front oxygen (A/F) sensor,
apply anti-seize compound only to threaded por-
tion of front oxygen (A/F) sensor to make the next
1) Disconnect battery ground cable. removal easier.
Anti-seize compound:
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to protector
of front oxygen (A/F) sensor.
G6M0095
2) Disconnect connector from front oxygen (A/F)

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

Tightening torque:
21±3 N·m (2.1±0.3 kg-m, 15.2±2.2 ft-lb)
B2M3439

4) Apply SUBARU CRC or its equivalent to
threaded portion of front oxygen (A/F) sensor, and
leave it for one minute or more.
5) Remove front oxygen (A/F) sensor. G2M0411
CAUTION: 3) Lower the vehicle.

When removing front oxygen (A/F) sensor, do 4) Connect connector of front oxygen (A/F) sen-
not force front oxygen (A/F) sensor especially sor.
when exhaust pipe is cold, otherwise it will
damage exhaust pipe.
B2M3439
G2M0411
FU(H4)-63
墌 00.5.31/68j/1fu4 墍
FRONT OXYGEN (A/F) SENSOR
G6M0095
FU(H4)-64
墌 00.5.31/68j/1fu4 墍
REAR OXYGEN SENSOR
17. Rear Oxygen Sensor S105657 B: INSTALLATION S105657A11
1) Before installing rear oxygen sensor, apply anti-
seize compound only to threaded portion of rear
1) Disconnect battery ground cable. oxygen sensor to make the next removal easier.
CAUTION:
Never apply anti-seize compound to protector
of rear oxygen sensor.
Anti-seize compound:
SS-30 by JET LUBE
B2M1723
2) Disconnect connector from rear oxygen sensor.
B2M0352A
2) Install rear oxygen sensor.

Tightening torque:
21±3 N·m (2.1±0.3 kg-m, 15.2±2.2 ft-lb)
B2M3440

4) Apply SUBARU CRC or its equivalent to
threaded portion of rear oxygen sensor, and leave
it for one minute or more.
5) Remove rear oxygen sensor.
CAUTION: B2M0351
When removing, do not force rear oxygen sen-
sor in an unnatural way especially when 3) Connect connector to rear oxygen sensor.
exhaust pipe is cold, otherwise it will damage
exhaust pipe.
B2M3440
B2M0351 4) Lower the vehicle.
FU(H4)-65
墌 00.5.31/68j/1fu4 墍
REAR OXYGEN SENSOR
B2M1723
FU(H4)-66
墌 00.5.31/68j/1fu4 墍
ENGINE CONTROL MODULE
18. Engine Control Module S105049

5) Remove nuts which hold ECM to bracket.
B2M3162
6) Remove clip from bracket.
G6M0095
2) Remove lower inner trim of passenger side.

<Ref. to EI-43 REMOVAL, Lower Inner Trim.>
B2M3163
7) Disconnect ECM connectors and take out

ECM.
B2M0672
3) Detach floor mat of front passenger seat.
B2M3155
B2M0673 Install in the reverse order of removal.

4) Remove protect cover. CAUTION:
When replacing ECM, be careful not to use the
wrong spec. ECM to avoid any damage to the
fuel injection system.
B2M3161
FU(H4)-67
墌 00.5.31/68j/1fu4 墍
MAIN RELAY
19. Main Relay S105050
G6M0095
2) Remove lower inner trim of passenger side.

<Ref. to EI-43 REMOVAL, Lower Inner Trim.>
B2M0672
3) Disconnect connectors from main relay.

4) Remove bolt which holds main relay bracket on
body.
B2M3656
FU(H4)-68
墌 00.5.31/68j/1fu4 墍
FUEL PUMP RELAY
20. Fuel Pump Relay S105048
G6M0095
2) Remove lower cover. <Ref. to EI-37

REMOVAL, Instrument Panel Assembly.>
3) Disconnect connector from fuel pump relay.
B2M3159
4) Remove fuel pump relay from mounting

bracket.
FU(H4)-69
FUEL
21. Fuel S105052

4) Remove front right side fuel tank cover.
1. RELEASING OF FUEL PRESSURE

S105052A1601
WARNING:
쐌 Place “NO FIRE” signs near the working
area.
쐌 Be careful not to spill fuel on the floor.
1) Disconnect connector from fuel pump relay.
B2M3173
5) Drain fuel from fuel tank.

Set a container under the vehicle and remove drain
plug from fuel tank.
B2M3159
2) Start the engine and run it until it stalls.

3) After the engine stalls, crank it for five more
seconds.
B2M3174
2. DRAINING FUEL S105052A1602
6) Tighten fuel drain plug and install front right side
WARNING: tank cover.
area. Tightening torque:
쐌 Be careful not to spill fuel on the floor. 26 N·m (2.65 kgf-m, 19.2 ft-lb)
1) Set vehicle on the lift.
B2M3174
G6M0095
FU(H4)-70
墌 00.5.31/68j/1fu4 墍
FUEL
Tightening torque: 11) Remove fuel sub level sensor.

18 N·m (1.8 kgf-m, 13.0 ft-lb)
B2M3178
B2M3173
12) Drain fuel from fuel tank by using hand pump.
7) Lower the vehicle. WARNING:
8) Remove sub service hole cover. Do not use a motor pump when draining fuel.
13) After draining fuel, reinstall fuel sub level sen-
sor.
Tightening torque:
T: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
B2M3175
9) Disconnect connector from fuel sub level sen-

sor.
B2M3178
NOTE:
If you have not removed fuel tank yet, proceed with
the procedure below for installation.
(1) Connect fuel jet pump hose.
B2M3176
10) Disconnect fuel jet pump hose.
B2M3177
B2M3177
FU(H4)-71
墌 00.5.31/68j/1fu4 墍
FUEL
(2) Connect connector from fuel sub level sen-

sor.
B2M3176
(3) Install sub service hole cover.
B2M3175
(4) Set rear seat and floor mat.
FU(H4)-72
墌 00.5.31/68j/1fu4 墍
FUEL TANK
22. Fuel Tank S105053

7) Separate quick connector of fuel delivery (A)
and return hose (B). <Ref. to FU(H4)-98
A: REMOVAL S105053A18 REMOVAL, Fuel Delivery, Return and Evaporation
1) Set vehicle on the lift. Lines.>
OPERATION, Fuel.>
3) Drain fuel from fuel tank. <Ref. to FU(H4)-70
DRAINING FUEL, OPERATION, Fuel.>
4) Remove holder clip which secures fuel tank
cord on bracket.
B2M3180B
8) Remove parking brake cable.

(1) Remove console box console. <Ref. to
EI-36 REMOVAL, Console Box.>
(2) Remove parking brake bracket and discon-
nect parking brake cable from equalizer. <Ref.
to.>
B2M3408
5) Disconnect connector of fuel tank cord to rear

harness.
B2M3181
9) Remove trunk trim. (Sedan model)

<Ref. to EI-51 REMOVAL, Trunk Trim.>
B2M3409 10) Remove rear quarter lower trim. (Wagon
6) Push grommet which holds fuel tank cord on model)
service hole cover into body side. <Ref. to EI-44 WAGON, REMOVAL, Rear Quarter
Trim.>
11) Remove pipe protector.
B2M3179
B2M3665
FU(H4)-73
墌 00.5.31/68j/1fu4 墍
FUEL TANK
12) Separate quick connector of evaporation pipe (2) Remove left and right rubber cushions.
(A). <Ref. to FU(H4)-98 REMOVAL, Fuel Delivery, CAUTION:
Return and Evaporation Lines.> Be careful not to pull down muffler.
B2M3666
B2M3119
13) Remove wheel nuts from rear wheels. (3) Remove front rubber cushion and detach
14) Lift-up the vehicle. muffler assembly.
15) Remove rear wheel.
16) Remove front side fuel tank cover.
B2M3118
B2M3173 18) Remove propeller shaft. <Ref. to DS-13

REMOVAL, Propeller Shaft.>
17) Remove rear exhaust pipe and muffler. 19) Disconnect connector from ABS sensor.
NOTE:
To facilitate removal, apply a coat of SUBARU
CRC to matching area of rubber cushions in
advance.
(1) Separate rear exhaust pipe from center
exhaust pipe.
B2M3184
B2M3109
FU(H4)-74
墌 00.5.31/68j/1fu4 墍
FUEL TANK
20) Remove bolts which hold parking brake cable 24) Remove rear brake caliper, then tie it up to the
holding bracket. body side of the vehicle as shown in figure. (Rear
21) Remove parking brake cable from cabin by disk brake model)
forcibly pulling it backward.
B2M3188
B2M3185
25) Disconnect brake pipes from wheel cylinder.
22) Remove bolts which hold parking brake cable (Rear drum brake model) <Ref. to BR-30
holding bracket. REMOVAL, Rear Drum Brake Shoe.>
B2M3186 B2M3301
23) Remove bolts which hold rear brake hoses 26) Remove rear suspension assembly.
holding bracket. WARNING:
A helper is required to perform this work.
(1) Support rear differential with transmission
jack.
(2) Remove bolt which holds rear shock
absorber to rear suspension arm.
B2M3187
B2M3189
FU(H4)-75
墌 00.5.31/68j/1fu4 墍
FUEL TANK
(3) Remove bolt which secure rear suspension 29) Disconnect air vent hose (A) from evaporation
assembly to body. pipe assembly and disconnect evaporation hose (I)
from pressure control solenoid valve.
B2M3668B
30) Support fuel tank with transmission jack,

remove bolts from bands and dismount fuel tank
from the vehicle.
WARNING:
B2M3190
(4) Remove rear suspension assembly.

27) Remove rear side fuel tank cover.
B2M3194
1) Support fuel tank with transmission jack and

push fuel tank harness into access hole with grom-
met.
B2M3191A
2) Set fuel tank and temporarily tighten bolts of
28) Disconnect fuel filler hose (A) and fuel tank fuel tank bands.
pressure sensor (B) hose. WARNING:
B2M3667B
B2M3194
FU(H4)-76
墌 00.5.31/68j/1fu4 墍
FUEL TANK
3) Connect air vent hose (A) to evaporation pipe 6) Install rear side fuel tank cover.
assembly and connect evaporation hose (I) to Tightening torque:
pressure control solenoid valve. 18 N·m (1.8 kgf-m, 13.0 ft-lb)
B2M3668B
B2M3191A
4) Connect fuel filler hose (A) and fuel tank pres- 7) Install rear suspension assembly.
sure sensor hose (B).
WARNING:
(1) Support rear suspension assembly and
then tighten bolts which secure rear suspension
assembly.
Tightening torque:
T1: 172 N·m (17.5 kgf-m, 127 ft-lb)
T2: 108 N·m (11.0 kgf-m, 80 ft-lb)
T3: 66 N·m (6.7 kgf-m, 48 ft-lb)
B2M3667B
5) Tighten band mounting bolts.

Tightening torque:
33 N·m (3.4 kgf-m, 25 ft-lb)
B2M3194
B2M3190A
FU(H4)-77
墌 00.5.31/68j/1fu4 墍
FUEL TANK
(2) Tighten bolt which holds rear shock 10) Tighten bolts which hold rear brake hoses
absorber to rear suspension arm. <Ref. to holding bracket.
RS-19 INSTALLATION, Link Upper.> Tightening torque:
Tightening torque: 33 N·m (3.4 kgf-m, 25 ft-lb)
157 N·m (16 kgf-m, 116 ft-lb)
B2M3187
B2M3189
11) Install parking brake cable to cabin by forcibly
8) Connect brake pipes to wheel cylinder. (Rear pushing it forward.
drum brake model) <Ref. to BR-36 12) Tighten bolts which hold parking brake cable
INSTALLATION, Rear Drum Brake Assembly.> holding bracket.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
B2M3301
9) Install rear brake caliper. (Rear disk brake

model) <Ref. to BR-27 INSTALLATION, Rear Disc B2M3185
Brake Assembly.>
Tightening torque:
32 N·m (3.3 kgf-m, 23.9 ft-lb)
B2M3196
B2M3186
FU(H4)-78
墌 00.5.31/68j/1fu4 墍
FUEL TANK
13) Connect connector to ABS sensor. (3) Install rear exhaust pipe to center exhaust
pipe.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
B2M3184
14) Install propeller shaft. <Ref. to DS-14

INSTALLATION, Propeller Shaft.>
15) Install rear exhaust pipe and muffler. B2M3109
NOTE: 16) Install front side fuel tank cover.

To facilitate the procedure, apply a coat of Tightening torque:
SUBARU CRC to matching area of rubber cush- 18 N·m (1.8 kgf-m, 13.0 ft-lb)
ions in advance.
(1) Install left and right rubber cushions.
B2M3173
17) Install rear wheel.

B2M3119 19) Tighten wheel nuts to rear wheel.
(2) Install front rubber cushion and attach muf- 20) Install parking brake cable. <Ref. to PB-6
fler assembly. INSTALLATION, Parking Brake Lever.>
B2M3181
B2M3118
FU(H4)-79
墌 00.5.31/68j/1fu4 墍
FUEL TANK
21) Install console box. <Ref. to EI-36 27) Connect fuel jet pump hose.
INSTALLATION, Console Box.>
22) Connect fuel hoses and hold them with quick
connector. <Ref. to FU(H4)-99 INSTALLATION,
Fuel Delivery, Return and Evaporation Lines.>
B2M3177
28) Connect connector to fuel sub level sensor.
B2M3180B
(A) Delivery hose

(B) Return hose
23) Connect evaporation pipe (A) and hold it with

quick connector. <Ref. to FU(H4)-99
INSTALLATION, Fuel Delivery, Return and Evapo-
ration Lines.>
B2M3176
29) Install sub service hole cover.
B2M3666
24) Install pipe protector.

B2M3175
30) Connect connectors to fuel tank cord and plug

service hole with grommet.
B2M3665
25) Install trunk room trim. (Sedan model)

26) Install luggage room trim. (Wagon model)
B2M3409
FU(H4)-80
墌 00.5.31/68j/1fu4 墍
FUEL TANK
31) Install holder clip which secures fuel tank cord

on bracket.
B2M3408
32) Set rear seat and floor mat.

33) Connect connector to fuel pump relay.
B2M3159
34) Bleed air from brake system. (Rear drum

brake model only) <Ref. to BR-53 BRAKE LINE,
PROCEDURE, Air Bleeding.>
35) Adjust parking brake lever stroke. <Ref. to.>
36) Check wheel alignment and adjust if neces-
sary. <Ref. to FS-6 INSPECTION, Wheel Align-
ment.>
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(H4)-81
墌 00.5.31/68j/1fu4 墍
FUEL FILLER PIPE
23. Fuel Filler Pipe S105022

6) Remove rear wheel nuts.
A: REMOVAL S105022A18 7) Remove rear wheel.
WARNING:
area.
B2M1748
8) Remove front right side fuel tank cover.
G6M0095
3) Open fuel filler flap lid and remove filler cap.
B2M3173
9) Drain fuel from fuel tank. Set a container under

the vehicle and remove drain plug from fuel tank.
B2M3197
4) Remove screws holding packing in place.
B2M3174
B2M3363
FU(H4)-82
墌 00.5.31/68j/1fu4 墍
FUEL FILLER PIPE
10) Tighten fuel drain plug and then install front (2) Remove left and right rubber cushions.
right side tank cover. CAUTION:
Tightening torque: Be careful not to pull down muffler.
26 N·m (2.65 kgf-m, 19.2 ft-lb)
B2M3119
B2M3174
(3) Remove front rubber cushion and detach
Tightening torque: muffler assembly.
18 N·m (1.8 kgf-m, 13.0 ft-lb)
B2M3118
B2M3173 12) Remove heat sealed cover.

NOTE:
To facilitate removal, apply a coat of SUBARU
CRC to matching area of rubber cushions in
advance.
(1) Separate rear exhaust pipe from center
exhaust pipe.
B2M3681
13) Place transmission jack under sub frame.
B2M3109
B2M3691
FU(H4)-83
墌 00.5.31/68j/1fu4 墍
FUEL FILLER PIPE
14) Remove bolt which holds rear shock absorber 17) Remove fuel filler pipe protector.
to rear suspension arm.
B2M3198
B2M3189
18) Disconnect air vent hose (A) and evaporation
15) Remove bolts which hold rear sub frame on hose (H) from evaporation pipe assembly.
body. 19) Disconnect evaporation hose (I) from pressure
B2M3682B
20) Remove bolt which holds evaporation pipe

assembly on body.
B2M3692
16) Lower the rear sub frame.

CAUTION:
B2M3669
Be sure to lower sub frame slowly.
A = 150 mm (5.91 in)
B2M3693A
FU(H4)-84
墌 00.5.31/68j/1fu4 墍
FUEL FILLER PIPE
21) Disconnect fuel filler hose. 26) Remove fuel filler pipe to under side of the
22) Remove bolt which holds fuel pressure sensor vehicle.
on fuel filler pipe and remove bolt which holds fuel
filler pipe on body. B: INSTALLATION S105022A11
1) Hold fuel filler flap open.

2) Set fuel saucer (A) with rubber packing (C) and
insert fuel filler pipe into hole from the inner side of
apron.
B2M3670
23) Disconnect canister hose from evaporation

pipe assembly.
B2M1196A
3) Align holes in fuel filler pipe neck and set cup

(B), and tighten screws.
NOTE:
If edges of rubber packing are folded toward the
inside, straighten it with a screwdriver.
B2M3671
24) Disconnect evaporation hose (O) from fuel

filler pipe.
B2M1196A
4) Tighten bolt which holds fuel filler pipe on body.

Tightening torque:
7.5 N·m (0.75 kgf-m, 5.4 ft-lb)
B2M3673
25) Remove bolt which holds fuel filler pipe to

body.
B2M3674
B2M3674
FU(H4)-85
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FUEL FILLER PIPE
5) Insert evaporation hose (O) approximately 25 L = 27.5±2.5 mm (1.083±0.098 in)

to 30 mm (0.98 to 1.18 in) into the lower end of
evaporation pipe and hold clip.
B2M1195A
(1) Hose
B2M3673
(2) Clip
(3) Pipe
L = 27.5±2.5 mm (1.083±0.098 in)
7) Tighten bolt which holds evaporation pipe
assembly on body.
Tightening torque:
7.5 N·m (0.75 kgf-m, 5.4 ft-lb)
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
B2M3669
6) Insert canister hoses approximately 25 to 30
mm (0.98 to 1.18 in) into the lower end of evapo- 8) Insert air vent hose (A), evaporation hose (H)
ration pipe assembly and tighten clamp. approximately 25 to 30 mm (0.98 to 1.18 in) into
the lower end of evaporation pipe assembly and
hold clip.
9) Insert evaporation hose (I) to pressure control
solenoid valve and hold clip.
B2M3671
B2M3682B
FU(H4)-86
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FUEL FILLER PIPE
L = 27.5±2.5 mm (1.083±0.098 in) 12) Jack-up the rear sub frame and tighten bolts
which hold rear sub frame on body.
Tightening torque:
T1: 66 N·m (6.7 kgf-m, 48.5 ft-lb)
T2: 172 N·m (17.5 kgf-m, 127 ft-lb)
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
10) Tighten bolt which holds fuel filler pipe on body

and tighten bolt which holds fuel pressure sensor
on fuel filler pipe.
Tightening torque:
7.5 N·m (0.75 kgf-m, 5.4 ft-lb)
11) Insert fuel filler hose approximately 35 to 40
mm (1.38 to 1.57 in) over the lower end of fuel filler
pipe and tighten clamp.
B2M3694A
13) Tighten bolt which holds rear shock absorber

to rear suspension arm. <Ref. to RS-22
INSTALLATION, Rear Shock Absorber.>
Tightening torque:
157 N·m (16 kgf-m, 116 ft-lb)
B2M3670
B2M3189
FU(H4)-87
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FUEL FILLER PIPE
14) Install heat shield cover. (3) Install rear exhaust pipe to center exhaust
pipe.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
B2M3681
15) Install rear exhaust pipe and muffler.

NOTE: B2M3109
To facilitate the procedure, apply a coat of
SUBARU CRC to matching area of rubber cush- 16) Install fuel filler pipe protector.
ions in advance.
(1) Install left and right rubber cushions.
B2M3198
17) Install rear right wheel.
B2M3119
(2) Install front rubber cushion and attach muf-

fler assembly.
B2M1748

19) Tighten wheel nuts.
20) Connect battery ground terminal.
B2M3118
G6M0095
FU(H4)-88
墌 00.5.31/68j/1fu4 墍
FUEL FILLER PIPE
21) Remove fuel filler pipe to under side of the D: ASSEMBLY S105022A02
vehicle.
1) Disconnect evaporation hose (M) and (N) from

evaporation pipe assembly.
B2M3683A
2) Remove shut valve from fuel filler pipe.
B2M3684
3) Remove nut which holds evaporation pipe

assembly on fuel filler pipe.
B2M3685
FU(H4)-89
墌 00.5.31/68j/1fu4 墍
FUEL PUMP
24. Fuel Pump S105025

WARNING:
area.
쐌 During work procedures, if fuel tank is more
NOTE:
Fuel pump assembly consists of fuel pump and
fuel level sensor. B2M3174

fuel tank cover.
OPERATION, Fuel.>
2) Open fuel filler flap lid and remove fuel filler Tightening torque:
cap. 26 N·m (2.65 kgf-m, 19.2 ft-lb)
B2M3197 B2M3174
3) Disconnect battery ground cable. Tightening torque:

18 N·m (1.8 kgf-m, 13.0 ft-lb)
G6M0095
4) Lift-up the vehicle. B2M3173

8) Raise rear seat and turn floor mat up.
B2M3173
FU(H4)-90
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FUEL PUMP
9) Remove access hole lid. 14) Take off fuel pump assembly from fuel tank.
Install in the reverse order of removal. Do the fol-

lowing:
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or for-
eign particles before installation.
(3) Tighten nuts in alphabetical sequence shown
in figure to specified torque.
5.9 N·m (0.6 kgf-m, 4.3 ft-lb)
B2M3307B
B2M3303
11) Move clips and then disconnect jet pump hose

(C).
12) Disconnect quick connector and then discon- 1) Remove fuel pump and pump holder.
nect fuel delivery hose (A) and return hose (B).
NOTE:
<Ref. to FU(H4)-98 REMOVAL, Fuel Delivery,
When disassembling pump holder, be careful as it
Return and Evaporation Lines.>
is installed with two pawls.
B2M3304A
B2M3675
13) Remove nuts which install fuel pump assem-
bly onto fuel tank. 2) Disconnect connector from fuel pump.
B2M3305 B2M3676
FU(H4)-91
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FUEL PUMP
Connect lead harness to connector terminal of fuel

pump and apply battery power supply to check
whether the pump operate.
WARNING:
쐌 Wipe off the fuel completely.
쐌 Keep battery as far apart from fuel pump as
possible.
쐌 Be sure to turn the battery supply ON and
OFF on the battery side.
쐌 Do not run fuel pump for a long time under
non-load condition.
B2M3677
FU(H4)-92
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FUEL LEVEL SENSOR
25. Fuel Level Sensor S105026 B: INSTALLATION S105026A11
WARNING: WARNING:
쐌 Place “NO FIRE” signs near the working 쐌 Ground cable must be connnected.
area. 쐌 Spark may occur and ignite if fuel is nearby.
NOTE:
Fuel level sensor is built in fuel pump assembly.
FU(H4)-90 REMOVAL, Fuel Pump.>
2) Disconnect connector from fuel pump bracket.
B2M3738
B2M3521
3) Pushing the pawls with a screwdriver, remove

fuel meter unit by pulling it downwards.
NOTE:
Replace fuel filter pawls with new ones as they
might brake when removed.
B2M3522
FU(H4)-93
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FUEL SUB LEVEL SENSOR
26. Fuel Sub Level Sensor S105023

fuel tank cover.
Tightening torque:
WARNING: 26 N·m (2.65 kgf-m, 19.2 ft-lb)
area.
B2M3174
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
G6M0095

B2M3173
6) Raise rear seat and turn floor mat up. (Wagon

model)
7) Remove rear seat. (Sedan model)
8) Remove service hole cover.
B2M3173

B2M3175
B2M3174
FU(H4)-94
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FUEL SUB LEVEL SENSOR
9) Disconnect connector from fuel sub level sen- B: INSTALLATION S105023A11

sor.
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
B2M3176
10) Disconnect fuel jet pump hose.

B2M3178
B2M3177
11) Remove bolts which install fuel sub level sen-

sor on fuel tank.
B2M3178
12) Remove fuel sub level sensor.
FU(H4)-95
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FUEL FILTER
27. Fuel Filter S105027
WARNING:
area.
OPERATION, Fuel.>
2) Disconnect fuel delivery hoses from fuel filter.
S2M0195
3) Remove filter from holder.
CAUTION:
쐌 If fuel hoses are damaged at the connecting
portion, replace it with a new one.
쐌 If clamps are badly damaged, replace with
new ones.
2) Tighten hose clamp screws.
Tightening torque:
1.0 N·m (0.1 kgf-m, 0.7 ft-lb)
S2M0195
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(H4)-96
FUEL CUT VALVE
28. Fuel Cut Valve S105021
1) Remove fuel tank. <Ref. to FU(H4)-73

2) Move clip and disconnect evaporation hose
from fuel cut valve.
B2M3678
3) Remove bolts which install fuel cut valve.

Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
B2M3679
FU(H4)-97
FUEL DELIVERY, RETURN AND EVAPORATION LINES
29. Fuel Delivery, Return and 4) Remove fuel tank. <Ref. to FU(H4)-73
Evaporation Lines S105019
5) Remove fuel filler pipe. <Ref. to FU(H4)-82
REMOVAL, Fuel Filler Pipe.>
6) Remove floor mat. <Ref. to EI-53 REMOVAL,
1) Set vehicle on the lift. Floor Mat.>
2) Release fuel pressure. <Ref. to FU(H4)-70 7) Remove fuel delivery pipes and hoses, fuel
RELEASING OF FUEL PRESSURE, return pipes and hoses, evaporation pipes and
OPERATION, Fuel.> hoses.
3) Open fuel filler flap lid and remove fuel filler
cap.
B2M3425
FU(H4)-98
墌 00.5.31/68j/1fu4 墍
8) In engine compartment, detach fuel delivery B: INSTALLATION S105019A11
hoses, return hoses and evaporation hose.

1) Connect quick connector on fuel delivery and
return line.
CAUTION:
쐌 Always use a new retainer.
쐌 Make sure that the connected portion is not
damaged or has dust. If necessary, clean seal
surface of pipe.
S2M0195
9) Separate quick connector on fuel delivery,

return line and evaporation line.
(1) Clean pipe and connector, if they are cov-
ered with dust.
(2) Hold connector (A) and push retainer (B)
down. S2M0229A
(3) Pull out connector (A) from retainer (B).
CAUTION: (1) Set new retainer (B) to connector (A).
Replace retainer with new ones. (2) Push pipe into connector completely.
NOTE:
At this time, two clicking sounds are heard.
S2M0228A
(A) Connector
(B) Retainer S2M0230A
(C) Pipe
(A) Connector
(B) Retainer
(C) Pipe
FU(H4)-99
墌 00.5.31/68j/1fu4 墍
CAUTION: 3) Connect evaporation hose to pipe by approx.

쐌 Pull the connector to ensure it is connected 15 mm (0.59 in) from hose end.
securely. L = 17.5±2.5 mm (0.689±0.098 in)
쐌 Ensure the two retainer pawls are engaged in
their mating positions in the connector. CAUTION:
쐌 Be sure to inspect hoses and their connec- Be sure to inspect hoses and their connections
tions for any leakage of fuel. for any leakage of fuel.
B2M1195A
S2M0231A
(1) Hose
(A) Connector
(2) Clip
(B) Retainer
(3) Pipe
(C) Pipe
2) Connect fuel delivery hose to pipe with an over- C: INSPECTION S105019A10
lap of 20 to 25 mm (0.79 to 0.98 in). 1) Make sure that there are no cracks on the fuel
Type A: When fitting length is specified. pipes and fuel hoses.
Type B: When fitting length is not specified. 2) Make sure that the fuel pipe and fuel hose con-
nections are tight.
: 2.5±1.5 mm (0.098±0.059 in)
L: 22.5±2.5 mm (0.886±0.098 in)
B2M1194B
(1) Fitting
(2) Clamp
(3) Hose
FU(H4)-100
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FUEL SYSTEM TROUBLE IN GENERAL
30. Fuel System Trouble in

General S105571

1. Insufficient fuel supply to the injector
1) Fuel pump will not operate.
Inspect connections, especially ground, and tighten
쎻 Defective terminal contact.
securely.
쎻 Trouble in electromagnetic or electronic circuit parts. Replace fuel pump.
2) Lowering of fuel pump function. Replace fuel pump.
3) Clogged dust or water in the fuel filter. Replace fuel filter, clean or replace fuel tank.
4) Clogged or bent fuel pipe or hose. Clean, correct or replace fuel pipe or hose.
5) Air is mixed in the fuel system. Inspect or retighten each connection part.
6) Clogged or bent breather tube or pipe. Clean, correct or replace air breather tube or pipe.
7) Damaged diaphragm of pressure regulator. Replace.
2. Leakage or blow out fuel
1) Loosened joints of the fuel pipe. Retightening.
2) Cracked fuel pipe, hose and fuel tank. Replace.
3) Defective welding part on the fuel tank. Replace.
4) Defective drain packing of the fuel tank. Replace.
Clean, correct or replace air breather tube or air vent
5) Clogged or bent air breather tube or air vent tube.
tube.
3. Gasoline smell inside of compartment
Loose joints at air breather tube, air vent tube and fuel
1) Retightening.
filler pipe.
2) Defective packing air tightness on the fuel saucer. Correct or replace packing.
3) Cracked fuel separator. Replace separator.
4) Inoperative fuel pump modulator or circuit. Replace.
4. Defective fuel meter indicator
1) Defective operation of fuel meter unit. Replace.
2) Defective operation of fuel meter. Replace.
5. Noise
1) Large operation noise or vibration of fuel pump. Replace.
NOTE: ing system. Refueling will also complement the

쐌 When the vehicle is left unattended for an effect of anti-freeze solution each time the fuel
extended period of time, water may accumulate in level drops to about one-half. After the winter
the fuel tank. season, drain water which may have accumu-
To prevent water condensation. lated in the fuel filter and fuel tank in the man-
(1) Top off the fuel tank or drain the fuel com- ner same as that described under Affected
pletely. areas below.
(2) Drain water condensation from the fuel fil- (2) Affected areas
ter. When water condensation is notched in the fuel
쐌 Refilling the fuel tank. filter, drain water from both the fuel filter and fuel
Refill the fuel tank while there is still some fuel left tank or use a water removing agent (or anti-
freeze solution) in the fuel tank.
in the tank.
쐌 Observe the instructions, notes, etc., indicated
쐌 Protecting the fuel system against freezing and
on the label affixed to the anti-freeze solution
water condensation.
(water removing agent) container before use.
(1) Cold areas
In snow-covered areas, mountainous areas,
skiing areas, etc. where ambient temperatures
drop below 0°C (32°F) throughout the winter
season, use an anti-freeze solution in the cool-
FU(H4)-101
FUEL SYSTEM TROUBLE IN GENERAL
MEMO:
FU(H4)-102
GENERAL DESCRIPTION
Ignition
Item Designation
Model FH0137
Manufacturer DEMCO
Ignition coil
Primary coil resistance 0.73 Ω±10%
and ignitor
assembly Secondary coil resistance 12.8 kΩ±15%
Insulation resistance between primary
More than 10 MΩ
terminal and case
RC10YC4 .......... CHAMPION
Type and manufacturer RC8YC4 .......... CHAMPION
Alternate BKR6E-11 .......... NGK
Spark plug
K20PR-U11 .......... NIPPONDENSO
Thread size mm 14, P = 1.25
Spark gap mm (in) 1.0 — 1.1 (0.039 — 0.043)
IG(H4)-2
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GENERAL DESCRIPTION
Ignition
B: CONPONENT S101001A05
S6M0329B
(1) Spark plug (4) Spark plug cord (#2, #4) Tightening torque: N·m (kgf-m, ft-lb)
(2) Spark plug cord (#1, #3)
T1: 20.6 (2.10, 15.2)
(3) Ignition coil and ignitor ASSY
T2: 6.4 (0.65, 4.7)
C: CAUTION S101001A03 removal, installation, disassembly, and replace-

ment.
쐌 Wear working clothing, including a cap, protec- 쐌 Be careful not to burn your hands, because each
tive goggles, and protective shoes during opera- part on the vehicle is hot after running.
tion. 쐌 Be sure to tighten fasteners including bolts and
쐌 Remove contamination including dirt and corro- nuts to the specified torque.
sion before removal, installation or disassembly. 쐌 Place shop jacks or safety stands at the speci-
쐌 Keep the disassembled parts in order and pro- fied points.
tect them from dust or dirt. 쐌 Before disconnecting electrical connectors of
쐌 Before removal, installation or disassembly, be sensors or units, be sure to disconnect negative
sure to clarify the failure. Avoid unnecessary terminal from battery.
IG(H4)-3
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SPARK PLUG
Ignition
2. Spark Plug S101003

(3) Remove air intake duct as a unit.
CAUTION:
All spark plugs installed on an engine, must be
of the same heat range.
Spark plug:
CHAMPION: RC10YC4
(Alternate)
CHAMPION: RC8YC4
NGK: BKR6E-11 B6M1224
NIPPONDENSO: K20PR-U11
1. RH SIDE S101003A1805
B6M1303
3) Remove spark plug cords by pulling boot, not

G6M0095 cord itself.
2) Remove air intake duct and resonator chamber.
(1) Remove bolt which installs air intake duct
on the front side of body.
B6M1238
4) Remove spark plugs with the spark plug socket.
B6M1222
(2) Remove bolt which installs air intake duct

on body.
B6M1239
B6M1302
IG(H4)-4
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SPARK PLUG
Ignition
2. LH SIDE S101003A1806 5) Remove spark plugs cord by pulling boot, not

cord itself.
B6M1244
G6M0095
6) Remove spark plug with the spark plugs socket.
2) Disconnect washer motor connector.
B6M1245
B6M0562B
3) Disconnect rear window glass washer hose B: INSTALLATION S101003A11
from washer motor, then plug connection with a

suitable cap.
1. RH SIDE S101003A1105
4) Remove the two bolts which hold the washer 1) Install in the reverse order of removal.
tank, then take the tank away from the working Tightening torque (Spark plug):
area. 20.6 N·m (2.10 kgf-m, 15.2 ft-lb)
CAUTION:
The above torque should be only applied to
new spark plugs without oil on their threads.
In case their threads are lubricated, the torque
should be reduced by approximately 1/3 of the
specified torque in order to avoid over-stress-
ing.
2. LH SIDE S101003A1106

B2M2023
Tightening torque (Spark plug):
20.6 N·m (2.10 kgf-m, 15.2 ft-lb)
CAUTION:
The above torque should be only applied to
new spark plugs without oil on their threads.
In case their threads are lubricated, the torque
should be reduced by approximately 1/3 of the
specified torque in order to avoid over-stress-
ing.
IG(H4)-5
墌 00.5.31/68j/1ig4 墍
SPARK PLUG
Ignition
C: INSPECTION S101003A10 3) Oil fouled

Wet black deposits show excessive oil entrance
Check electrodes and inner and outer porcelain of into combustion chamber through worn rings and
plugs, noting the type of deposits and the degree pistons or excessive clearance between valve
of electrode erosion. guides and stems. If same condition remains after
repair, use a hotter plug.
G6M0086
G6M0089
1) Normal
Brown to grayish-tan deposits and slight electrode 4) Overheating
wear indicate correct spark plug heat range. White or light gray insulator with black or gray
brown spots and bluish burnt electrodes indicate
engine overheating. Moreover, the appearance
results from incorrect ignition timing, loose spark
plugs, wrong selection of fuel, hotter range plug,
etc. It is advisable to replace with plugs having
colder heat range.
G6M0087
2) Carbon fouled
Dry fluffy carbon deposits on insulator and elec-
trode are mostly caused by slow speed driving in
city, weak ignition, too rich fuel mixture, dirty air
cleaner, etc. G6M0090
It is advisable to replace with plugs having hotter
heat range.
D: CLEANING S101003E56
Clean spark plugs in a sand blast type cleaner.

Avoid excessive blasting. Clean and remove car-
bon or oxide deposits, but do not wear away por-
celain.
If deposits are too stubborn, replace plugs.
G6M0088
IG(H4)-6
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SPARK PLUG
Ignition
Correct it if the spark plug gap is measured with a

gap gauge, and it is necessary.
Spark plug gap: L
1.0 — 1.1 mm (0.039 — 0.043 in)
G6M0091
IG(H4)-7
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IGNITION COIL AND IGNITOR ASSEMBLY
Ignition
3. Ignition Coil and Ignitor 4) Remove ignition coil and ignitor assembly.
Assembly S101015
B6M0930

G6M0095
Tightening torque:
2) Disconnect spark plug cords from ignition coil 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
and ignitor assembly. CAUTION:
Be sure to connect wires to their proper posi-
tions. Failure to do so will damage unit.
S6M0373
3) Disconnect connector from ignition coil and B6M0930

ignitor assembly.
B6M0932
IG(H4)-8
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IGNITION COIL AND IGNITOR ASSEMBLY
Ignition
Using accurate tester, inspect the following items,

and replace if defective.
1) Primary resistance
2) Secondary coil resistance
CAUTION:
If the resistance is extremely low, this indicates
the presence of a short-circuit.
Specified resistance:
[Primary side]
Between terminal No. 1 and No. 2
0.73 Ω±10%
Between terminal No. 2 and No. 4
0.73 Ω±10%
B6M0931C
[Secondary side]
Between (A) and (B)
12.8 kΩ±15%
Between (C) and (D)
12.8 kΩ±15%
B6M0773G
3) Insulation between primary terminal and case:

10 MΩ or more.
IG(H4)-9
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SPARK PLUG CORD
Ignition
4. Spark Plug Cord S101014
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(H4)-10
GENERAL DESCRIPTION
Intake (Induction)
B2M3456A
IN(H4)-2
墌 00.5.31/68j/1in4 墍
GENERAL DESCRIPTION
Intake (Induction)
(1) Spacer (12) Air cleaner case stay LH (MT Tightening torque: N·m (kgf-m, ft-lb)
(2) Bush vehicles)
T1: 32.3 (3.3, 23.9)
(3) Resonator chamber (13) Air cleaner case stay LH (AT
T2: 6.4 (0.65 4.7)
(4) Cushion rubber vehicles)
T3: 7.5 (0.76, 5.5)
(5) Air intake duct A (14) Air cleaner case stay RH
(6) Air intake duct B (15) Engine harness bracket T4: 16 (1.6, 11.6)
(7) Cushion (16) Clamp T5: 2.5 (0.25, 1.8)
(8) Air cleaner case A (17) Bush T6: 2.9 (0.3, 2.2)
(9) Clip (18) Spacer
(10) Air cleaner element (19) Intake air temperature sensor
(11) Air cleaner case B (20) Rubber bush
IN(H4)-3
墌 00.5.31/68j/1in4 墍
GENERAL DESCRIPTION
Intake (Induction)

tion.
ment.
fied points.
sensor or units, be sure to disconnect negative
IN(H4)-4
墌 00.5.31/68j/1in4 墍
AIR CLEANER
Intake (Induction)
2. Air Cleaner S104087
1) Remove bolt (A) which install air cleaner case

to stays.
2) Remove the clip (B) above the air cleaner case.
H2M2947A
3) Remove air cleaner.

CAUTION:
Fasten with a clip after inserting the lower tab
of the case.
Replace if excessively damaged or dirty.
IN(H4)-5
AIR CLEANER CASE
Intake (Induction)
3. Air Cleaner Case S104089

4) Disconnect hoses from air cleaner case.
5) Remove bolts which install air cleaner case to
A: REMOVAL S104089A18 stays.
H2M2947
G6M0095 6) Remove air cleaner case.

2) Disconnect connector from intake air tempera- B: INSTALLATION S10489A11
ture sensor. (MT vehicles)
Inspect for cracks and loose connections.
B2M2285
3) Loosen clamp which connects air cleaner case

to throttle body.
H2M2946
IN(H4)-6
墌 00.5.31/68j/1in4 墍
AIR INTAKE DUCT
Intake (Induction)
4. Air Intake Duct S104566
1) Remove bolts which install air intake duct on

the front side of body.
B6M1222
2) Remove bolt which installs air intake duct on

body.
B6M1302
3) Remove air intake ducts as a unit.
B6M1224
Inspect for cracks and loose connections. Check

that no foreign objects are mixed in the air intake
duct.
IN(H4)-7
墌 00.5.31/68j/1in4 墍
RESONATOR CHAMBER
Intake (Induction)
5. Resonator Chamber S104639 B: INSTALLATION S104639A11
1) Remove air intake duct. <Ref. to IN(H4)-7 Tightening torque:
REMOVAL, Air Intake Duct.> 33 N·m (3.4 kgf-m, 24.6 ft-lb)
2) Remove resonator chamber.
B6M1237
B6M1237
Inspect for cracks and loose connections.
IN(H4)-8
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GENERAL DESCRIPTION
Lubrication
Lubrication method Forced lubrication

Pump type Trochoid type
Inner rotor 9
Number of teeth
Outer rotor 10
Outer rotor diameter × thickness 78 × 9 mm (3.07 × 0.35 in)
STANDARD 0.04 — 0.14 mm (0.0016 — 0.0055 in)
Tip clearance between inner and outer rotor
LIMIT 0.18 mm (0.0071 in)
Side clearance between inner rotor and pump STANDARD 0.02 — 0.07 mm (0.0008 — 0.0028 in)
Oil pump case LIMIT 0.12 mm (0.0047 in)
Case clearance between outer rotor and pump STANDARD 0.10 — 0.175 mm (0.0039 — 0.0069 in)
case LIMIT 0.20 mm (0.0079 in)
- pressure 98 kPa (1.0 kg/cm2, 14 psi)
700 rpm Discharge
Capacity at - quantity 4.2 (4.4 US qt, 3.7 Imp qt)/min.
80°C (176°F) - pressure 294 kPa (3.0 kg/cm2, 43 psi)
5,000 rpm Discharge
- quantity 42.0 (11.10 US gal, 9.24 Imp gal)/min.
Relief valve operation pressure 490 kPa (5.0 kg/cm2, 71 psi)
Type Full-flow filter type
Filtration area 1,000 cm2 (155 sq in)
Oil filter By-pass valve opening pressure 157 kPa (1.6 kg/cm2, 23 psi)
Outer diameter × width 80 × 70 mm (3.15 × 2.76 in)
Oil filter to engine thread size M 20 × 1.5
Relief valve (on rocker shaft) operation pressure 69 kPa (0.7kg/cm2, 10 psi)
Type Immersed contact point type
Oil pressure Working voltage — wattage 12 V — 3.4 W or less
switch Warning light activation pressure 14.7 kPa (0.15 kg/cm2, 2.1 psi)
Proof pressure More than 981 kPa (10 kg/cm2, 142 psi)
Oil capacity (at replacement) 4.0 (4.2 US qt, 3.5 Imp qt)
LU(H4)-2
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GENERAL DESCRIPTION
Lubrication
B2M2235D
(1) Plug (14) Oil filler duct (27) Gasket

(2) Washer (15) O-ring
(3) Relief valve spring (16) Oil filler cap Tightening torque: N·m (kgf-m, ft-lb)
(4) Relief valve (17) O-ring T1: 5 (0.5, 3.6)
(5) Oil seal (18) Baffle plate T2: 5 (0.5, 3.6)
(6) Oil pump case (19) O-ring T3: 6.4 (0.65, 4.7)
(7) Inner rotor (20) Oil strainer T4: 10 (1.0, 7.2)
(8) Outer rotor (21) Oil level gauge guide T5: 44.1 (4.5, 32.5)
(9) Oil pump cover (22) O-ring
T6: 6.4 (0.65, 4.7)
(10) Oil filter (23) Oil pan
T7: 25 (2.5, 18.1)
(11) O-ring (24) Oil level gauge
T8: 44 (4.5, 33)
(12) Oil pump ASSY (25) Drain plug
(13) Oil pressure switch (26) Metal gasket
LU(H4)-3
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GENERAL DESCRIPTION
Lubrication

tion.
removal, installation, disassembly, and replace- D: PREPARATION TOOL S108001A17
ment.

499977100 CRANK PULLEY Used for stopping rotation of crankshaft pulley
WRENCH when loosening and tightening crankshaft pulley
bolt.
B2M3870
498547000 OIL FILTER Used for removing and installing oil filter.
WRENCH
B2M3872
499587100 OIL SEAL Used for installing oil pump oil seal.
INSTALLER
B2M3875
LU(H4)-4
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OIL PRESSURE SYSTEM
Lubrication
2. Oil Pressure System S108076 A: SCHEMATIC S108076A21
LU(H4)-5 B2M4136
墌 00.5.31/68j/1lu4 墍
OIL PRESSURE SYSTEM
Lubrication

1 CHECK COMBINATION METER. Does the warning lights go Go to step 2. Repair or replace
1) Turn ignition switch to ON. (engine OFF) on? the combination
2) Check other warning lights. meter. <Ref. to
IDI-10
INSPECTION,
Combination
Meter System.>
2 CHECK HARNESS CONNECTOR Is the voltage more than 10 Replace oil pres- Go to step 3.
BETWEEN COMBINATION METER AND OIL V? sure switch.
PRESSURE SWITCH.
2) Disconnect connector from the oil pressure
switch.
4) Measure the voltage of harness between
the combination meter connector and chassis
ground.
(E11) No. 1 — Chassis ground:
3 CHECK COMBINATION METER. Is the resistance less than Replace the har- Repair or replace
1) Turn ignition switch to OFF. 10 Ω? ness connector the combination
2) Remove the combination meter. between combina- meter and the oil
3) Measure the resistance of the combination tion meter and oil pressure switch
meter. pressure switch. warning light bulb.
Terminal
No. C13 — No. C3:
LU(H4)-6
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ENGINE OIL
Lubrication
3. Engine Oil S108077

2) Open engine oil filler cap for quick draining of
the engine oil.
1) Park vehicle on a level surface.

2) Remove oil level gauge and wipe it clean.
3) Reinsert the level gauge all the way. Be sure
that the level gauge is correctly inserted and in the
proper orientation.
4) Remove it again and note the reading. If the
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
B2M3883A
for the oil to drain back into the oil pan before
checking the level. 3) Replace drain plug gasket.
6) Just after driving or while the engine is warm, 4) Tighten engine oil drain plug after draining
engine oil level may show in the range between the engine oil.
“F” line and the notch mark. This is caused by
thermal expansion of the engine oil. Tightening torque:
7) To prevent overfilling the engine oil, do not add 44 N·m (4.5 kgf-m, 33 ft-lb)
oil above the “F” line when the engine is cold.
B2M3884
B2M3883A
5) Fill engine oil through filler pipe up to upper
point on level gauge. Make sure that vehicle is
B: REPLACEMENT S108077A20
placed level when checking oil level. Use engine oil
of proper quality and viscosity, selected in accor-
1) Drain engine oil by loosening engine oil drain dance with the table in figure.
plug.
Recommended oil
API classification
SJ or SH with the words “Energy Con-
serving or Energy conserving II”, CCMC
specification G4 or G5, ACEA specifica-
tion A1, A2 or A3, or New API mark dis-
played on the container (If it is impos-
sible to get SJ or SH grade, you may use
SG grade.)
Engine oil capacity:
B2M3884 Upper level
4.0 (4.2 US qt, 3.5 Imp qt)
Lower level
3.0 (3.2 US qt, 2.6 Imp qt)
LU(H4)-7
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ENGINE OIL
Lubrication
B2M3885A
The proper viscosity helps vehicle get good cold

and hot starting by reducing viscous friction and
thus increasing cranking speed.
CAUTION:
When replenishing oil, it does not matter if the
oil to be added is a different brand from that in
the engine; however, use oil having the API
classification and SAE viscosity No. desig-
nated by SUBARU.
NOTE:
If vehicle is used in desert areas with very high
temperatures or for other heavy duty applications,
the following viscosity oils may be used: API clas-
sification: SJ or SH
SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W-
50.
6) Close engine oil filler cap.
7) Start engine and warm it up for a time.
8) After engine stops, recheck the oil level. If
necessary, add engine oil up to upper level on level
gauge.
B2M3883A
LU(H4)-8
墌 00.5.31/68j/1lu4 墍
OIL PUMP
Lubrication
4. Oil Pump S108070

6) Remove radiator. <Ref. to CO(H4)-15
A: REMOVAL S108070A18 REMOVAL, Radiator.>
B2M2933
G6M0095 7) Remove crankshaft position sensor.

B2M1252
8) Remove V-belts. <Ref. to ME(H4)-43

B2M2920 REMOVAL, V-belt.>
4) Drain coolant. <Ref. to CO(H4)-6 DRAINING
OF ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
G2M0286
9) Remove rear side V-belt tensioner.
B2M2921
S2M0113
LU(H4)-9
墌 00.5.31/68j/1lu4 墍
OIL PUMP
Lubrication
10) Remove crankshaft pulley by using ST. 14) Remove bolts which install oil pump onto cyl-
ST 499977100 CRANKSHAFT PULLEY inder block.
WRENCH
S2M0117
S2M0114
15) Remove oil pump by using flat bladed screw-
11) Remove water pump. <Ref. to CO(H4)-8 driver.
REMOVAL, Water Pump.> CAUTION:
Be careful not to scratch mating surfaces of
cylinder block and oil pump.
S2M0022
12) Remove timing belt guide. (MT vehicles only)

G2M0071

Do the following:
1) Apply fluid packing to matching surfaces of oil
pump.
Fluid packing:
S2M0115
13) Remove crankshaft sprocket.
S2M0739A
2) Replace O-ring with a new one.

S2M0116
LU(H4)-10
墌 00.5.31/68j/1lu4 墍
OIL PUMP
Lubrication
3) Apply a coat of engine oil to the inside of the oil C: DISASSEMBLY S108070A06
seal.
Remove screws which secure oil pump cover and
disassemble oil pump. Inscribe alignment marks
on inner and outer rotors so that they can be
replaced in their original positions during reassem-
bly.
CAUTION:
Before removing relief valve, loosen plug when
removing oil pump from cylinder block.
S2M0118A
4) Be careful not to scratch oil seal when installing

oil pump on cylinder block.
5) Position the oil pump, aligning the notched area
with the crankshaft, and push the oil pump straight.
CAUTION:
Make sure the oil seal lip is not folded.
6) Install oil pump.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
S2M0735A
(A) Oil seal

S2M0740A
(B) Pump case
(C) Inner rotor
(D) Outer rotor
(E) Pump cover
(F) Relief valve
(G) Relief spring
(H) Plug
(I) Washer
LU(H4)-11
墌 00.5.31/68j/1lu4 墍
OIL PUMP
Lubrication
D: ASSEMBLY S108070A02 E: INSPECTION S108070A10
1) Install front oil seal by using ST. 1. TIP CLEARANCE S108070A1001

Measure the tip clearance of rotors. If the clear-
CAUTION: ance exceeds the limit, replace rotors as a
Use a new oil seal. matched set.
Tip clearance:
Standard
0.04 — 0.14 mm (0.0016 — 0.0055 in)
Limit
0.18 mm (0.0071 in)
S2M0235A
2) Apply a coat of engine oil to inner and outer

rotors.
3) Install inner and outer rotors in their original
positions.
4) Install oil relief valve and relief spring. S2M0736A
5) Install oil pump cover.
Tightening torque: 2. CASE CLEARANCE S108070A1002
T1: 5 N·m (0.5 kgf-m, 3.6 ft-lb)
T2: 44.1 N·m (4.5 kgf-m, 32.5 ft-lb) Measure the clearance between the outer rotor
and the cylinder block rotor housing. If the clear-
ance 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)
S2M0737A
S2M0735B
LU(H4)-12
墌 00.5.31/68j/1lu4 墍
OIL PUMP
Lubrication
3. SIDE CLEARANCE S108070A1003
Measure clearance between oil pump inner rotor

and pump cover. If the clearance exceeds the limit,
replace rotor or pump body.
Side clearance:
Standard
0.02 — 0.07 mm (0.0008 — 0.0028 in)
Limit
0.15 mm (0.0059 in)
S2M0738
4. OIL RELIEF VALVE S108070A1004
Check the valve for fitting condition and damage,

and the relief valve spring for damage and deterio-
ration. 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 kg, 17.33 lb)
5. OIL PUMP CASE S108070A1005
Check the oil pump case for worn shaft hole,

clogged oil passage, worn rotor chamber, cracks,
and other faults.
6. OIL SEAL S108070A1006
Check the oil seal lips for deformation, hardening,

wear, etc. and replace if defective.
LU(H4)-13
墌 00.5.31/68j/1lu4 墍
OIL PAN AND STRAINER
Lubrication
5. Oil Pan and Strainer S108071

6) Remove pitching stopper.
1) Set the vehicle on lift arms.

2) Remove front wheels.
S2M0126
7) Remove radiator upper brackets.
G6M0095
4) Remove air intake duct and air cleaner case.

<Ref. to IN(H4)-7 REMOVAL, Air Intake Duct.>
B2M2931
8) Support engine with a lifting device and wire

ropes.
B2M3101
5) Disconnect connector from front oxygen (A/F)

sensor.
G2M0297

CAUTION:
At this time, raise up wire ropes.
B2M3439
B2M2920
LU(H4)-14
墌 00.5.31/68j/1lu4 墍
Lubrication
11) Drain engine oil. 15) Remove bolts which install oil pan on cylinder
Set container under the vehicle, and remove drain block while raising up engine.
plug from oil pan. 16) Insert oil pan cutter blade between cylinder
block-to-oil pan clearance.
CAUTION:
Do not use a screwdriver or similar tool in
place of oil pan cutter.
B2M3102
12) Disconnect connector from rear oxygen sen-

sor.
G2M0081
17) Remove oil strainer.
B2M3440
13) Remove front and center exhaust pipes. <Ref.

to EX(H4)-5 REMOVAL, Front Exhaust Pipe.>
S2M0238
18) Remove baffle plate.
B2M3200
14) Remove nuts which install front cushion rub-

ber onto front crossmember. S2M0309
G2M0293
LU(H4)-15
墌 00.5.31/68j/1lu4 墍
Lubrication
B: INSTALLATION S108071A11 4) Tighten bolts which install oil pan onto engine
block.
CAUTION:
Before installing oil pan, clean sealant from oil Tightening torque:
pan and engine block. 5 N·m (0.5 kgf-m, 3.6 ft-lb)
1) Install baffle plate.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
G2M0081
5) Lower engine onto front crossmember.

6) Tighten nuts which install front cushion rubber
S2M0309
onto front crossmember.
Tightening torque:
2) Install oil strainer onto baffle plate. 69 N·m (7.0 kgf-m, 51 ft-lb)
CAUTION:
Replace O-ring with a new one.
Tightening torque:
10 N·m (1.0 kgf-m, 7 ft-lb)
G2M0293
7) Install front and center exhaust pipes.

<Ref. to EX(H4)-6 INSTALLATION, Front Exhaust
Pipe.>
S2M0238
CAUTION:
3) Apply fluid packing to mating surfaces and Always use the new gaskets.
install oil pan.
Fluid packing:
B2M3200
G2M0084
LU(H4)-16
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Lubrication
8) Connect connector to rear oxygen sensor. 13) Install pitching stopper.

Tightening torque:
T1: 49 N·m (5.0 kgf-m, 36.2 ft-lb)
T2: 57 N·m (5.8 kgf-m, 42 ft-lb)
B2M3440

S2M0126D
14) Install radiator upper brackets.
B2M2920

CAUTION:
B2M2931
At this time, lower lifting device and release
steel cables. 15) Install air intake duct.
11) Remove lifting device and steel cables. <Ref. to IN(H4)-7 INSTALLATION, Air Intake
Duct.>
G2M0297
B2M3101
12) Connect connector to front oxygen (A/F) sen-
sor. 16) Install front wheels.
B2M3439
LU(H4)-17
墌 00.5.31/68j/1lu4 墍
Lubrication
G6M0095
18) Fill engine oil. <Ref. to LU(H4)-7

INSPECTION, Engine Oil.>
By visual check make sure oil pan, oil strainer, oil

strainer stay and baffle plate are not damaged.
LU(H4)-18
墌 00.5.31/68j/1lu4 墍
OIL PRESSURE SWITCH
Lubrication
6. Oil Pressure Switch S108069

(4) Remove bolts which install generator on
bracket.
1) Remove generator from bracket.

(1) Disconnect connector and terminal from
generator.
S6M0352
2) Disconnect terminal from oil pressure switch.
B2M3105
(2) Remove V-belt cover.
G2M0091
3) Remove oil pressure switch.
B2M3106

front side V-belt.
S2M0119
G2M0286
LU(H4)-19
墌 00.5.31/68j/1lu4 墍
OIL PRESSURE SWITCH
Lubrication
1) Apply fluid packing to oil pressure switch

threads.
Fluid packing:
S6M0352
5) Install front side V-belt and adjust it.

<Ref. to ME(H4)-43 INSTALLATION, V-belt.>
6) Install V-belt cover.
S2M0124A
2) Install oil pressure switch onto engine block.

Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B2M3106
7) Connect connector and terminal to generator.
S2M0119
3) Connect terminal of oil pressure switch.
B2M3105
Make sure oil does not leak or seep from where the
oil pressure switched in installed.
G2M0091
4) Install generator on bracket and temporarily

tighten installing bolts.
LU(H4)-20
墌 00.5.31/68j/1lu4 墍
ENGINE OIL FILTER
Lubrication
7. Engine Oil Filter S108585
1) Remove access lid.
B2M3887
2) Remove oil filter with ST.

ST 498547000 OIL FILTER WRENCH
B2M3888A
1) Get a new oil filter and apply a thin coat of

engine oil to the seal rubber.
2) Install oil filter by turning it by hand, being care-
ful not to damage seal rubber.
3) Tighten more (approximately 2/3 to 3/4 turn)
after the seal rubber contacts the oil pump case.
Do not tighten excessively, or oil may leak.
1) After installing oil filter, run engine and make

sure that no oil is leaking around seal rubber.
NOTE:
The filter element and filter case are permanently
jointed; therefore, interior cleaning is not neces-
sary.
2) Check the engine oil level. <Ref. to LU(H4)-7
INSPECTION, Engine Oil.>
LU(H4)-21
ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL
Lubrication
8. Engine Lubrication System

Trouble in General S108100
Before performing diagnostics, make sure that the engine oil level is correct and no oil leakage exists.
Trouble Possible cause Corrective action
1) Oil pressure switch Cracked diaphragm or oil leakage within switch Replace.
failure Broken spring or seized contacts Replace.
Clogged oil filter Replace.
Malfunction of oil by-pass valve of oil filter Clean or replace.
Malfunction of oil relief valve of oil pump Clean or replace.
1. Warning light remains 2) Low oil pressure Clogged oil passage Clean.
on. Excessive tip clearance and side clearance of oil
Replace.
pump rotor and gear
Clogged oil strainer or broken pipe Clean or replace.
Insufficient engine oil Replenish.
3) No oil pressure Broken pipe of oil strainer Replace.
Stuck oil pump rotor Replace.
1) Burn-out bulb Replace.
2. Warning light does
2) Poor contact of switch contact points Replace.
not go on.
3) Disconnection of wiring Repair.
1) Poor contact at terminals Repair.
2) Defective wiring harness Repair.
3. Warning light flickers
momentarily. Check for the same
3) Low oil pressure possible causes as
listed in 1.—2).
LU(H4)-22
GENERAL DESCRIPTION
Mechanical
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gaso-

Type
line engine
Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder
Bore x Stroke mm (in) 99.5 x 79.0 (3.917 x 3.110)
Displacement cm3 (cu in) 2,457 (150)
Compression ratio 10.0
Compression pres-
sure (at 200 — 300 kPa (kg/cm2, psi) 1,079 — 1,275 (11.0 — 13.0, 156 — 185)
rpm)
Number of piston rings Pressure ring: 2, Oil ring: 1
Opening 1° BTDC
Engine Intake valve timing
Closing 51° ABDC
Exhaust valve tim- Opening 50° BBDC
ing Closing 6° ATDC
Intake mm (in) 0.20±0.02 (0.0079±0.0008)
Valve clearance
Exhaust mm (in) 0.25±0.02 (0.0098±0.0008)
Idling speed [At neutral position MT: 650±100 (No load)
on MT, or “P” or “N” position on rpm AT: 700±100 (No load)
AT] 850±100 (A/C switch ON)
Firing order 1→3→2→4
MT: 10°±8°/650
Ignition timing BTDC/rpm
AT: 15°±8°/700
NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer
Diameter US: Undersize OS: Oversize
Belt ten-
sioner Protrusion of adjuster rod 5.2 — 6.2 mm (0.205 — 0.244 in)
adjuster
Spacer O.D. 17.955 — 17.975 mm (0.7069 — 0.7077 in)
Tensioner bush I.D. 18.00 — 18.08 mm (0.7087 — 0.7118 in)
Belt ten- STD 0.025 — 0.125 mm (0.0010 — 0.0049 in)
Clearance between spacer and bush
sioner Limit 0.175 mm (0.0069 in)
STD 0.20 — 0.55 mm (0.0079 — 0.0217 in)
Side clearance of spacer
Limit 0.81 mm (0.0319 in)
Valve rocker STD 0.020 — 0.054 mm (0.0008 — 0.0021 in)
Clearance between shaft and arm
arm Limit 0.10 mm (0.0039 in)
Bend limit 0.020 mm (0.0008 in)
STD 0.030 — 0.090 mm (0.0012 — 0.0035 in)
Thrust clearance
Limit 0.11 mm (0.0043 in)
STD 39.485 — 39.585 mm (1.5545 — 1.5585 in)
Intake
Limit 39.385 mm (1.5506 in)
Cam lobe height
Camshaft STD 39.257 — 39.357 mm (1.5455 — 1.5495 in)
Exhaust
Limit 39.157 mm (1.5416 in)
Camshaft journal O.D. 31.928 — 31.945 mm (1.2570 — 1.2577 in)
Camshaft journal hole I.D. 32.000 — 32.018 mm (1.2598 — 1.2605 in)
STD 0.055 — 0.090 mm (0.0022 — 0.0035 in)
Oil clearance
Limit 0.10 mm (0.0039 in)
ME(H4)-2
墌 00.5.31/68j/1me4 墍
GENERAL DESCRIPTION
Mechanical
Surface warpage limit 0.05 mm (0.0020 in)

Cylinder
Surface grinding limit 0.1 mm (0.004 in)
head
Standard height 98.3 mm (3.870 in)
Refacing angle 90°
STD 1.0 mm (0.039 in)
Intake
Valve set Limit 1.7 mm (0.067 in)
Contacting width
STD 1.4 mm (0.055 in)
Exhaust
Limit 2.1 mm (0.083 in)
Inner diameter 6.000 — 6.012 mm (0.2362 — 0.2367 in)
Valve guide Intake 20.0 — 20.5 mm (0.787 — 0.807 in)
Protrusion above head
Exhaust 16.5 — 17.0 mm (0.650 — 0.669 in)
STD 1.0 mm (0.039 in)
Intake
Limit 0.6 mm (0.024 in)
Head edge thickness
STD 1.2 mm (0.047 in)
Exhaust
Limit 0.6 mm (0.024 in)
Intake 5.950 — 5.965 mm (0.2343 — 0.2348 in)
Stem diameter
Valve Exhaust 5.945 — 5.960 mm (0.2341 — 0.2346 in)
Intake 0.035 — 0.062 mm (0.0014 — 0.0024 in)
STD
Stem oil clearance Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit — 0.15 mm (0.0059 in)
Intake 120.6 mm (4.75 in)
Overall length
Exhaust 121.7 mm (4.79 in)
Free length 54.30 mm (2.1378 in)
Squareness 2.5°, 2.4 mm (0.094 in)
Valve spring 214.8 — 246.2 N (21.9 — 25.1 kg, 48.3 — 55.3 lb)/
Tension/spring height 45.0 mm (1.772 in) 526.6 — 581.6 N (53.7 — 59.3 kg,
118.4 — 130.8 lb)/34.7 mm (1.366 in)
Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
Surface grinding limit 0.1 mm (0.004 in)
A 99.505 — 99.515 mm (3.9175 — 3.9179 in)
Cylinder bore STD
B 99.495 — 99.505 mm (3.9171 — 3.9175 in)
STD 0.015 mm (0.0006 in)
Cylinder Taper
Limit 0.050 mm (0.0020 in)
block
STD 0.010 mm (0.0004 in)
Out-of-roundness
Limit 0.050 mm (0.0020 in)
STD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Piston clearance
Limit 0.050 mm (0.0020 in)
Enlarging (boring) limit 0.5 mm (0.020 in)
A 99.485 — 99.495 mm (3.9167 — 3.9171 in)
STD
B 99.475 — 99.485 mm (3.9163 — 3.9167 in)
0.25 mm (0.0098 in)
Outer diameter 99.725 — 99.735 mm (3.9262 — 3.9266 in)
Piston OS
0.50 mm (0.0197 in)
99.975 — 99.985 mm (3.9360 — 3.9364 in)
OS
Standard inner diameter of piston pin hole 23.000 — 23.006 mm (0.9055 — 0.9057 in)
Outer diameter 22.994 — 23.000 mm (0.9053 — 0.9055 in)
Standard clearance between piston pin and hole in pis-
0.004 — 0.008 mm (0.0002 — 0.0003 in)
Piston pin ton
Piston pin must be fitted into position with thumb at
Degree of fit
20°C (68°F).
ME(H4)-3
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GENERAL DESCRIPTION
Mechanical
STD 0.20 — 0.35 mm (0.0079 — 0.0138 in)

Top ring
Limit 1.0 mm (0.039 in)
Second STD 0.35 — 0.50 mm (0.0138 — 0.0197 in)
Piston ring gap
ring Limit 1.0 mm (0.039 in)
STD 0.20 — 0.70 mm (0.0079 — 0.0276 in)
Piston ring Oil ring
Limit 1.5 mm (0.059 in)
Clearance STD 0.040 — 0.080 mm (0.0016 — 0.0031 in)
Top ring
between piston Limit 0.15 mm (0.0059 in)
ring and piston Second STD 0.030 — 0.070 mm (0.0012 — 0.0028 in)
ring groove ring Limit 0.15 mm (0.0059 in)
Bend twist per 100 mm (3.94
Limit 0.10 mm (0.0039 in)
Connecting in) in length
rod STD 0.070 — 0.330 mm (0.0028 — 0.0130 in)
Side clearance
Limit 0.4 mm (0.016 in)
STD 0.020 — 0.046 mm (0.0008 — 0.0018 in)
Oil clearance
Limit 0.05 mm (0.0020 in)
STD 1.486 — 1.498 mm (0.0585 — 0.0590 in)
0.03 mm (0.0012 in)
Connecting 1.504 — 1.512 mm (0.0592 — 0.0595 in)
US
rod bearing
Thickness at center portion 0.05 mm (0.0020 in)
1.514 — 1.522 mm (0.0596 — 0.0599 in)
US
0.25 mm (0.0098 in)
1.614 — 1.622 mm (0.0635 — 0.0639 in)
US
Connecting Clearance between piston pin STD 0 — 0.022 mm (0 — 0.0009 in)
rod bushing and bushing Limit 0.030 mm (0.0012 in)
Bend limit 0.035 mm (0.0014 in)
Crank pin and Out-of-roundness 0.020 mm (0.0008 in) or less
crank journal Grinding limit 0.250 mm (0.0098 in)
STD 51.984 — 52.000 mm (2.0466 — 2.0472 in)
0.03 mm (0.0012 in)
51.954 — 51.970 mm (2.0454 — 2.0461 in)
US
Crank pin outer diameter 0.05 mm (0.0020 in)
51.934 — 51.950 mm (2.0446 — 2.0453 in)
US
0.25 mm (0.0098 in)
51.734 — 51.750 mm (2.0368 — 2.0374 in)
US
STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm (0.0012 in)
59.962 — 59.978 mm (2.3607 — 2.3613 in)
US
#1, #5, #3 0.05 mm (0.0020 in)
Crankshaft 59.942 — 59.958 mm (2.3599 — 2.3605 in)
US
0.25 mm (0.0098 in)
59.742 — 59.758 mm (2.3520 — 2.3527 in)
Crank journal US
outer diameter STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm (0.0012 in)
59.962 — 59.978 mm (2.3607 — 2.3613 in)
US
#2, #4 0.05 mm (0.0020 in)
59.942 — 59.958 mm (2.3599 — 2.3605 in)
US
0.25 mm (0.0098 in)
59.742 — 59.758 mm (2.3520 — 2.3527 in)
US
STD 0.030 — 0.115 mm (0.0012 — 0.0045 in)
Thrust clearance
Limit 0.25 mm (0.0098 in)
STD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Oil clearance
Limit 0.040 mm (0.0016 in)
ME(H4)-4
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GENERAL DESCRIPTION
Mechanical
STD 1.998 — 2.011 mm (0.0787 — 0.0792 in)

0.03 mm (0.0012 in)
2.017 — 2.020 mm (0.0794 — 0.0795 in)
US
#1, #5 0.05 mm (0.0020 in)
2.027 — 2.030 mm (0.0798 — 0.0799 in)
US
0.25 mm (0.0098 in)
2.127 — 2.130 mm (0.0837 — 0.0839 in)
Crankshaft Crankshaft bear- US
bearing ing thickness STD 2.000 — 2.013 mm (0.0787 — 0.0793 in)
0.03 mm (0.0012 in)
2.019 — 2.022 mm (0.0795 — 0.0796 in)
US
#2, #3, #4 0.05 mm (0.0020 in)
2.029 — 2.032 mm (0.0799 — 0.0800 in)
US
0.25 mm (0.0098 in)
2.129 — 2.132 mm (0.0838 — 0.0839 in)
US
ME(H4)-5
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GENERAL DESCRIPTION
Mechanical
1. TIMINGBELT S103001A0501
B2M3428A
(1) Belt cover No. 2 (RH) (8) Tensioner bracket Tightening torque: N·m (kgf-m, ft-lb)
(2) Timing belt guide (MT vehicles (9) Belt idler (No. 2)
T1: 5 (0.5, 3.6)
only) (10) Automatic belt tension adjuster
T2: 9.8 (1.0, 7.2)
(3) Crankshaft sprocket (AT ASSY
T3: 25 (2.5, 18.1)
vehicles) (11) Belt idler No. 2
(4) Crankshaft sprocket (MT (12) Camshaft sprocket No. 2 T4: 39 (4.0, 28.9)
vehicles) (13) Timing belt T5: 78 (8.0, 57.9)
(5) Belt cover No. 2 (LH) (14) Front belt cover T6: 177 (18.0, 130.2)
(6) Camshaft sprocket No. 1 (15) Belt cover (LH)
(7) Belt idler (No. 1) (16) Crankshaft pulley
ME(H4)-6
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GENERAL DESCRIPTION
Mechanical
2. CYLINDER HEAD AND CAMSHAFT

S103001A0502
B2M1954D
(1) Rocker cover (RH) (11) Cylinder head (LH) Tightening torque: N·m (kgf-m, ft-lb)
(2) Intake valve rocker ASSY (12) Camshaft (LH)
T1: <Ref. to ME(H4)-59 CYLIN-
(3) Exhaust valve rocker ASSY (13) Camshaft cap (LH) DER HEAD, INSTALLATION,
(4) Camshaft cap (RH) (14) Oil filler cap Cylinder Head Assembly.>
(5) Oil seal (15) Gasket T2: 5 (0.5, 3.6)
(6) Camshaft (RH) (16) Oil filler pipe
T3: 10 (1.0, 7.2)
(7) Plug (17) O-ring
T4: 18 (1.8, 13.0)
(8) Spark plug pipe gasket (18) Rocker cover (LH)
T5: 25 (2.5, 18.1)
(9) Cylinder head (RH) (19) Stud bolt
(10) Cylinder head gasket T6: 6.4 (0.65, 4.7)
ME(H4)-7
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GENERAL DESCRIPTION
Mechanical
3. VALVE ROCKER ASSEMBLY S103001A0503
B2M1956A
(1) Intake valve rocker arm (6) Intake rocker shaft Tightening torque: N·m (kgf-m, ft-lb)
(2) Valve rocker nut (7) Exhaust rocker shaft
T1: 5 (0.5, 3.6)
(3) Valve rocker adjust screw (8) Exhaust valve rocker arm
T2: 10 (1.0, 7.2)
(4) Spring
T3: 25 (2.5, 18.1)
(5) Rocker shaft support
ME(H4)-8
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GENERAL DESCRIPTION
Mechanical
4. CYLINDER HEAD AND VALVE

ASSEMBLY S103001A0504
B2M1955A
(1) Exhaust valve (5) Intake valve oil seal (9) Exhaust valve guide
(2) Intake valve (6) Valve spring (10) Exhaust valve spring seat
(3) Intake valve guide (7) Retainer (11) Exhaust valve oil seal
(4) Intake valve spring seat (8) Retainer key
ME(H4)-9
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GENERAL DESCRIPTION
Mechanical
5. CYLINDER BLOCK S103001A0505
B2M4154A
(1) Oil pressure switch (14) Baffle plate Tightening torque: N·m (kgf-m, ft-lb)
(2) Cylinder block (RH) (15) Oil filter connector
T1: 5 (0.5, 3.6)
(3) Service hole plug (16) Oil strainer
T2: 6.4 (0.65, 4.7)
(4) Gasket (17) Gasket
T3: 10 (1.0, 7)
(5) Oil separator cover (18) Oil pan
(6) Water by-pass pipe (19) Drain plug T4: 25 (2.5, 18.1)
(7) Oil pump (20) Metal gasket T5: 47 (4.8, 34.7)
(8) Front oil seal (21) Oil level gauge guide T6: 69 (7.0, 50.6)
(9) Rear oil seal (22) Water pump sealing T7: First 12 (1.2, 8.7)
(10) O-ring (23) Oil filter Second 12 (1.2, 8.7)
(11) Service hole cover (24) Gasket T8: 16 (1.6, 11.6)
(12) Cylinder block (LH) (25) Water pump hose T9: 44 (4.5, 33)
(13) Water pump T10: 25 (2.5, 18.1)
ME(H4)-10
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GENERAL DESCRIPTION
Mechanical
6. CRANKSHAFT AND PISTON S103001A0506
B2M3429A
ME(H4)-11
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GENERAL DESCRIPTION
Mechanical
(1) Flywheel (MT) (9) Circlip (17) Crankshaft bearing #2, #4

(2) Reinforcement (AT) (10) Connecting rod bolt (18) Crankshaft bearing #5
(3) Drive plate (AT) (11) Connecting rod
(4) Top ring (12) Connecting rod bearing Tightening torque: N·m (kgf-m, ft-lb)
(5) Second ring (13) Connecting rod cap T1: 44.6 (4.55, 32.9)
(6) Oil ring (14) Crankshaft T2: 72 (7.3, 52.8)
(7) Piston (15) Woodruff key
(8) Piston pin (16) Crankshaft bearing #1, #3
ME(H4)-12
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GENERAL DESCRIPTION
Mechanical
7. ENGINE MOUNTING S103001A0507
B2M3382A
(1) Front cushion rubber (3) Front cushion rubber (Except Tightening torque: N·m (kgf-m, ft-lb)
(BRIGHTON and L AT vehicles) BRIGHTON and L AT vehicles)
T1: 34 (3.5, 25.3)
(2) Front engine mounting bracket
T2: 41 (4.2, 30)
(BRIGHTON and L AT vehicles)
T3: 74 (7.5, 54)
C: CAUTION S103001A03 removal, installation, disassembly, and replace-

ment.
쐌 Wear working clothing, including a cap, protec- 쐌 Be careful not to burn your hands, because each
tive goggles, and protective shoes during opera- part in the vehicle is hot after running.
tion. 쐌 Be sure to tighten fasteners including bolts and
쐌 Remove contamination including dirt and corro- nuts to the specified torque.
sion before removal, installation or disassembly. 쐌 Place shop jacks or safety stands at the speci-
쐌 Keep the disassembled parts in order and pro- fied points.
tect them from dust or dirt. 쐌 Before disconnecting electrical connectors of
쐌 Before removal, installation or disassembly, be sensors or units, be sure to disconnect negative
sure to clarify the failure. Avoid unnecessary terminal from battery.
ME(H4)-13
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GENERAL DESCRIPTION
Mechanical
쐌 All parts should be thoroughly cleaned, paying 쐌 Remove or install engine in an area where chain
special attention to the engine oil passages, pis- hoists, lifting devices, etc. are available for ready
tons and bearings. use.
쐌 Rotating parts and sliding parts such as piston, 쐌 Be sure not to damage coated surfaces of body
bearing and gear should be coated with oil prior to panels with tools or stain seats and windows with
assembly. coolant or oil. Place a cover over fenders, as
쐌 Be careful not to let oil, grease or coolant con- required, for protection.
tact the timing belt, clutch disc and flywheel. 쐌 Prior to starting work, prepare the following:
쐌 All removed parts, if to be reused, should be Service tools, clean cloth, containers to catch cool-
reinstalled in the original positions and directions. ant and oil, wire ropes, chain hoist, transmission
쐌 Bolts, nuts and washers should be replaced with jacks, etc.
new ones as required.
쐌 Lift-up or lower the vehicle when necessary.
쐌 Even if necessary inspections have been made
Make sure to support the correct positions.
in advance, proceed with assembly work while
making rechecks.

498267800 CYLINDER 쐌 Used for replacing valve guides.
HEAD TABLE 쐌 Used for removing and installing valve springs.
B2M3850
498457000 ENGINE STAND Used with ENGINE STAND (499817000).
ADAPTER RH
B2M3851
498457100 ENGINE STAND Used with ENGINE STAND (499817000).
ADAPTER LH
B2M3852
ME(H4)-14
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GENERAL DESCRIPTION
Mechanical

498497100 CRANKSHAFT Used for stopping rotation of flywheel when loos-
STOPPER ening and tightening crankshaft pulley bolt, etc.
B2M3853
498747300 PISTON GUIDE Used for installing piston in cylinder.
B2M3854
498857100 VALVE OIL SEAL Used for press-fitting of intake and exhaust valve
GUIDE guide oil seals.
B2M3855
499017100 PISTON PIN Used for installing piston pin, piston and connect-
GUIDE ing rod.
B2M3856
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GENERAL DESCRIPTION
Mechanical

499037100 CONNECTING Used for removing and installing connecting rod
ROD BUSHING bushing.
REMOVER &
INSTALLER
B2M3857
499097700 PISTON PIN Used for removing piston pin.
REMOVER ASSY
B2M3858
499207100 CAMSHAFT Used for removing and installing camshaft
SPROCKET sprocket.
WRENCH
B2M3859
499587700 CAMSHAFT OIL Used for installing cylinder head plug.
SEAL
INSTALLER
B2M3860
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GENERAL DESCRIPTION
Mechanical

499587200 CRANKSHAFT 쐌 Used for installing crankshaft oil seal.
OIL SEAL 쐌 Used with CRANKSHAFT OIL SEAL GUIDE
B2M3861
499597000 OIL SEAL GUIDE 쐌 Used for installing camshaft oil seal.
쐌 Used with CAMSHAFT OIL SEAL INSTALLER
(499587100).
B2M3862
499597100 CRANKSHAFT 쐌 Used for installing crankshaft oil seal.
OIL SEAL GUIDE 쐌 Used with CRANKSHAFT OIL SEAL
B2M3863
499718000 VALVE SPRING Used for removing and installing valve spring.
REMOVER
B2M3864
ME(H4)-17
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GENERAL DESCRIPTION
Mechanical

499767700 VALVE GUIDE Used for installing intake valve guides.
ADJUSTER
B2M3865
499767800 VALVE GUIDE Used for installing exhaust valve guide.
ADJUSTER
B2M3865
499767200 VALVE GUIDE Used for removing valve guides.
REMOVER
B2M3867
499767400 VALVE GUIDE Used for reaming valve guides.
REAMER
B2M3868
ME(H4)-18
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GENERAL DESCRIPTION
Mechanical

499817100 ENGINE STAND 쐌 Stand used for engine disassembly and
assembly.
쐌 Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).
B2M3869
499977100 CRANK PULLEY Used for stopping rotation of crankshaft pulley
WRENCH when loosening and tightening crankshaft pulley
bolts.
B2M3870
499987500 CRANKSHAFT Used for rotating crankshaft.
SOCKET
B2M3871
498547000 OIL FILTER Used for removing and installing oil filter.
WRENCH
B2M3872
ME(H4)-19
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GENERAL DESCRIPTION
Mechanical

499497000 TORX PLUS Used for removing and installing camshaft cap.
B2M3873
499587500 OIL SEAL Used for installing front camshaft oil seal.
INSTALLER
B2M3874
499587100 OIL SEAL Used for installing oil pump oil seal.
INSTALLER
B2M3875
498277200 STOPPER SET Used for installing automatic transmission
assembly to engine.
B3M2043
ME(H4)-20
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GENERAL DESCRIPTION
Mechanical

B2M3876
22771AA030 SELECT MONI- Troubleshooting for electrical systems.
TOR KIT 쐌 English: 22771AA030 (Without printer)
B2M3877
TOOL NAME REMARKS

Compression gauge Used for measuring compression.
Tachometer (Secondary pick-up type) Used for measuring idle speed.
Timing light Used for measuring ignition timing.
E: PROCEDURE S103001E45
It is possible to conduct the following service pro-

cedures 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.
쐌 Timing Belt
쐌 Valve Rocker Assembly
쐌 Camshaft
쐌 Cylinder Head
ME(H4)-21
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COMPRESSION
Mechanical
2. Compression S103081
CAUTION:
After warming-up, engine becomes very hot.
Be careful not to burn yourself during mea-
surement.
1) After warming-up the engine, turn ignition
switch to OFF.
2) Make sure that the battery is fully charged.
RELEASING OF FUEL PRESSURE, Fuel.>
4) Remove all the spark plugs. <Ref. to IG(H4)-4
REMOVAL, Spark Plug.>
5) Fully open throttle valve.
6) Check the starter motor for satisfactory perfor-
mance and operation.
7) Hold the compression gauge tight against the
spark plug hole.
CAUTION:
When using a screw-in type compression
gauge, the screw (put into cylinder head spark
plug hole) should be less than 18 mm (0.71 in)
long.
8) Crank the engine by means of the starter motor,
and read the maximum value on the gauge when
the pointer is steady.
B2M3133
9) Perform at least two measurements per

cylinder, and make sure that the values are correct.
Compression (350 rpm and fully open
throttle):
Standard;
1,216 kPa (12.4 kg/cm2, 176 psi)
Limit;
941 kPa (9.6 kg/cm2, 137 psi)
Difference between cylinders;
49 kPa (0.5 kg/cm2, 7 psi), or less
ME(H4)-22
IDLE SPEED
Mechanical
3. Idle Speed S103082

5) When using tachometer (Secondary pick-up
type).
A: INSPECTION S103082A10 (1) Attach the pick-up clip to No. 1 cylinder
spark plug cord.
1) Before checking idle speed, check the follow- (2) Start the engine, and read engine idle
ing: speed.
(1) Ensure that air cleaner element is free from
clogging, ignition timing is correct, spark plugs
are in good condition, and that hoses are con-
nected properly.
(2) Ensure that malfunction indicator light
(CHECK ENGINE light) does not illuminate.
2) Warm-up the engine.
3) Stop the engine, and turn igintion switch to
OFF.
4) When using SUBARU SELECT MONITOR
<Ref. to ME(H4)-14 SPECIAL TOOLS, PREPARA- B2M3131
TION TOOL, General Description.>
(1) Insert the cartridge to SUBARU SELECT NOTE:
MONITOR. 쐌 When using the OBD-II general scan tool, care-
(2) Connect SUBARU SELECT MONITOR to fully read its operation manual.
the data link connector. 쐌 This ignition system provides simultaneous igni-
tion for #1 and #2 plugs. It must be noted that
some tachometers may register twice that of actual
engine speed.
6) Check idle speed when unloaded. (With
headlights, heater fan, rear defroster, radiator fan,
air conditioning, etc. OFF)
Idle speed (No load and gears in neutral (MT),
or N or P (AT) position):
MT vehicle: 650±100 rpm
AT vehicle: 700±100 rpm
B2M3148A
7) Check idle speed when loaded. (Turn air con-
(3) Turn igintion switch to ON, and SUBARU ditioning switch to “ON” and operate compressor
SELECT MONITOR switch to ON. for at least one minute before measurement.)
(4) Select {2. Each System Check} in Main
Idle speed [A/C “ON”, no load and gears in
Menu. neutral (MT) or N or P (AT) position]:
(5) Select {Engine Control System} in Selection 850±100 rpm
Menu.
(6) Select {1. Current Data Display & Save} in CAUTION:
Engine Control System Diagnosis. Never rotate idle adjusting screw. If idle speed
(7) Select {1.12 Data Display} in Data Display is out of specifications, refer to General On-
Menu. board Diagnosis Table under “Engine Control
(8) Start the engine, and read engine idle System”. <Ref. to EN(H4)-2, Basic Diagnostic
Procedure.>
speed.
ME(H4)-23
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IGNITION TIMING
Mechanical
4. Ignition Timing S103086
CAUTION:
After warming-up, engine becomes very hot.
Be careful not to burn yourself during mea-
surement.
1) Warm-up the engine.
2) To check the ignition timing, connect a timing
light to #1 cylinder spark plug cord, and illuminate
the timing mark with the timing light.
3) Start the engine at idle speed and check the
ignition timing.
Ignition timing [BTDC/rpm]:
MT vehicle: 10°±8°/650
AT vehicle: 15°±8°/700
B2M3130
If the timing is not correct, check the ignition con-

trol system.
Refer to Engine Control System. <Ref. to
EN(H4)-2, Basic Diagnostic Procedure.>
ME(H4)-24
INTAKE MANIFOLD VACUUM
Mechanical
5. Intake Manifold Vacuum S103654

3) Keep the engine at the idle speed and read the
vacuum gauge indication.
A: INSPECTION S103654A10 By observing the gauge needle movement, the
1) Warm-up the engine. internal condition of the engine can be diagnosed
2) Disconnect the brake vacuum hose and install as described below.
the vacuum gauge to the hose fitting on the mani-
fold.
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 ten- Leakage around intake manifold gasket or disconnection or
dency becomes more evident as engine temperature rises. damaged vacuum hose
2. When engine speed is reduced slowly from higher speed, Back pressure too high, or exhaust system clogged
needle stops temporarily when it is lowering or becomes
steady above normal position.
3. Needle intermittently drops to position lower than normal Leakage around cylinder
position.
4. Needle drops suddenly and intermittently from normal posi- Sticky valves
tion.
5. When engine speed is gradually increased, needle begins to Weak or broken valve springs
vibrate rapidly at certain speed, and then vibration increases
as engine speed increases.
6. Needle vibrates above and below normal position in narrow Defective ignition system or throttle chamber idle adjustment
range.
ME(H4)-25
ENGINE OIL PRESSURE
Mechanical
6. Engine Oil Pressure S103655

front side V-belt.
G2M0286
(4) Remove generator lock bolt.

G6M0095 (5) Remove bolt which install generator on
2) Remove generator from bracket. bracket.
(1) Disconnect connector and terminal from
generator.
S6M0352
3) Disconnect connector from oil pressure switch.

B2M3105 4) Remove oil pressure switch from engine cylin-
(2) Remove V-belt cover. der block. <Ref. to LU(H4)-19 REMOVAL, Oil Pres-
sure Switch.>
B2M3106
G2M0091
5) Connect oil pressure gauge hose to cylinder

block.
ME(H4)-26
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ENGINE OIL PRESSURE
Mechanical
G6M0095
7) Start the engine, and measure oil pressure.
S2M0242
Oil pressure:
98 kPa (1.0 kg/cm2, 14 psi) or more at 800
rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at
5,000 rpm
CAUTION:
쐌 If oil pressure is out of specification, check
oil pump, oil filter and lubrication line. <Ref. to
LU(H4)-22 INSPECTION, Engine Lubrication
System Trouble in General.>
쐌 If oil pressure warning light is turned ON and
oil pressure is in specification, replace oil pres-
sure switch. <Ref. to LU(H4)-22 INSPECTION,
Engine Lubrication System Trouble in Gen-
eral.>
NOTE:
The specified data is based on an engine oil tem-
perature of 80°C (176°F).
8) After measuring oil pressure, install oil pressure
switch. <Ref. to LU(H4)-20 INSTALLATION, Oil
Pressure Switch.>
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
9) Install generator and V-belt in the reverse order
of removal, and adjust the V-belt deflection. <Ref.
to ME(H4)-43 INSTALLATION, V-belt.>
ME(H4)-27
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FUEL PRESSURE
Mechanical
7. Fuel Pressure S103656

A: INSPECTION S103656A10 pressure regulator vacuum hose from intake mani-
fold.
WARNING:
Before removing fuel pressure gauge, release 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 pressure
regulator and pressure regulator vacuum hose.
1) Release fuel pressure. <Ref. to FU(H4)-xx
RELEASING OF FUEL PRESSURE OPERATION,
Fuel.>
S2M0248
7) After connecting pressure regulator vacuum

hose, measure fuel pressure.
Fuel pressure:
Standard; 206 — 235 kPa (2.1 — 2.4
kg/cm2, 30 — 34 psi)
B2M3135
3) Disconnect fuel delivery hoses from fuel filter,

and connect fuel pressure gauge.
S2M0248
NOTE:
The fuel pressure gauge registers 10 to 20 kPa
S2M0195 (0.1 to 0.2 kg/cm2, 1 to 3 psi) higher than standard
values during high-altitude operations.
4) Connect connector of fuel pump relay.
B2M3159
ME(H4)-28
墌 00.5.31/68j/1me4 墍
VALVE CLEARANCE
Mechanical
8. Valve Clearance S103083

7) Remove rocker cover.
8) When inspecting #1 and #3 cylinders;
A: INSPECTION S103083A10 (1) Remove bolt which secures air intake duct
CAUTION: to radiator panel side.
Inspection and adjustment of valve clearance (2) Remove air intake duct as a unit.
should be performed while engine is cold.
1) Set the vehicle onto the lift.
B6M1224
(3) Remove bolt, and then remove resonator

chamber.
B2M2920
B6M1237
(4) Disconnect spark plug cords from spark

plugs (#1 and #3 cylinders).
G6M0095

6) Remove timing belt cover (LH).
B2M3374
(5) Disconnect PCV hose from rocker cover

(RH).
B2M2031 (6) Remove bolts, then remove rocker cover
(RH).
ME(H4)-29
墌 00.5.31/68j/1me4 墍
VALVE CLEARANCE
Mechanical
9) When inspecting #2 and #4 cylinders; (6) Disconnect PCV hose from rocker cover
(1) Disconnect battery cables, and then (LH).
remove battery and battery carrier. (7) Remove bolts, then remove rocker cover
(LH).
10) Set #1 cylinder piston to top dead center of
compression stroke by rotating crankshaft pulley
clockwise using ST.
ST 499977100 CRANKSHAFT PULLEY
WRENCH
NOTE:
When arrow mark on camshaft sprocket (LH)
comes exactly to the top, #1 cylinder piston is
brought to the top dead center of compression
S2M0545
stroke.
(2) Remove the two bolts which hold washer
tank.
B2M2027A
B2M3139 11) Measure #1 cylinder valve clearance by using

thickness gauge.
(3) Disconnect washer motor connectors.
CAUTION:
쐌 Insert the thickness gauge in as horizontal a
direction as possible with respect to the valve
stem end face.
쐌 Measure exhaust valve clearances while lift-
ing-up the vehicle.
Valve clearance:
Intake;
0.20±0.02 mm (0.0079±0.0008 in)
Exhaust;
B6M0562B 0.25±0.02 mm (0.0098±0.0008 in)
(4) Move washer tank to forward.
B2M2028A
B2M3140 12) If necessary, adjust the valve clearance. <Ref.

to ME(H4)-31 ADJUSTMENT, Valve Clearance.>
(5) Disconnect spark plug cords from spark
plugs (#2 and #4 cylinders).
ME(H4)-30
墌 00.5.31/68j/1me4 墍
VALVE CLEARANCE
Mechanical
13) Similar to measurement procedures used for 1) Set #1 cylinder piston to top dead center of
#1 cylinder, measure #2, #3 and #4 cylinder valve compression stroke by rotating crankshaft pulley
clearances. clockwise using ST.
NOTE: ST 499977100 CRANKSHAFT PULLEY
쐌 Be sure to set cylinder pistons to their respective WRENCH
top dead centers on compression stroke before NOTE:
measuring valve clearances. When arrow mark on camshaft sprocket (LH)
쐌 To set #3, #2 and #4 cylinder pistons to their top comes exactly to the top, #1 cylinder piston is
dead centers on compression stroke, turn crank- brought to the top dead center of compression
shaft pulley clockwise 90° at a time starting with stroke.
arrow mark on left-hand camshaft sprocket facing
up.
B2M2027A
2) Adjust the #1 cylinder valve clearance.

B2M2029A
(1) Loosen the valve rocker nut and screw.
14) After inspection, install the related parts in the (2) Place suitable thickness gauge.
reverse order of removal. (3) While noting valve clearance, tighten valve
rocker adjust screw.
Tightening torque: (4) When specified valve clearance is obtained,
Resonator chamber; tighten valve rocker nut.
32 N·m (3.3 kgf-m, 24 ft-lb)
Tightening torque:
10 N·m (1.0 kgf-m, 7.2 ft-lb)
CAUTION:
쐌 Insert the thickness gauge in as horizontal a
direction as possible with respect to the valve
stem end face.
쐌 Adjust exhaust valve clearances while lift-
ing-up the vehicle.
Valve clearance:
Intake;
B6M1237 0.20±0.02 mm (0.0079±0.0008 in)
Exhaust;
0.25±0.02 mm (0.0098±0.0008 in)
B: ADJUSTMENT S103083A01
CAUTION:
Adjustment of valve clearance should be per-
formed while engine is cold.
B2M2030
3) Ensure that valve clearances are within speci-

fications.
ME(H4)-31
墌 00.5.31/68j/1me4 墍
VALVE CLEARANCE
Mechanical
4) Turn crankshaft two complete rotations until #1

cylinder piston is again set to top dead center on
compression stroke.
5) Ensure that valve clearances are within speci-
fications. If necessary, readjust valve clearances.
6) Similar to adjustment procedures used for #1
cylinder, adjust #2, #3 and #4 cylinder valve clear-
ances.
NOTE:
쐌 Be sure to set cylinder pistons to their respective
top dead centers on compression stroke before
adjusting valve clearances.
쐌 To set #3, #2 and #4 cylinder pistons to their top
dead centers on compression stroke, turn crank-
shaft pulley clockwise 90° at a time starting with
arrow mark on left-hand camshaft sprocket facing
up.
B2M2029A
ME(H4)-32
墌 00.5.31/68j/1me4 墍
ENGINE ASSEMBLY
Mechanical
9. Engine Assembly S103079

10) Remove radiator from vehicle. <Ref. to
CO(H4)-15 REMOVAL, Radiator.>
1) Set the vehicle on lift arms.

2) Open front hood fully and support with stay.
3) Raise rear seat, and turn floor mat up.
OPERATION, Fuel.>
5) Remove filler cap.
6) Disconnect battery ground terminal.
B2M2933
11) Remove V-belt cover.
G6M0095
7) Remove air intake duct and air cleaner case.

<Ref. to IN(H4)-7, REMOVAL, Air Intake Duct.>
B2M3401
Case.> 12) Collect refrigerant, and remove pressure
hoses. (With A/C)
(1) Place and connect the attachment hose to
the refrigerant recycle system.
(2) Collect refrigerant from A/C system.
(3) Disconnect A/C pressure hoses from A/C
compressor.
B2M3101

9) Drain coolant.
Set container under the vehicle, and loose drain
cock from radiator. <Ref. to CO(H4)-6 DRAINING
OF ENGINE COOLANT, REPLACEMENT, Engine
Coolant.> B2M3385
B2M2921A
ME(H4)-33
墌 00.5.31/68j/1me4 墍
ENGINE ASSEMBLY
Mechanical
13) Remove air cleaner case stay. (3) Engine harness connectors
쐌 MT model
S2M0900
쐌 AT model
B2M3414
(4) Alternator connector, terminal and A/C com-

S2M0901 pressor connector
14) Disconnect the following connectors and
cables.
(1) Front oxygen sensor connector
B2M3386B
(A) A/C compressor connector

(B) Alternator connector and terminal
B2M3413
(5) Accelerator cable and cruise control cable
(2) Engine ground terminal
B2M3415A
S2M0731
(A) Accelerator cable
(B) Cruise control cable
ME(H4)-34
墌 00.5.31/68j/1me4 墍
ENGINE ASSEMBLY
Mechanical
(6) Pressure switch 16) Remove power steering pump from bracket.
B2M3416
B6M1237
15) Disconnect the following hoses.
(1) Brake booster vacuum hose (2) Loosen lock bolt and slider bolt, and remove
front side V-belt.
B2M3419
G2M0286
(2) Heater inlet outlet hose
(3) Remove pipe with bracket.
B2M3390
B2M3366
(4) Remove bolts which install power steering

pump bracket.
B2M3151
ME(H4)-35
墌 00.5.31/68j/1me4 墍
ENGINE ASSEMBLY
Mechanical
(5) Remove power steering tank from the 19) Remove nuts which install front cushion rub-
bracket by pulling it upward. ber onto front crossmember.
B2M3153 B2M3417A
(6) Place power steering pump on the right side 20) Separate torque converter clutch from drive
wheel apron. plate. (AT model)
(1) Lower the vehicle.
(2) Remove service hole plug.
(3) Remove bolts which hold torque converter
clutch to drive plate.
(4) Remove other bolts while rotating the
engine using ST.
ST 499977100 CRANK PULLEY WRENCH
B2M3154A
17) Remove front and center exhaust pipe.

<Ref. to EX(H4)-5 REMOVAL, Front Exhaust
Pipe.> and <Ref. to EX(H4)-8 REMOVAL, Center
Exhaust Pipe.>
S2M0207
21) Remove pitching stopper.
G2M0290
18) Remove nuts which hold lower side of trans-

mission to engine.
H3M1839
B3M2047
ME(H4)-36
墌 00.5.31/68j/1me4 墍
ENGINE ASSEMBLY
Mechanical
22) Disconnect fuel delivery hose, return hose and 25) Separation of engine and transmission.
evaporation hose. (1) Remove starter. <Ref. to SC(H4)-7
REMOVAL, Starter.>
CAUTION:
(2) Remove bolts which hold upper side of
쐌 Disconnect hose with its end wrapped with transmission to engine.
cloth to prevent fuel from splashing.
쐌 Catch fuel from hose into container.
B3M2044
S2M0500 26) Install ST to torque converter clutch case. (AT

model)
23) Support engine with a lifting device and wire ST 498277200 STOPPER SET
ropes.
H2M1961A
B2M3391
27) Remove engine from vehicle.
24) Support transmission with a garage jack. (1) Slightly raise engine.
(2) Raise transmission with garage jack.
CAUTION: (3) Move engine horizontally until main shaft is
Before moving engine away from transmission, withdrawn from clutch cover.
check to be sure no work has been overlooked. (4) Slowly move engine away from engine
Doing this is very important in order to facili- compartment.
tate re-installation and because transmission
lowers under its own weight. CAUTION:
Be careful not to damage adjacent parts or
body panels with crank pulley, oil level gauge,
etc.
G2M0298
B2M3391
28) Remove front cushion rubbers.
ME(H4)-37
墌 00.5.31/68j/1me4 墍
ENGINE ASSEMBLY
Mechanical
B: INSTALLATION S103079A11 6) Install pitching stopper.

1) Install front cushion rubbers. Tightening torque:
T1: 49 N·m (5.0 kgf-m, 36.2 ft-lb)
Tightening torque: T2: 57 N·m (5.8 kgf-m, 42 ft-lb)
34±5 N·m (3.5±0.5 kgf-m, 25.3±3.6 ft-lb)
2) Install engine onto transmission.
(1) Position engine in engine compartment and
align it with transmission.
CAUTION:
Be careful not to damage adjacent parts or
body panels with crank pulley, oil level gauge,
etc.
H3M1839A
7) Remove ST from torque converter clutch case.

(AT model)
NOTE:
Be careful not to drop the ST into the torque con-
verter clutch case when removing ST.
ST 498277200 STOPPER SET
B2M3391 8) Install starter. <Ref. to SC(H4)-8
INSTALLATION, Starter.>
(2) Apply a small amount of grease to spline of 9) Install torque converter clutch onto drive plate.
main shaft. (MT model) (AT model)
3) Tighten bolts which hold upper side of transmis- (1) Tighten bolts which hold torque converter
sion to engine. clutch to drive plate.
Tightening torque: (2) Tighten other bolts while rotating the engine
50 N·m (5.1 kgf-m, 36.9 ft-lb) by using ST.
CAUTION:
Be careful not to drop bolts into torque con-
verter clutch housing.
ST 499977100 CRANK PULLEY WRENCH
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B3M2044
4) Remove lifting device and wire ropes.
S2M0207
(3) Clog plug onto service hole.

10) Install power steering pump on bracket.
B2M3391
5) Remove garage jack.
ME(H4)-38
墌 00.5.31/68j/1me4 墍
ENGINE ASSEMBLY
Mechanical
(1) Install power steering tank on bracket. (5) Install resonator chamber.
Tightening torque:
33 N·m (3.4 kgf-m, 24.6 ft-lb)
B2M3153
(2) Install power steering pump on bracket, and

tighten bolts. B6M1237
Tightening torque: 11) Tighten nuts which hold lower side of trans-
20.1 N·m (2.05 kgf-m, 14.8 ft-lb) mission to engine.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
B2M3151A
(3) Tighten bolt which installs power steering

pump bracket, and install spark plug codes. B3M2047
12) Tighten nuts which install front cushion rubber

onto crossmember.
Tightening torque:
83 N·m (8.5 kgf-m, 61 ft-lb)
CAUTION:
Make sure the front cushion rubber mounting
bolts (A) and locator (B) are securely installed.
B2M3366
(4) Intake front side V-belt, and adjust it.
B2M3880A
13) Install front and center exhaust pipe.

<Ref. to EX(H4)-6 INSTALLATION, Front Exhaust
Pipe.> and <Ref. to EX(H4)-8 INSTALLATION,
G2M0286 Center Exhaust Pipe.>
14) Connect the following hoses.
ME(H4)-39
墌 00.5.31/68j/1me4 墍
ENGINE ASSEMBLY
Mechanical
(1) Fuel delivery hose, return hose and evapo- 20) Install V-belt cover.
ration hose
(2) Heater inlet and outlet hoses
(3) Brake booster vacuum hose
15) Connect the following connectors.
(1) Engine ground terminals
Tightening torque:
14 N·m (1.4 kgf-m, 10.1 ft-lb)
(2) Engine harness connectors
(3) Oxygen sensor connector (Except general
model) B2M3401
(4) Alternator connector and terminal
(5) A/C compressor connectors 21) Install air intake duct and cleaner case.
(6) Power steering pressure switch <Ref. to IN(H4)-2 General Description.>
16) Connect the following cables.
(1) Accelerator cable
(2) Cruise control cables (With cruise control)
CAUTION:
After connecting each cable, adjust them.
17) Install air cleaner case stay.
Tightening torque:
16 N·m (1.6 kgf-m, 11.6 ft-lb)
18) Install A/C pressure hoses. B2M3101
<Ref. to AC-37 INSTALLATION, Flexible Hose.>
CAUTION: 23) Install battery in the vehicle, and connect
Use new O-rings. cables.
Tightening torque: 24) Fill coolant.
25 N·m (2.5 kgf-m, 18.1 ft-lb) <Ref. to CO(H4)-6 FILLING OF ENGINE
COOLANT, REPLACEMENT, Engine Coolant.>
25) Check ATF level and correct if necessary. (AT
model)
<Ref. to AT-9 Automatic Transmission Fluid.>
26) Charge A/C system with refrigerant.
<Ref. to AC-19 OPERATION, Refrigerant Charging
Procedure.>
27) Remove front hood stay, and close front hood.
28) Take off the vehicle from lift arms.
B2M3385
1) Make sure pipes and hoses are installed cor-
19) Install radiator to vehicle. <Ref. to CO(H4)-16 rectly.
INSTALLATION, Radiator.> 2) Make sure the engine coolant and ATF are at
specified levels.
ME(H4)-40
墌 00.5.31/68j/1me4 墍
ENGINE MOUNTING
Mechanical
10. Engine Mounting S103085
1) Remove engine assembly. <Ref. to ME(H4)-33

REMOVAL, Engine Assembly.>
2) Remove engine mounting from engine assem-
bly.

Tightening torque:
Engine mounting;
34 N·m (3.5 kgf-m, 25.3 ft-lb)
Make sure there are no cracks or other damage.
ME(H4)-41
PREPARATION FOR OVERHAUL
Mechanical
11. Preparation for Overhaul S103091
1) After removing the engine from the body,

secure it in the ST shown below.
ST1 498457000 ENGINE STAND ADAPTER
RH
ST2 498457100 ENGINE STAND ADAPTER
LH
ST3 499817100 ENGINE STAND
B2M2582A
2) In this section the procedures described under

each index are all connected and stated in order.
It will be the complete procedure for overhauling of
the engine itself when you go through all steps in
the process.
Therefore, in this section, to conduct the particular
procedure within the flow of a section, you need to
go back and conduct the procedure described pre-
viously in order to do that particular procedure.
ME(H4)-42
V-BELT
Mechanical
12. V-belt S103080 C: INSPECTION S103080A10
1) Replace belts, if cracks, fraying or wear is
found.
1) Loosen the lock nut (A). 2) Check drive belt tension and adjust it if neces-
2) Loosen the slider bolt (B). sary by changing generator installing position
and/or idler pulley installing position.
Belt tension
(A)
replaced: 7 — 9 mm (0.276 — 0.354 in)
reused: 9 — 11 mm (0.354 — 0.433 in)
(B)*
replaced: 7.5 — 8.5 mm (0.295 — 0.335
in)
reused: 9.0 — 10.0 mm (0.354 — 0.394 in)
B2M2584A
3) Remove the A/C belt.

4) Remove the A/C belt tensioner.
B2M4123A
C/P Crankshaft pulley

GEN Generator
P/S Power steering oil pump pulley
B2M2585 A/C Air conditioning compressor pulley
I/P Idler pulley
1) Install a new belt, and tighten the slider bolt so

as to obtain the specified belt tension. <Ref. to
ME(H4)-43 INSPECTION, V-belt.>
2) Tighten the slider bolt (B).
3) Tighten the lock nut (A).
Tightening torque:
Lock nut (A);
22.6 N·m (2.3 kgf-m, 16.6 ft-lb)
B2M2584A
ME(H4)-43
墌 00.5.31/68j/1me4 墍
CRANKSHAFT PULLEY
Mechanical
13. Crankshaft Pulley S103098

Crankshaft pulley bolt:
12369AA011
(2) Clean the crankshaft thread using an air
1) Remove V-belt. <Ref. to ME(H4)-43 gun.
REMOVAL, V-belt.> (3) Tighten the bolts temporarily with tightening
2) Remove crankshaft pulley bolt. To lock torque of 44 N·m (4.5 kgf-m, 33 ft-lb).
crankshaft, use ST. (4) Tighten the crankshaft pulley bolts keeping
ST 499977100 them in an angle between 65 degrees and 75
CRANKSHAFT PULLEY WRENCH degrees.
CAUTION:
Conduct the tightening procedures by confirm-
ing the turning angle of the crankshaft pulley
bolt referring to the gauge indicated on the belt
cover.
4) Install A/C belt tensioner.
H2M2393C
3) Remove crankshaft pulley.
1) Install crankshaft pulley.

2) Install pulley bolt. B2M2585
To lock crankshaft, use ST.
5) Install A/C belt.
WRENCH
(1) Clean the crankshaft pulley thread using an
air gun.
(2) Apply engine oil to the crankshaft pulley bolt
seat and thread.
(3) Tighten the bolts temporarily with tightening
torque of 44 N·m (4.5 kgf-m, 33 ft-lb).
(4) Tighten the crankshaft pulley bolts.
Tightening torque:
177 N·m (18.0 kgf-m, 130.2 ft-lb) B2M2584
1) Make sure the V-belt is not worn or otherwise

damaged.
2) Check the tension of the belt. <Ref. to
H2M2393A
3) Confirm that the tightening angle of the crank-

shaft pulley bolt is 65 degrees or more. If not, con-
duct the following procedures (1) through (4).
(1) Replace the crankshaft pulley bolts and
clean them.
ME(H4)-44
墌 00.5.31/68j/1me4 墍
BELT COVER
Mechanical
14. Belt Cover S103582
1) Remove V-belt. <Ref. to ME(H4)-43

REMOVAL, V-belt.>
2) Remove crankshaft pulley. <Ref. to ME(H4)-44
REMOVAL, Crankshaft Pulley.>
3) Remove belt cover (LH).
4) Remove front belt cover.
B2M2587A
1) Install front belt cover.

Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
2) Install belt cover (LH).
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
B2M2587A
3) Install crankshaft pulley. <Ref. to ME(H4)-44

INSTALLATION, Crankshaft Pulley.>
4) Install V-belt. <Ref. to ME(H4)-43
Make sure the cover is not damaged.
ME(H4)-45
TIMING BELT ASSEMBLY
Mechanical
15. Timing Belt Assembly S103099
1. TIMING BELT S103099A1802

REMOVAL, V-belt.>
3) Remove belt cover. <Ref. to ME(H4)-45
REMOVAL, Belt Cover.>
4) Remove timing belt guide. (MT vehicle only)
B2M3430A
S2M0294
(2) Using white paint, put alignment and/or
5) If alignment mark (a) and/or arrow mark (which arrow marks on timing belts in relation to the
indicates rotation direction) on timing belt fade crank sprocket and cam sprockets.
away, put new marks before removing timing belt
as shown in procedures below.
(1) Turn crankshaft using ST. Align mark (a) of
sprocket to cylinder block notch (b) and ensure
that right side cam sprocket mark (c), cam cap
and cylinder head matching surface (d) and/or
left side cam sprocket mark (e) and belt cover
notch (f) are properly adjusted.
B2M2591
Specified data:
Z1: 44 tooth length
Z2: 40.5 tooth
B2M2590A
B2M3434A
ME(H4)-46
墌 00.5.31/68j/1me4 墍
Mechanical
6) Remove belt idler (No. 2). B: INSTALLATION S103099A11
7) Remove belt idler No. 2.

1. AUTOMATIC BELT TENSION
ADJUSTER ASSEMBLY AND BELT IDLER
S103099A1102
1) Preparation for installation of automatic belt

tension adjuster assembly;
CAUTION:
쐌 Always use a vertical type pressing tool to
move the adjuster rod down.
쐌 Do not use a lateral type vise.
S2M1008
쐌 Push adjuster rod vertically.
쐌 Be sure to slowly move the adjuster rod
8) Remove timing belt. down applying a pressure of 294 N (30 kg, 66
lb).
쐌 Press-in the push adjuster rod gradually tak-
ing more than three minutes.
쐌 Do not allow press pressure to exceed 9,807
N (1,000 kg, 2,205 lb).
쐌 Press the adjuster rod as far as the end sur-
face of the cylinder. Do not press the adjuster
rod into the cylinder. Doing so may damage the
cylinder.
쐌 Do not release press pressure until stopper
B2M3435 pin is completely inserted.
(1) Attach the automatic belt tension adjuster
2. BELT IDLER AND AUTOMATIC BELT assembly to the vertical pressing tool.
TENSION ADJUSTER ASSEMBLY S103099A1803 (2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kg, 66 lb) until the
1) Remove belt idler (No. 1). adjuster rod is aligned with the stopper pin hole
in the cylinder.
B2M2596
2) Remove automatic belt tension adjuster assem- H2M2382
bly.
H2M2375
ME(H4)-47
墌 00.5.31/68j/1me4 墍
Mechanical
(3) With a 2 mm (0.08 in) dia. stopper pin or a (1) Turn camshaft sprocket No. 2 using ST1,
2 mm (0.08 in) (nominal) dia. hex bar wrench and turn camshaft sprocket No. 1 using ST2 so
inserted into the stopper pin hole in the cylinder, that their alignment marks come to top posi-
secure the adjuster rod. tions.
ST1 499207100 CAMSHAFT SPROCKET
WRENCH
H2M2383A
2) Install automatic belt tension adjuster assem- B2M3436A

bly.
Tightening torque: (2) While aligning alignment mark on timing
39 N·m (4.0 kgf-m, 28.9 ft-lb) belt with marks on sprockets, position timing
belt properly.
CAUTION:
Ensure belt’s rotating direction is correct.
H2M2384
3) Install belt idler (No. 1).

Tightening torque: B2M3437A
39 N·m (4.0 kgf-m, 28.9 ft-lb)
3) Install belt idler No. 2.
Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
4) Install belt idler (No. 2).
Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
B2M2596
1) Preparation for installation of automatic belt

tension adjuster assembly. <Ref. to ME(H4)-47
AUTOMATIC BELT TENSION ADJUSTER
ASSEMBLY AND BELT IDLER, INSTALLATION, S2M1008
2) Installation of timing belt
ME(H4)-48
墌 00.5.31/68j/1me4 墍
Mechanical
5) After ensuring that the marks on timing belt and (3) Tighten remaining bolts.
camshaft sprockets are aligned, remove stopper Tightening torque:
pin from belt tensioner adjuster. 9.8 N·m (1.0 kgf-m, 7.2 ft-lb)
CAUTION:
After properly installing timing belt, remove
rocker cover and ensure that the valve lash
adjuster contains no air.
H2M2415
7) Install belt cover. <Ref. to ME(H4)-45

INSTALLATION, Belt Cover.>
H2M2387A
6) Install timing belt guide. (MT vehicles only) 9) Install V-belt. <Ref. to ME(H4)-43
(1) Temporarily tighten remaining bolts. INSTALLATION, V-belt.>
1) Check timing belt teeth for breaks, cracks, and

wear. If any fault is found, replace belt.
2) Check the condition of back side of belt; if any
crack is found, replace belt.
CAUTION:
쐌 Be careful not to let oil, grease or coolant
S2M0294
contact the belt. Remove quickly and thor-
(2) Check and adjust clearance between timing oughly if this happens.
belt and timing belt guide by using thickness 쐌 Do not bend the belt sharply.
gauge. Bending radius: h
Clearance: 60 mm (2.36 in) or more
1.0±0.5 mm (0.039±0.020 in)
G2M0115
S2M0297
2. AUTOMATIC BELT TENSION
ADJUSTER S103099A1002
1) Visually check oil seals for leaks, and rod ends
for abnormal wear or scratches. If necessary,
replace faulty parts.
ME(H4)-49
墌 00.5.31/68j/1me4 墍
Mechanical
CAUTION: 3) Check tension pulley for grease leakage.

Slight traces of oil at rod’s oil seal does not
indicate a problem. 4. BELT IDLER S103099A1004
2) Check that the adjuster rod does not move 1) Check belt idler for smooth rotation. Replace if
when a pressure of 294 N (30 kg, 66 lb) is applied noise or excessive play is noted.
2) Check belt outer contacting surfaces of idler
to it. This is to check adjuster rod stiffness.
pulley for abnormal wear and scratches.
3) If the adjuster rod is not stiff and moves freely
3) Check belt idler for grease leakage.
when applying 294 N (30 kg, 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 kg, 66 lb) to it.
Check adjuster rod stiffness.
(3) If the adjuster rod is not stiff and moves
down, replace the automatic belt tension
adjuster assembly with a new one.
CAUTION:
쐌 Always use a vertical type pressing tool to
move the adjuster rod down.
쐌 Do not use a lateral type vise.
쐌 Push adjuster rod vertically.
쐌 Press-in the push adjuster rod gradually tak-
ing more than three minutes.
쐌 Do not allow press pressure to exceed 9,807
N (1,000 kg, 2,205 lb).
쐌 Press the adjuster rod as far as the end sur-
face 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
5.7±0.5 mm (0.224±0.020 in)
H2M2381A
3. BELT TENSION PULLEY S103099A1003
1) Check mating surfaces of timing belt and con-

tact point of adjuster rod for abnormal wear or
scratches. Replace automatic belt tension adjuster
assembly if faulty.
2) Check tension pulley for smooth rotation.
Replace if noise or excessive play is noted.
ME(H4)-50
墌 00.5.31/68j/1me4 墍
CAMSHAFT SPROCKET
Mechanical
16. Camshaft Sprocket S103097

A: REMOVAL S103097A18 4) Install crankshaft pulley. <Ref. to ME(H4)-44
1. REMOVAL S103097A1804
1) Remove V-belt. <Ref. to ME(H4)-43 INSTALLATION, V-belt.>
REMOVAL, V-belt.>
2) Remove crankshaft pulley. <Ref. to ME(H4)-44 C: INSPECTION S103097A10
REMOVAL, Crankshaft Pulley.> 1) Check sprocket teeth for abnormal wear and
3) Remove belt cover. <Ref. to ME(H4)-45 scratches.
REMOVAL, Belt Cover.> 2) Make sure there is no free play between
4) Remove timing belt assembly. <Ref. to sprocket and key.
ME(H4)-46 REMOVAL, Timing Belt Assembly.> 3) Check crankshaft sprocket notch for sensor for
5) Remove camshaft sprocket No. 1 and No. 2. To damage and contamination of foreign matter.
lock camshaft, use ST.
WRENCH
H2M2377A
1) Install camshaft sprocket No. 1 and No. 2. To

lock camshaft, use ST.
WRENCH
Tightening torque:
78 N·m (8.0 kgf-m, 57.9 ft-lb)
CAUTION:
Do not confuse left and right side camshaft
sprockets during installation. The camshaft
sprocket No. 2 is identified by a projection
used to monitor camshaft position sensor.
H2M2377A
2) Install timing belt assembly. <Ref. to ME(H4)-47

INSTALLATION, Timing Belt Assembly.>
ME(H4)-51
CRANKSHAFT SPROCKET
Mechanical
17. Crankshaft Sprocket S103101 B: INSTALLATION S103101A11
1) Install crankshaft sprocket.
REMOVAL, V-belt.>
4) Remove timing belt assembly. <Ref. to
ME(H4)-46 REMOVAL, Timing Belt Assembly.>
5) Remove camshaft sprocket. <Ref. to
ME(H4)-51 REMOVAL, Camshaft Sprocket.>
B2M2600C
6) Remove crankshaft sprocket.
B2M2600C S2M0414C
2) Install camshaft sprocket. <Ref. to ME(H4)-51

INSTALLATION, Camshaft Sprocket.>
INSTALLATION, Camshaft Pulley.>
S2M0414C
1) Check sprocket teeth for abnormal wear and

scratches.
2) Make sure there is no free play between
sprocket and key.
3) Check crankshaft sprocket notch for sensor for
damage and contamination of foreign matter.
ME(H4)-52
墌 00.5.31/68j/1me4 墍
VALVE ROCKER ASSEMBLY
Mechanical
18. Valve Rocker Assembly S103094

(2) Tighten bolts (e) through (h) to specified
torque.
A: REMOVAL S103094A18 (3) Tighten bolts (a) through (d) to specified
torque.
REMOVAL, V-belt.> Tightening torque:
2) Remove crankshaft pulley. <Ref. to ME(H4)-44 25 N·m (2.5 kgf-m, 18.1 ft-lb)
6) Disconnect PCV hose and remove rocker
cover.
7) Removal of valve rocker assembly
(1) Remove bolts (a) through (h) in alphabetical B2M2605A
sequence. 2) Adjust the valve clearances. <Ref. to

CAUTION: ME(H4)-31 ADJUSTMENT, Valve Clearance.>
Leave two or three threads of bolts (g and h) 3) Install rocker cover and connect PCV hose.
engaged to retain valve rocker assembly. 4) Install camshaft sprocket. <Ref. to ME(H4)-51
B2M2605F
1) Remove bolts which secure rocker shaft.
(2) Remove valve rocker assembly. 2) Extract rocker shaft. Remove valve rocker
arms, springs, plates and shaft supports from
rocker shaft.
CAUTION:
Arrange all removed parts in order so that they
can be installed in their original positions.
3) Remove nut and adjuster screw from valve
rocker.
B2M2606 1) Install adjuster screw and nut to valve rocker.

2) Arrange valve rocker arms, springs and shaft
supports in assembly order and insert valve rocker
B: INSTALLATION S103094A11 shaft.
1) Installation of valve rocker assembly Tightening torque (Shaft supports installing
(1) Temporarily tighten bolts (a) through (d) bolts):
equally as shown in figure. 5±1 N·m (0.5±0.1 kgf-m, 3.6±0.7 ft-lb)
CAUTION: CAUTION:
Do not allow valve rocker assembly to gouge Valve rocker arms, rocker shaft and shaft sup-
knock pins. ports have identification marks. Ensure parts
with same markings are properly assembled.
ME(H4)-53
墌 00.5.31/68j/1me4 墍
Mechanical
3) Install valve rocker shaft securing bolts. 4) If oil clearance exceeds the limit, replace rocker
shaft support or shaft, whichever shows greater
E: INSPECTION S103094A10 amount of wear.
1. VALVE ROCKER ARM S103094A1002
Rocker shaft support inside diameter:
22.005 — 22.026 mm (0.8663 — 0.8672 in)
1) Measure inside diameter of valve rocker arm
and outside diameter of valve rocker shaft, and Rocker shaft diameter:
determine the difference between the two (= oil 21.987 — 22.000 mm (0.8656 — 0.8661 in)
clearance). 5) If cam or valve contact surface of valve rocker
Clearance between arm and shaft: arm is worn or dented excessively, replace valve
rocker arm.
Standard
6) Check that valve rocker arm roller rotates
0.020 — 0.054 mm (0.0008 — 0.0021 in)
smoothly. If not, replace valve rocker arm.
Limit
0.10 mm (0.0039 in) 2. INTAKE AND EXHAUST VALVE
ROCKER SHAFT S103094A1003
Visually check oil relief valve of shaft end for any
of the following abnormalities.
쐌 Breaks in check ball body
쐌 Foreign particles caught in valve spring
쐌 Oil leakage at check ball
CAUTION:
Repair or replace valve rocker shaft as neces-
sary.
B2M0072
B2M0073
2) If oil clearance exceeds the limit, replace valve

rocker arm or shaft, whichever shows greater
amount of wear.
Rocker arm inside diameter:
22.020 — 22.041 mm (0.8669 — 0.8678 in)
Rocker shaft diameter:
21.987 — 22.000 mm (0.8656 — 0.8661 in)
3) Measure inside diameter of rocker shaft sup-
port 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(H4)-54
墌 00.5.31/68j/1me4 墍
CAMSHAFT
Mechanical
19. Camshaft S103092

(1) Remove bolts (a) through (b) in alphabetical
sequence.

B2M2612B
6) Remove crankshaft sprocket. <Ref. to (2) Equally loosen bolts (c) through (j) all the
ME(H4)-52 REMOVAL, Crankshaft Sprocket.> way in alphabetical sequence.
7) Remove belt cover No. 2 (LH).
8) Remove belt cover No. 2 (RH).
CAUTION:
Do not damage or lose the seal rubber when
removing belt covers.
B2M2612C
(3) Remove bolts (k) through (p) in alphabetical

sequence using ST.
ST 499497000 TORX PLUS
B2M2601
9) Remove tensioner bracket.
B2M2612D
(4) Remove camshaft cap.
H2M2380
10) Remove camshaft position sensor support.

(LH side only)
11) Remove oil level gauge guide. (LH side only)
12) Remove valve rocker assembly. <Ref. to
ME(H4)-53 REMOVAL, Valve Rocker Assembly.>
13) Remove camshaft cap.
B2M2613
14) Remove camshaft.

15) Remove oil seal.
ME(H4)-55
墌 00.5.31/68j/1me4 墍
CAMSHAFT
Mechanical
16) Remove plug from rear side of camshaft. (3) Install valve rocker assembly.
CAUTION:
쐌 Do not remove oil seal unless necessary.
쐌 Do not scratch journal surface when remov-
ing oil seal.
1) Apply a coat of engine oil to camshaft journals

and install camshaft.
2) Install camshaft cap.
(1) Apply liquid gasket on the around of cam-
B2M2615
shaft cap.
Liquid gasket: (4) Tighten bolts (a) through (h) in alphabetical
THREE BOND 1280B sequence.
P/N K0877YA018 Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B2M2619
B2M2621B
NOTE:
Apply a coat of 3 mm (0.12 in) dia. liquid gasket (5) Tighten TORX bolts (i) through (n) in alpha-
along edge of cam cap mating surface. betical sequence using ST.
ST 499427000 TORX PLUS
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
S2M1199A
(2) Temporarily tighten bolts (g) through (j) in

alphabetical sequence.
B2M2621C
B2M2612E
ME(H4)-56
墌 00.5.31/68j/1me4 墍
CAMSHAFT
Mechanical
(6) Tighten bolts (o) through (v) in alphabetical 8) Install camshaft position sensor support. (LH
sequence. side only)
Tightening torque: 9) Install tensioner bracket.
10 N·m (1.0 kgf-m, 7.2 ft-lb) Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B2M2621D
H2M2380
(7) Tighten bolts (w) through (x) in alphabetical
sequence. 10) Install belt cover No. 2 (RH).
Tightening torque: Tightening torque:
10 N·m (1.0 kgf-m, 7.2 ft-lb) 5 N·m (0.5 kgf-m, 3.6 ft-lb)
11) Install belt cover No. 2 (LH).
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
B2M2621E
3) Apply a coat of grease to oil seal lips and install

oil seal (A) on camshaft using ST1 and ST2.
CAUTION: B2M2601
Use a new oil seal.
12) Install timing belt assembly. <Ref. to
ST1 499597000 OIL SEAL GUIDE ME(H4)-47 INSTALLATION, Timing Belt Assem-
ST2 499587500 OIL SEAL INSTALLER
bly.>
S2M1123A
4) Install plug using ST.

5) Adjust the valve clearance. <Ref. to ME(H4)-31
ADJUSTMENT, Valve Clearance.>
6) Install rocker cover and connect PCV hose.
7) Install oil level gauge guide. (LH side only)
ME(H4)-57
墌 00.5.31/68j/1me4 墍
CAMSHAFT
Mechanical
C: INSPECTION S103092A10 Cam base circle diameter A:

IN: 34.00 mm (1.3386 in)
1. CAMSHAFT S103092A1001
EX: 34.00 mm (1.3386 in)
1) Measure the bend, and repair or replace if nec-
essary.
Limit:
0.025 mm (0.0010 in)
B2M1209A
2. CAMSHAFT SUPPORT S103092A1002
Measure the thrust clearance of camshaft with dial

B2M2617 gauge. If the clearance exceeds the limit, replace
camshaft support.
2) Check journal for damage and wear. Replace if
Standard:
faulty.
0.030 — 0.090 mm (0.0012 — 0.0035 in)
3) Measure outside diameter of camshaft journal
and inside diameter of cylinder head journal, and Limit:
determine the difference between the two (= oil 0.10 mm (0.0039 in)
clearance). If oil clearance exceeds specifications,
replace camshaft or cylinder head as necessary.
Unit: mm (in)
Clearance Standard 0.055 — 0.090 (0.0022 — 0.0035)
at journal Limit 0.10 (0.0039)
31.928 — 31.945 (1.2570 —
Camshaft journal O.D.
1.2577)
32.000 — 32.018 (1.2598 —
Journal hole I.D.
1.2605)
B2M2618A
4) Check cam face condition; remove minor faults
by grinding with oil stone. Measure the cam height
H; replace if the limit has been exceeded.
Cam height: H
Item Unit: mm (in)
39.485 — 39.585
STD
Intake (1.5545 — 1.5585)
Limit 39.385 (1.5506)
39.257 — 39.357
STD
Exhaust (1.5455 — 1.5495)
Limit 39.157 (1.5416)
ME(H4)-58
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CYLINDER HEAD ASSEMBLY
Mechanical
20. Cylinder Head Assembly S103093

CAUTION:
Do not scratch the mating surface of cylinder
A: REMOVAL S103093A18 head and cylinder block.
1) Remove V-belt. <Ref. to ME(H4)-43 14) Similarly, remove right side cylinder head.
REMOVAL, V-belt.>
2) Remove crankshaft pulley. <Ref. to ME(H4)-44 B: INSTALLATION S103093A11

1. CYLINDER HEAD S103093A1102
REMOVAL, Belt Cover.> 1) Install cylinder head and gaskets on cylinder
4) Remove timing belt assembly. <Ref. to block.
ME(H4)-46 REMOVAL, Timing Belt Assembly.> CAUTION:
5) Remove camshaft sprocket. <Ref. to 쐌 Use new cylinder head gaskets.
ME(H4)-51 REMOVAL, Camshaft Sprocket.> 쐌 Be careful not to scratch the mating surface
6) Remove intake manifold. <Ref. to FU(H4)-19 of cylinder block and oil pump.
REMOVAL, Intake Manifold.>
7) Remove bolt which installs A/C compressor 2) Tighten cylinder head bolts.
bracket on cylinder head. (1) Apply a coat of engine oil to washers and
8) Remove valve rocker assembly. <Ref. to bolt threads.
ME(H4)-53 REMOVAL, Valve Rocker Assembly.> (2) Tighten all bolts to 29 N·m (3.0 kgf-m, 22
9) Remove camshaft. <Ref. to ME(H4)-55 ft-lb) in alphabetical sequence.
REMOVAL, Camshaft.> Then tighten all bolts to 69 N·m (7.0 kgf-m, 51
ft-lb) in alphabetical sequence.
10) Remove cylinder head bolts in alphabetical
(3) Back off all bolts by 180° first; back them off
sequence shown in figure.
by 180° again.
CAUTION: (4) Tighten bolts (a) and (b) to 34 N·m (3.5
Leave bolts (a) and (c) engaged by three or four kgf-m, 25 ft-lb).
threads to prevent cylinder head from falling. (5) Tighten bolts (c), (d), (e) and (f) to 15 N·m
(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
S2M1589A the former two steps], do not exceed 180°.
11) While tapping cylinder head with a plastic

hammer, separate it from cylinder block.
12) Remove bolts (a) and (b) to remove cylinder
head.
S2M1589B
3) Install camshaft. <Ref. to ME(H4)-56

INSTALLATION, Camshaft.>
4) Install valve rocker assembly. <Ref. to
ME(H4)-53 INSTALLATION, Valve Rocker Assem-
S2M1589A
bly.>
13) Remove cylinder head gasket. 5) Install A/C compressor bracket on cylinder
head.
ME(H4)-59
墌 00.5.31/68j/1me4 墍
Mechanical
6) Install intake manifold. <Ref. to FU(H4)-22

INSTALLATION, Intake Manifold.>
1) Place cylinder head on ST.

ST 498267800 CYLINDER HEAD TABLE
2) Set ST on valve spring. Compress valve spring
and remove the valve spring retainer key. Remove
each valve and valve spring.
ST 499718000 VALVE SPRING REMOVER
CAUTION:
쐌 Mark each valve to prevent confusion.
쐌 Use extreme care not to damage the lips of
the intake valve oil seals and exhaust valve oil
seals.
B2M2630A
ME(H4)-60
墌 00.5.31/68j/1me4 墍
Mechanical
B2M2629B
(1) Valve (6) Retainer (11) Plug

(2) Valve guide (7) Retainer key (12) Camshaft cap
(3) Valve spring seat (8) Spark plug gasket (13) Valve rocker ASSY
(4) Oil seal (9) Camshaft
(5) Valve spring (10) Oil seal
1) Installation of valve spring and valve (4) Set ST on valve spring.

(1) Place cylinder head on ST. ST 499718000 VALVE SPRING REMOVER
(2) Coat stem of each valve with engine oil and
insert valve into valve guide.
CAUTION:
When inserting valve into valve guide, use spe-
cial care not to damage the oil seal lip.
(3) Install valve spring and retainer.
CAUTION:
Be sure to install the valve springs with their
close-coiled end facing the seat on the cylinder B2M2630A
head.
ME(H4)-61
墌 00.5.31/68j/1me4 墍
Mechanical
(5) Compress valve spring and fit valve spring 2. INTAKE AND EXHAUST VALVE OIL
retainer key. SEAL S103093A1003
Replace oil seal with new one, if lip is damaged or
spring out of place, or when the surfaces of intake
valve and valve seat are reconditioned or intake
valve guide is replaced. Use pliers to pinch and
remove oil seal from valve.
1) Place cylinder head on ST1.
2) Press-fit oil seal to the specified dimension indi-
cated in the figure using ST2.
CAUTION:
B2M2634A 쐌 Apply engine oil to oil seal before press-fit-
ting.
(6) After installing, tap valve spring retainers 쐌 When press-fitting oil seal, do not use ham-
lightly with wooden hammer for better seating. mer or strike in.
쐌 Differentiate between intake valve oil seal
and exhaust valve oil seal by noting their dif-
1. VALVE SPRING S103093A1002
ference in color.
1) Check valve springs for damage, free length, ST1 498267800 CYLINDER HEAD TABLE
and tension. Replace valve spring if it is not to the ST2 498857100 VALVE OIL SEAL GUIDE
specifications presented below. Color of rubber part:
2) To measure the squareness of the valve spring, Intake [Black]
stand the spring on a surface plate and measure Exhaust [Brown]
its deflection at the top using a try square.
Color of spring part:
Free length 54.30 mm (2.1378 in) Intake [Silver]
Squareness 2.5°, 2.4 mm (0.094 in) Exhaust [Silver]
214.8 — 246.2 N
(21.9 — 25.1 kg, 48.3 — 55.3 lb)/
45.0 mm (1.772 in)
Tension/spring height
526.6 — 581.6 N
(53.7 — 59.3 kg, 118.4 — 130.8
lb)/34.7 mm (1.366 in)
B2M2633A
1. CYLINDER HEAD S103093A0101
G2M0154
1) Make sure that no crack or other damage
exists. In addition to visual inspection, inspect
important areas by means of red lead check.
Also make sure that gasket installing surface
shows no trace of gas and water leaks.
2) Place cylinder head on ST.
3) Measure the warping of the cylinder head sur-
face 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.
ME(H4)-62
墌 00.5.31/68j/1me4 墍
Mechanical
Warping limit: 2. VALVE SEAT S103093A0102
0.05 mm (0.0020 in)

Inspect intake and exhaust valve seats, and cor-
Grinding limit: rect the contact surfaces with valve seat cutter if
0.3 mm (0.012 in) they are defective or when valve guides are
Standard height of cylinder head: replaced.
97.5 mm (3.839 in) Valve seat width: W
CAUTION: Intake
Uneven torque for the cylinder head bolts can Standard 1.0 mm (0.039 in)
cause warping. When reassembling, pay spe- Limit 1.7 mm (0.067 in)
cial attention to the torque so as to tighten Exhaust
evenly. Standard 1.4 mm (0.055 in)
Limit 2.1 mm (0.083 in)
G2M0148
G2M0149
B2M0074
3. VALVE GUIDE S103093A0103
1) Check the clearance between valve guide and

stem. The clearance can be checked by measur-
ing the outside diameter of valve stem and the
inside diameter of valve guide with outside and
inside micrometers respectively.
ME(H4)-63
墌 00.5.31/68j/1me4 墍
Mechanical
Clearance between the valve guide and valve (2) Insert ST2 into valve guide and press it
stem: down to remove valve guide.
Standard ST1 498267800 CYLINDER HEAD TABLE
Intake 0.035 — 0.062 mm (0.0014 — ST2 499767200 VALVE GUIDE REMOVER
0.0024 in)
Exhaust 0.040 — 0.067 mm (0.0016 —
0.0026 in)
Limit
0.15 mm (0.0059 in)
G2M0150
(3) Turn cylinder head upside down and place

ST as shown in the figure.
Intake side:
B2M0387A
ST 499767700 VALVE GUIDE ADJUSTER
Exhaust side:
ST 499767800 VALVE GUIDE ADJUSTER
B2M0076A
B2M0077B
2) If the clearance between valve guide and stem
exceeds the limit, replace valve guide or valve (4) Before installing new oversize valve guide,
itself whichever shows greater amount of wear. make sure that neither scratches nor damages
See following procedure for valve guide replace- exist on the inside surface of the valve guide
ment. holes in cylinder head.
Valve guide inner diameter:
6.000 — 6.012 mm (0.2362 — 0.2367 in)
Valve stem outer diameters:
Intake
5.950 — 5.965 mm (0.2343 — 0.2348 in)
Exhaust
5.945 — 5.960 mm (0.2341 — 0.2346 in)
(1) Place cylinder head on ST1 with the com-
bustion chamber upward so that valve guides
enter the holes in ST1.
ME(H4)-64
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Mechanical
(5) Put new valve guide, coated with sufficient (7) Ream the inside of valve guide with ST.
oil, in cylinder, and insert ST1 into valve guide. Gently rotate the reamer clockwise while press-
Press in until the valve guide upper end is flush ing it lightly into valve guide, and return it also
with the upper surface of ST2. rotating clockwise. After reaming, clean valve
ST1 499767200 VALVE GUIDE REMOVER guide to remove chips.
Intake side: CAUTION:
ST2 499767700 VALVE GUIDE ADJUSTER 쐌 Apply engine oil to the reamer when ream-
Exhaust side: ing.
ST2 499767800 VALVE GUIDE ADJUSTER 쐌 If the inner surface of the valve guide is torn,
the edge of the reamer should be slightly
ground with an oil stone.
쐌 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.
B2M0077A
ME(H4)-65
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Mechanical
4. INTAKE AND EXHAUST VALVE S103093A0104
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 sur-
face. <Ref. to ME(H4)-63 VALVE SEAT,
ADJUSTMENT, Cylinder Head Assembly.> Install
a new intake valve oil seal after lapping.
ME(H4)-66
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CYLINDER BLOCK
Mechanical
21. Cylinder Block S103090

13) Remove cylinder head gasket.
CAUTION:
Do not scratch the mating surface of cylinder
NOTE: head and cylinder block.
Before conducting this procedure, drain engine oil 14) Similarly, remove right side cylinder head.
completely if applicable. 15) Remove clutch housing cover (MT vehicles
1) Remove intake manifold. <Ref. to FU(H4)-19 only).
REMOVAL, Intake Manifold.> 16) Remove flywheel (MT vehicles only) or drive
2) Remove V-belt. <Ref. to ME(H4)-43 plate (AT vehicles only).
REMOVAL, V-belt.> Using ST, lock crankshaft.
3) Remove crankshaft pulley. <Ref. to ME(H4)-44 ST 498497100 CRANKSHAFT STOPPER
7) Remove crankshaft sprocket. <Ref. to
ME(H4)-44 REMOVAL, Crankshaft Sprocket.>
8) Remove generator and A/C compressor with
their brackets. G2M0776
9) Remove rocker cover.
10) Remove cylinder head bolts in alphabetical
sequence shown in figure.
CAUTION:
Leave bolts (a) and (b) engaged by three or four
threads to prevent cylinder head from falling.
B2M3395B
17) Remove oil separator cover.

18) Remove water by-pass pipe for heater.
19) Remove water pump.
20) Remove oil pump from cylinder block.
B2M2628A Use a flat-bladed screwdriver as shown in figure
11) While tapping cylinder head with a plastic when removing oil pump.
hammer, separate it from cylinder block. CAUTION:
12) Remove bolts (a) and (b) to remove cylinder Be careful not to scratch the mating surface of
head. cylinder block and oil pump.
B2M2628A G2M0162
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CYLINDER BLOCK
Mechanical
21) Removal of oil pan 26) Remove water pipe.

(1) Turn cylinder block with #2 and #4 piston
sides facing upward.
(2) Remove bolts which secure oil pan to cylin-
der block.
(3) Insert a oil pan cutter blade between cylin-
der block-to-oil pan clearance and remove oil
pan.
CAUTION:
Do not use a screwdriver or similar tool in
place of oil pan cutter.
B2M2638
G2M0163
22) Remove oil strainer stay.

23) Remove oil strainer.
24) Remove baffle plate.
25) Remove oil filter using ST.
B2M2611A
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CYLINDER BLOCK
Mechanical
S2M1590A
(1) Service hole plug (3) Circlip (5) Service hole cover
(2) Gasket (4) Piston pin
27) Remove service hole cover and service hole 28) Rotate crankshaft to bring #1 and #2 pistons
plugs using hexagon wrench [14 mm (0.55 in)]. to bottom dead center position, then remove piston
circlip through service hole of #1 and #2 cylinders.
B2M2620
G2M0165
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CYLINDER BLOCK
Mechanical
29) Draw out piston pin from #1 and #2 pistons 30) Similarly remove piston pins from #3 and #4
using ST. pistons.
ST 499097700 PISTON PIN REMOVER 31) Remove bolts which connect cylinder block on
CAUTION: the side of #2 and #4 cylinders.
Be careful not to confuse original combination 32) Back off bolts which connect cylinder block on
of piston, piston pin and cylinder. the side of #1 and #3 cylinders two or three turns.
33) Set up cylinder block so that #1 and #3 cylin-
ders are on the upper side, then remove cylinder
block connecting bolts.
34) Separate left-hand and right-hand cylinder
blocks.
CAUTION:
When separating cylinder block, do not allow
the connecting rod to fall and damage the cyl-
inder block.
G2M0166
B2M2408A
(1) Cylinder block (3) Crankshaft (5) Piston

(2) Rear oil seal (4) Crankshaft bearing
35) Remove rear oil seal. CAUTION:

36) Remove crankshaft together with connecting Do not confuse combination of crankshaft
rod. bearings. Press bearing at the end opposite to
37) Remove crankshaft bearings from cylinder locking lip.
block using hammer handle.
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CYLINDER BLOCK
Mechanical
B2M2407A
(1) Crankshaft bearing (4) Rear oil seal Tightening torque: N·m (kgf-m, ft-lb)
(2) Crankshaft
T1: 25 (2.5, 18.1)
(3) Cylinder block
T2: 47 (4.8, 34.7)
CAUTION:
Remove oil in the mating surface of bearing
and cylinder block before installation. Also
apply a coat of engine oil to crankshaft pins.
1) Position crankshaft on the #2 and #4 cylinder
block.
2) Apply fluid packing to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.
Fluid packing: G2M0185

3) Temporarily tighten 10 mm cylinder block con-
CAUTION: necting bolts in alphabetical sequence shown in
Do not allow fluid packing to jut into O-ring figure.
grooves, oil passages, bearing grooves, etc.
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CYLINDER BLOCK
Mechanical
B2M0088D G2M0186
4) Tighten 10 mm cylinder block connecting bolts 7) Position the top ring gap at (A) or (B) in the fig-
in alphabetical sequence. ure.
Tightening torque:
47±3 N·m (4.8±0.3 kgf-m, 34.7±2.2 ft-lb)
B2M3722A
8) Position the second ring gap at 180° on the

B2M0088D reverse side for the top ring gap.
5) Tighten 8 mm and 6 mm cylinder block connect- 9) Position the upper rail gap at (C) or (D) in the
ing bolts in alphabetical sequence shown in figure. figure.
Tightening torque:
(A) — (G): 25±2 N·m (2.5±0.2 kgf-m,
18.1±1.4 ft-lb)
(H): 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
B2M3723A
10) Position the expander gap at 180° of the

reverse side for the upper rail gap.
11) Position the lower rail gap at (E) or (F) in the
B2M0089F figure.
6) Install rear oil seal using ST1 and ST2. CAUTION:

ST1 499597100 OIL SEAL GUIDE 쐌 Ensure ring gaps do not face the same direc-
ST2 499587200 OIL SEAL INSTALLER tion.
쐌 Ensure ring gaps are not within the piston
skirt area.
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CYLINDER BLOCK
Mechanical
CAUTION:
Piston front mark faces towards the front of the
engine.
B2M3723A
12) Install circlip.

Install circlips in piston holes located opposite ser-
vice holes in cylinder block, when positioning all B2M3724A
pistons in the corresponding cylinders.
CAUTION:
Use new circlips.
B2M1403A
B2M1322J
(1) Piston (4) Gasket Tightening torque: N·m (kgf-m, ft-lb)

(2) Piston pin (5) Service hole plug
T: 69 (7.0, 50.6)
(3) Circlip
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CYLINDER BLOCK
Mechanical
13) Installing piston CAUTION:

(1) Turn cylinder block so that #1 and #2 cylin- Use new circlips.
ders face upward.
(2) Using ST1, turn crankshaft so that #1 and
#2 connecting rods are set at bottom dead cen-
ter.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to pistons and
cylinders and insert pistons in their cylinders
using ST2.
ST2 498747300 PISTON GUIDE
G2M0190
(4) Apply fluid packing around the service hole

plug.
Fluid packing:
S2M0306A
14) Installing piston pin

(1) Insert ST3 into service hole to align piston
pin hole with connecting rod small end.
CAUTION:
Apply a coat of engine oil to ST3 before inser-
tion.
B2M2625
ST3 499017100 PISTON PIN GUIDE
(5) Install service hole plug and gasket.
CAUTION:
Use a new gasket.
G2M0189
(2) Apply a coat of engine oil to piston pin and

insert piston pin into piston and connecting rod
through service hole. B2M2620
(3) Install circlip.
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CYLINDER BLOCK
Mechanical
B2M1323K
(1) Piston (5) Service hole plug Tightening torque: N·m (kgf-m, ft-lb)
(2) Piston pin (6) Service hole cover
T1: 6.4 (0.65, 4.7)
(3) Circlip (7) O-ring
T2: 69 (7.0, 50.6)
(4) Gasket
(6) Turn cylinder block so that #3 and #4 cylin- 19) Apply fluid packing to matching surfaces and
ders face upward. Using the same procedures install oil pan.
as used for #1 and #2 cylinders, install pistons
Fluid packing:
and piston pins.
15) Install water pipe. THREE BOND 1215 or equivalent
G2M0084
B2M2638
16) Install baffle plate. 20) Apply fluid packing to matching surfaces and
install oil separator cover.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb) Fluid packing:
17) Install oil strainer and O-ring
Tightening torque:
10 N·m (1.0 kgf-m, 7 ft-lb)
18) Install oil strainer stay.
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CYLINDER BLOCK
Mechanical
(2) Apply fluid packing to matching surface of

oil pump.
Fluid packing:
G2M0194
21) Install flywheel or drive plate.

To lock crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
Tightening torque: S2M0739A
72 N·m (7.3 kgf-m, 52.8 ft-lb)
(3) Apply a coat of engine oil to the inside of the
oil seal.
B2M3361A
S2M0118A
(4) Install oil pump on cylinder block. Be care-

ful not to damage oil seal during installation.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
CAUTION:
쐌 Do not forget to install O-ring and seal when
installing oil pump.
B2M3393A
쐌 Align flat surface of oil pump’s inner rotor
with crankshaft before installation.
22) Install housing cover.
23) Installation of oil pump 24) Install water pump and gasket.
(1) Discard front oil seal after removal. Replace Tightening torque:
with a new one using ST. First; 12 N·m (1.2 kgf-m, 8.7 ft-lb)
ST 499587100 OIL SEAL INSTALLER Second; 12 N·m (1.2 kgf-m, 8.7 ft-lb)
CAUTION:
쐌 Be sure to use a new gasket.
쐌 When installing water pump, tighten bolts in
two stages in alphabetical sequence as shown
in figure.
S2M0235
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CYLINDER BLOCK
Mechanical
H2M1568B B2M2628B
25) Install water by-pass pipe for heater. 28) Install oil level gauge guide and tighten attach-
26) Install oil filter using ST. ing bolt (left side only).
ST 498547000 OIL FILTER WRENCH 29) Install rocker cover.
30) Install crankshaft sprocket. <Ref. to
ME(H4)-52 INSTALLATION, Crankshaft
Sprocket.>
32) Install timing belt assembly. <Ref. to
ME(H4)-47 INSTALLATION, Timing Belt Assem-
bly.>
34) Install crankshaft pulley. <Ref. to ME(H4)-44,
B2M2611A INSTALLATION, Crankshaft pulley.>
35) Install generator and A/C compressor brackets
27) Tighten cylinder head bolts.
on cylinder head.
(1) Apply a coat of engine oil to washers and
bolt threads. INSTALLATION, V-belt.>
(2) Tighten all bolts to 29 N·m (3.0 kg-m, 22 37) Install intake manifold. <Ref. to FU(H4)-22
ft-lb) in alphabetical sequence. INSTALLATION, Intake Manifold.>
Then tighten all bolts to 69 N·m (7.0 kg-m, 51
ft-lb) in alphabetical sequence.
(3) Back off all bolts by 180º first; back them off
by 180º again.
(4) Tighten bolts (a) and (b) to 34 N·m (3.5
kg-m, 25 ft-lb).
(5) Tighten bolts (c), (d), (e) and (f) to 15 N·m
(1.5 kg-m, 11 ft-lb).
(6) Tighten all bolts by 80 to 90º in alphabetical
sequence.
CAUTION:
Do not tighten bolts more than 90º.
(7) Further tighten all bolts by 80 to 90º in
alphabetical sequence.
CAUTION:
Ensure that the total “re-tightening angle” [in
the former two steps], do not exceed 180º.
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CYLINDER BLOCK
Mechanical
B2M1320I
(1) Connecting rod cap (3) Top ring (5) Oil ring
(2) Connecting rod bearing (4) Second ring (6) Circlip
1) Remove connecting rod cap.

2) Remove connecting rod bearing.
CAUTION:
Arrange removed connecting rod, connecting
rod cap and bearing in order to prevent confu-
sion.
3) Remove piston rings using the piston ring
expander.
4) Remove the oil ring by hand.
CAUTION:
Arrange the removed piston rings in good
order to prevent confusion.
5) Remove circlip.
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CYLINDER BLOCK
Mechanical
B2M1320J
(1) Connecting rod bearing (5) Second ring Tightening torque: N·m (kgf-m, ft-lb)
(2) Connecting rod (6) Top ring
T: 44.6 (4.55, 32.9)
(3) Connecting rod cap (7) Circlip
(4) Oil ring
1) Install connecting rod bearings on connecting 1) Visually check for cracks and damage.
rods and connecting rod caps. Especially, inspect important parts by means of red
CAUTION: lead check.
Apply oil to the surfaces of the connecting rod 2) Check the oil passages for clogging.
bearings. 3) Inspect crankcase surface that mates with cyl-
inder head for warping by using a straight edge,
2) Install connecting rod on crankshaft. and correct by grinding if necessary.
CAUTION: Warping limit:
Position each connecting rod with the side 0.05 mm (0.0020 in)
marked facing forward.
Grinding limit:
3) Install connecting rod cap with connecting rod 0.1 mm (0.004 in)
nut.
Ensure the arrow on connecting rod cap faces the Standard height of cylinder block:
front during installation. 201.0 mm (7.91 in)
CAUTION:
쐌 Each connecting rod has its own mating cap.
Make sure that they are assembled correctly by
checking their matching number.
쐌 When tightening the connecting rod nuts,
apply oil on the threads.
4) Install oil ring spacer, upper rail and lower rail in
this order by hand. Then install second ring and top
ring with a piston ring expander.
1. CYLINDER BLOCK S103090A1002
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CYLINDER BLOCK
Mechanical
2. CYLINDER AND PISTON S103090A1003 2) How to measure the inner diameter of each
cylinder
1) The cylinder bore size is stamped on the cylin-
Measure the inner diameter of each cylinder in
der block’s front upper surface.
both the thrust and piston pin directions at the
CAUTION: heights shown in the figure, using a cylinder bore
Measurement should be performed at a tem- gauge.
perature 20°C (68°F).
CAUTION:
NOTE: Measurement should be performed at a tem-
Standard sized pistons are classified into two perature 20°C (68°F).
grades, “A” and “B”. These grades should be used
Taper:
as a guide line in selecting a standard piston.
Standard
Standard diameter: 0.015 mm (0.0006 in)
A: 99.505 — 99.515 mm (3.9175 — 3.9179 Limit
in) 0.050 mm (0.0020 in)
B: 99.495 — 99.505 mm (3.9171 — 3.9175
Out-of-roundness:
in)
Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)
H2M1732A
G2M0170
3) When piston is to be replaced due to general or

cylinder wear, determine a suitable sized piston by
measuring the piston clearance.
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CYLINDER BLOCK
Mechanical
4) How to measure the outer diameter of each (2) If the cylinder inner diameter exceeds the
piston limit after boring and honing, replace the crank-
Measure the outer diameter of each piston at the case.
height shown in the figure. (Thrust direction) CAUTION:
CAUTION: Immediately after reboring, the cylinder diam-
Measurement should be performed at a tem- eter may differ from its real diameter due to
perature of 20°C (68°F). temperature rise. Thus, pay attention to this
Piston grade point H: when measuring the cylinder diameter.
37.0 mm (1.457 in) Limit of cylinder enlarging (boring):
Piston outer diameter: 0.5 mm (0.020 in)
Standard 3. PISTON AND PISTON PIN S103090A1004
A: 99.485 — 99.495 mm
(3.9167 — 3.9171 in) 1) Check pistons and piston pins for damage,
B: 99.475 — 99.485 mm cracks, and wear and the piston ring grooves for
(3.9163 — 3.9167 in) wear and damage. Replace if defective.
0.25 mm (0.0098 in) oversize 2) Measure the piston-to-cylinder clearance at
99.725 — 99.735 mm each cylinder. <Ref. to ME-80 CYLINDER AND
(3.9262 — 3.9266 in) PISTON, INSPECTION, Cylinder Block.> If any of
0.50 mm (0.0197 in) oversize the clearances is not to specification, replace the
99.975 — 99.985 mm piston or bore the cylinder to use an oversize pis-
(3.9360 — 3.9364 in) ton.
3) Make sure that piston pin can be inserted into
the piston pin hole with a thumb at 20°C (68°F).
Replace if defective.
Standard clearance between piston pin and
hole in piston:
Standard
0.004 — 0.008 mm (0.0002 — 0.0003 in)
Limit
0.020 mm (0.0008 in)
B2M1305A
5) Calculate the clearance between cylinder and

piston.
CAUTION:
Measurement should be performed at a tem-
perature of 20°C (68°F).
Cylinder to piston clearance at 20°C (68°F):
Standard
0.010 — 0.030 mm (0.0004 — 0.0012 in)
B2M1401
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 B2M0084A
boring on one cylinder only, nor use an over-
size piston for one cylinder only.
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CYLINDER BLOCK
Mechanical
4) Check circlip installation groove on the piston 2) Squarely place piston ring and oil ring in
for burr. If necessary, remove burr from the groove cylinder, and measure the piston ring gap with a
so that piston pin can lightly move. thickness gauge.
Unit: mm (in)
Standard Limit
0.20 — 0.35
Top ring 1.0 (0.039)
(0.0079 — 0.0138)
Piston Second 0.35 — 0.50
1.0 (0.039)
ring gap ring (0.0138 — 0.0197)
Oil ring 0.20 — 0.70
1.5 (0.059)
rail (0.0079 — 0.0276)
B2M0420A
5) Check piston pin circlip for distortion, cracks

and wear.
4. PISTON RING S103090A1005
1) If piston ring is broken, damaged, or worn, or if

its tension is insufficient, or when the piston is
replaced, replace piston ring with a new one of the
same size as the piston. G2M0174
CAUTION: 3) Measure the clearance between piston ring and

쐌 “R” is marked on the end of the top and sec- piston ring groove with a thickness gauge.
ond rings. When installing the rings to the
piston, face this mark upward. CAUTION:
Before measuring the clearance, clean the pis-
ton ring groove and piston ring.
Unit: mm (in)
Standard Limit
0.040 — 0.080
Clearance Top ring (0.0016 — 0.15 (0.0059)
between pis- 0.0031)
ton ring and
0.030 — 0.070
piston ring Second
groove (0.0012 — 0.15 (0.0059)
ring
0.0028)
G2M0623
쐌 The oil ring is a combined ring consisting of

two rails and a spacer in between. When
installing, be careful to assemble correctly.
B2M1402A
G2M0624
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CYLINDER BLOCK
Mechanical
5. CONNECTING ROD S103090A1006 5) Measure the oil clearance on individual con-

necting rod bearings by means of plastigauge. If
1) Replace connecting rod, if the large or small
any oil clearance is not within specification, replace
end thrust surface is damaged.
the defective bearing with a new one of standard
2) Check for bend or twist using a connecting rod
size or undersize as necessary. (See the table
aligner. Replace connecting rod if the bend or twist
below.)
exceeds the limit.
Connecting rod oil clearance:
Limit of bend or twist per 100 mm (3.94 in) in
Standard
length:
0.020 — 0.046 mm (0.0008 — 0.0018 in)
0.10 mm (0.0039 in)
Limit
0.050 mm (0.0020 in)
Unit: mm (in)
Bearing size Outer diameter of
Bearing
(Thickness at center) crank pin
1.486 — 1.498 51.984 — 52.000
Standard
(0.0585 — 0.0590) (2.0466 — 2.0472)
0.03
1.504 — 1.512 51.954 — 51.970
(0.0012)
(0.0592 — 0.0595) (2.0454 — 2.0461)
undersize
0.05
1.514 — 1.522 51.934 — 51.950
(0.0020)
(0.0596 — 0.0599) (2.0446 — 2.0453)
undersize
0.25
1.614 — 1.622 51.734 — 51.750
(0.0098)
(0.0635 — 0.0639) (2.0368 — 2.0374)
undersize
B2M1005A
3) Install connecting rod fitted with bearing to

crankshaft and measure the side clearance (thrust
clearance). Replace connecting rod if the side
clearance exceeds the specified limit.
Connecting rod side clearance:
Standard
0.070 — 0.330 mm (0.0028 — 0.0130 in)
Limit
0.4 mm (0.016 in)
G2M0176
4) Inspect connecting rod bearing for scar,

peeling, seizure, melting, wear, etc.
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CYLINDER BLOCK
Mechanical
6) Inspect bushing at connecting rod small end, 6. CRANKSHAFT AND CRANKSHAFT

and replace if worn or damaged. Also measure the BEARING S103090A1007
piston pin clearance at the connecting rod small
1) Clean crankshaft completely and check for
end.
cracks by means of red lead check etc., and
Clearance between piston pin and bushing: replace if defective.
Standard 2) Measure the crankshaft bend, and correct or
0 — 0.022 mm (0 — 0.0009 in) replace if it exceeds the limit.
Limit
CAUTION:
0.030 mm (0.0012 in)
If a suitable V-block is not available, install #1
and #5 crankshaft bearing on cylinder block,
position crankshaft on these bearings and
measure crankshaft bend using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
B2M0085
G2M0178
3) Inspect the crank journal and crank pin for

wear. If they are not within the specifications,
replace bearing with a suitable (undersize) one,
and replace or recondition crankshaft as neces-
B2M0084A sary. When grinding crank journal or crank pin, fin-
ish them to the specified dimensions according to
7) Replacement procedure is as follows. the undersize bearing to be used.
(1) Remove bushing from connecting rod with
ST and press. Crank pin and crank journal:
(2) Press bushing with ST after applying oil on Out-of-roundness
the periphery of bushing. 0.020 mm (0.0008 in) or less
ST 499037100 CONNECTING ROD BUSH- Taper limit
ING REMOVER AND 0.07 mm (0.0028 in)
INSTALLER Grinding limit
0.250 mm (0.0098 in)
G2M0177
G2M0179
(3) Make two 3 mm (0.12 in) holes in bushing.
Ream the inside of bushing.
(4) After completion of reaming, clean bushing
to remove chips.
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CYLINDER BLOCK
Mechanical
Unit: mm (in)
Crank journal diameter
Crank pin diameter
#1, #3 #2, #4, #5
59.992 — 60.008 59.992 — 60.008 51.984 — 52.000
Journal O.D.
(2.3619 — 2.3625) (2.3619 — 2.3625) (2.0466 — 2.0472)
Standard Bearing size
1.998 — 2.011 2.000 — 2.013 1.492 — 1.501
(Thickness at cen-
(0.0787 — 0.0792) (0.0787 — 0.0793) (0.0587 — 0.0591)
ter)
59.962 — 59.978 59.962 — 59.978 51.954 — 51.970
Journal O.D.
(2.3607 — 2.3613) (2.3607 — 2.3613) (2.0454 — 2.0461)
0.03 (0.0012)
undersize Bearing size
2.017 — 2.020 2.019 — 2.022 1.510 — 1.513
(Thickness at cen-
(0.0794 — 0.0795) (0.0795 — 0.0796) (0.0594 — 0.0596)
ter)
59.942 — 59.958 59.942 — 59.958 51.934 — 51.950
Journal O.D.
(2.3599 — 2.3605) (2.3599 — 2.3605) (2.0446 — 2.0453)
0.05 (0.0020)
Bearing size
undersize 2.027 — 2.030 2.029 — 2.032 1.520 — 1.523
(Thickness at cen-
(0.0798 — 0.0799) (0.0799 — 0.0800) (0.0598 — 0.0600)
ter)
59.742 — 59.758 59.742 — 59.758 51.734 — 51.750
Journal O.D.
(2.3520 — 2.3527) (2.3520 — 2.3527) (2.0368 — 2.0374)
0.25 (0.0098)
Bearing size
undersize 2.127 — 2.130 2.129 — 2.132 1.620 — 1.623
(Thickness at cen-
(0.0837 — 0.0839) (0.0838 — 0.0839) (0.0638 — 0.0639)
ter)
O.D. ... Outer Diameter
4) Measure the thrust clearance of crankshaft at 6) Measure the oil clearance on each crankshaft
center bearing. If the clearance exceeds the limit, bearing by means of plastigauge. If the measure-
replace bearing. ment is not within the specification, replace defec-
tive bearing with an undersize one, and replace or
Crankshaft thrust clearance:
recondition crankshaft as necessary.
Standard
0.030 — 0.115 mm (0.0012 — 0.0045 in) Unit: mm (in)
Limit Crankshaft oil clearance
0.25 mm (0.0098 in) Standard 0.010 — 0.030 (0.0004 —
0.0012)
Limit 0.040 (0.0016)
H2M2939A
5) Inspect individual crankshaft bearings for signs

of flaking, seizure, melting, and wear.
ME(H4)-85
墌 00.5.31/68j/1me4 墍
ENGINE TROUBLE IN GENERAL
Mechanical
22. Engine Trouble in General

S103095
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 PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK
1. Engine will not start.
1) Starter does not turn. 쐌 Starter 쐌 Defective battery-to-starter harness B
쐌 Defective starter switch C
쐌 Defective inhibitor switch or neutral switch C
쐌 Defective starter B
쐌 Battery 쐌 Poor terminal connection A
쐌 Run-down battery A
쐌 Defective charging system B
쐌 Friction 쐌 Seizure of crankshaft and connecting rod bearing C
쐌 Seized camshaft C
쐌 Seized or stuck piston and cylinder C
2) Initial combustion does not 쐌 Starter 쐌 Defective starter C
occur. 쐌 Engine control system <Ref. to EN(H4)-2 Basic Diagnostic Procedure.> A
쐌 Fuel line 쐌 Defective fuel pump and relay A
쐌 Lack of or insufficient fuel B
쐌 Belt 쐌 Defective B
쐌 Defective timing B
쐌 Compression 쐌 Incorrect valve clearance C
쐌 Loosened spark plugs or defective gasket C
쐌 Loosened cylinder head bolts or defective gasket C
쐌 Improper valve seating C
쐌 Defective valve stem C
쐌 Worn or broken valve spring B
쐌 Worn or stuck piston rings, cylinder and piston C
쐌 Incorrect valve timing B
쐌 Improper engine oil (low viscosity) B
ME(H4)-86
Mechanical

3) Initial combustion occur. 쐌 Engine control system <Ref. to EN(H4)-2 Basic Diagnostic Procedure.> A
쐌 Intake system 쐌 Defective intake manifold gasket B
쐌 Defective throttle body gasket B
쐌 Fuel line 쐌 Defective fuel pump and relay C
쐌 Clogged fuel line C
4) Engine stalls after initial 쐌 Engine control system <Ref. to EN(H4)-2 Basic Diagnostic Procedure.> A
combustion. 쐌 Intake system 쐌 Loosened or cracked intake duct B
쐌 Loosened or cracked PCV hose C
쐌 Loosened or cracked vacuum hose C
쐌 Defective intake manifold gasket B
쐌 Dirty air cleaner element C
쐌 Fuel line 쐌 Clogged fuel line C
ME(H4)-87
Mechanical

2. Rough idle and engine 쐌 Engine control system <Ref. to EN(H4)-2 Basic Diagnostic Procedure.> A
stall 쐌 Intake system 쐌 Loosened or cracked intake duct A
쐌 Loosened or cracked PCV hose A
쐌 Loosened or cracked vacuum hose A
쐌 Defective PCV valve C
쐌 Loosened oil filter cap B
쐌 Dirty air cleaner element C
쐌 Fuel line 쐌 Defective fuel pump and relay C
쐌 Clogged fuel line C
쐌 Belt 쐌 Defective timing C
쐌 Compression 쐌 Incorrect valve clearance B
쐌 Loosened spark plugs or defective gasket B
쐌 Loosened cylinder head bolts or defective gasket B
쐌 Improper valve seating B
쐌 Worn or stuck piston rings, cylinder and piston B
쐌 Incorrect valve timing A
쐌 Lubrication system 쐌 Incorrect oil pressure B
쐌 Defective rocker cover gasket C
쐌 Cooling system 쐌 Overheating C
쐌 Others 쐌 Malfunction of evaporative emission control sys- A
tem
쐌 Stuck or damaged throttle valve B
쐌 Accelerator cable out of adjustment C
ME(H4)-88
Mechanical

3. Low output, hesitation and 쐌 Engine control system <Ref. to EN(H4)-2 Basic Diagnostic Procedure.> A
poor acceleration 쐌 Intake system 쐌 Loosened or cracked intake duct A
쐌 Loosened or cracked vacuum hose B
쐌 Defective PCV valve B
쐌 Dirty air cleaner element A
쐌 Fuel line 쐌 Defective fuel pump and relay B
쐌 Clogged fuel line B
쐌 Lack of or insufficient fuel C
쐌 Belt 쐌 Defective timing B
쐌 Loosened spark plugs or defective gasket B
쐌 Loosened cylinder head bolts or defective gasket B
쐌 Lubrication system 쐌 Incorrect oil pressure B
쐌 Cooling system 쐌 Overheating C
쐌 Over cooling C
쐌 Others 쐌 Malfunction of evaporative emission control sys- A
tem
4. Surging 쐌 Engine control system <Ref. to EN(H4)-2 Basic Diagnostic Procedure.> A
쐌 Intake system 쐌 Loosened or cracked intake duct A
쐌 Loosened or cracked vacuum hose A
쐌 Dirty air cleaner element B
쐌 Fuel line 쐌 Defective fuel pump and relay B
쐌 Clogged fuel line B
쐌 Lack of or insufficient fuel C
쐌 Worn or broken valve spring C
쐌 Cooling system 쐌 Overheating B
쐌 Others 쐌 Malfunction of evaporative emission control sys- C
tem
ME(H4)-89
Mechanical

5. Engine does not return to 쐌 Engine control system <Ref. to EN(H4)-2 Basic Diagnostic Procedure.> A
idle. 쐌 Intake system 쐌 Loosened or cracked vacuum hose A
쐌 Others 쐌 Stuck or damaged throttle valve A
쐌 Accelerator cable out of adjustment B
6. Dieseling (Run-on) 쐌 Engine control system <Ref. to EN(H4)-2 Basic Diagnostic Procedure.> A
쐌 Cooling system 쐌 Overheating B
쐌 Others 쐌 Malfunction of evaporative emission control sys- B
tem
7. After burning in exhaust 쐌 Engine control system <Ref. to EN(H4)-2 Basic Diagnostic Procedure.> A
system 쐌 Intake system 쐌 Loosened or cracked intake duct C
쐌 Loosened or cracked PCV hose C
쐌 Loosened or cracked vacuum hose B
쐌 Loosened oil filler cap C
쐌 Lubrication system 쐌 Incorrect oil pressure C
쐌 Cooling system 쐌 Over cooling C
쐌 Others 쐌 Malfunction of evaporative emission control sys- C
tem
8. Knocking 쐌 Engine control system <Ref. to EN(H4)-2 Basic Diagnostic Procedure.> A
쐌 Intake system 쐌 Loosened oil filter cap B
쐌 Cooling system 쐌 Overheating A
9. Excessive engine oil con- 쐌 Intake system 쐌 Loosened or cracked PCV hose A
sumption 쐌 Defective PCV valve B
쐌 Loosened oil filter cap C
쐌 Compression 쐌 Defective valve stem A
쐌 Worn or stuck piston rings, cylinder and piston A
쐌 Lubrication system 쐌 Loosened oil pump attaching bolts and defective B
gasket
쐌 Defective oil filter seal B
쐌 Defective crankshaft oil seal B
쐌 Defective rocker cover gasket B
쐌 Loosened oil drain plug or defective gasket B
쐌 Loosened oil pan fitting bolts or defective oil pan B
ME(H4)-90
Mechanical

10. Excessive fuel consump- 쐌 Engine control system <Ref. to EN(H4)-2 Basic Diagnostic Procedure.> A
tion 쐌 Intake system 쐌 Dirty air cleaner element A
쐌 Worn or stuck piston rings, cylinder and piston B
쐌 Lubrication system 쐌 Incorrect oil pressure C
쐌 Cooling system 쐌 Over cooling C
쐌 Others 쐌 Accelerator cable out of adjustment B
ME(H4)-91
ENGINE NOISE
Mechanical
23. Engine Noise S103096
Type of sound Condition Possible cause

쐌 Valve mechanism is defective.
쐌 Incorrect valve clearance
Sound increases as engine
Regular clicking sound 쐌 Worn valve rocker
speed increases.
쐌 Worn camshaft
쐌 Broken valve spring
쐌 Worn crankshaft main bearing
Oil pressure is low.
쐌 Worn connecting rod bearing (big end)
Heavy and dull clank
쐌 Loose flywheel mounting bolts
Oil pressure is normal.
쐌 Damaged engine mounting
쐌 Ignition timing advanced
High-pitched clank (Spark Sound is noticeable when 쐌 Accumulation of carbon inside combustion chamber
knock) accelerating with an overload. 쐌 Wrong spark plug
쐌 Improper gasoline
Sound is reduced when fuel
Clank when engine speed is injector connector of noisy cyl- 쐌 Worn crankshaft main bearing
medium (1,000 to 2,000 rpm). inder is disconnected. 쐌 Worn bearing at crankshaft end of connecting rod
(NOTE*)
Sound is reduced when fuel
쐌 Worn cylinder liner and piston ring
injector connector of noisy cyl-
쐌 Broken or stuck piston ring
Knocking sound when engine inder is disconnected. 쐌 Worn piston pin and hole at piston end of connecting rod
is operating under idling speed (NOTE*)
and engine is warm Sound is not reduced if each 쐌 Unusually worn valve lifter
fuel injector connector is dis- 쐌 Worn cam gear
connected in turn. (NOTE*) 쐌 Worn camshaft journal bore in crankcase
Squeaky sound — 쐌 Insufficient generator lubrication
Rubbing sound — 쐌 Defective generator brush and rotor contact
Gear scream when starting 쐌 Defective ignition starter switch
—
engine 쐌 Worn gear and starter pinion
Sound like polishing glass with 쐌 Loose drive belt
—
a dry cloth 쐌 Defective water pump shaft
쐌 Loss of compression
Hissing sound — 쐌 Air leakage in air intake system, hoses, connections or
manifolds
쐌 Loose timing belt
Timing belt noise —
쐌 Belt contacting case/adjacent part
Valve tappet noise — 쐌 Incorrect valve clearance
NOTE*:
When disconnecting fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code is
stored in ECM memory.
Therefore, carry out the CLEAR MEMORY MODE <Ref. to EN(H4)-63 Clear Memory Mode.> and INSPECTION MODE <Ref. to
EN(H4)-60 Inspection Mode.> after connecting fuel injector connector.
ME(H4)-92
GENERAL DESCRIPTION
Starting/Charging Systems
Designation
Item
MT AT
Type Reduction type
Model TN128000-8311 TN128000-8321
Manufacturer NIPPONDENSO TENNESSEE
Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW
Direction of rotation Counterclockwise (when observed from pinion)
Number of pinion teeth 8 9
Voltage 11 V
No-load characteristics Current 90 A or less
Starter
Rotating speed 3,000 rpm or more 2,900 rpm or more
Voltage 8V
Current 280 A or less 370 A or less
Load characteristics
Torque 9.8 N·m (1.0 kgf-m, 7.2 ft-lb) 13.7 N·m (1.4 kgf-m, 10.1 ft-lb)
Rotating speed 900 rpm or more 880 rpm or more
Voltage 5V
Lock characteristics Current 800 A or less 1,050 A or less
Torque 27.5 N·m (2.8 kgf-m, 20.3 ft-lb) or more
Type Rotating-field three-phase type, Voltage regulator built-in type
Model A2TB2891ZC LR190-742
MITUBISHI ELECTRIC HITACHI AUTOMOTIVE
Manufacturer
CORPORATION PRODUCTS
Voltage and output 12 V — 90 A 12 V — 90 A
Polarity on ground side Negative
Generator
Rotating direction Clockwise (when observed from pulley side.)
Armature connection 3-phase Y-type
1,500 rpm — 36 A or more 1,500 rpm — 39 A or more
Output current 2,500 rpm — 65 A or more 2,500 rpm — 66 A or more
5,000 rpm — 86 A or more 5,000 rpm — 85 A or more
+0.3
Regulated voltage 14.5 /−0.4 V [20°C (68°F)]
SC(H4)-2
墌 00.5.31/68j/1sc4 墍
GENERAL DESCRIPTION
1. STARTER S109001A0501
B6M0412C
(1) Front ball bearing (9) Screw & washer (17) Retainer
(2) Armature (10) Cover (18) Roller
(3) Rear ball bearing (11) Through bolt (19) Idle gear
(4) O-ring (12) Screw & washer (20) Nut
(5) Yoke (13) Starter housing (21) Spring washer
(6) Brush spring (14) Overrunning clutch (22) Magnet switch
(7) Brush holder (15) Steel ball (23) Nut
(8) End frame (16) Spring
SC(H4)-3
墌 00.5.31/68j/1sc4 墍
GENERAL DESCRIPTION
B6M0413C
(1) Front ball bearing (9) Cover (17) Retainer

(2) Armature (10) Screw & washer (18) Roller
(3) Rear ball bearing (11) Through bolt (19) Idle gear
(4) O-ring (12) Screw & washer (20) Nut
(5) Yoke (13) Starter housing (21) Spring washer
(6) Brush spring (14) Overrunning clutch (22) Magnet switch
(7) Brush holder (15) Steel ball (23) Nut
(8) End frame (16) Spring
SC(H4)-4
墌 00.5.31/68j/1sc4 墍
GENERAL DESCRIPTION
2. GENERATOR S109001A0502
B6M0414B
(1) Pulley nut (9) IC regulator ASSY (17) Nut

(2) Pulley (10) Condenser (18) Bolt
(3) Front cover ASSY (11) Diode ASSY (19) Through bolt
(4) Ball bearing (12) Bolt
(5) Bearing retainer (13) Bolt Tightening torque: N·m (kgf-m, ft-lb)
(6) Screw (14) Brush holder ASSY T1: 3.1 (0.32, 2.3)
(7) Rotor (15) Rear cover T2: 63.7 (6.5, 47.0)
(8) Stator coil (16) BAT. terminal
SC(H4)-5
墌 00.5.31/68j/1sc4 墍
GENERAL DESCRIPTION

tion.
ment.
fied points.
SC(H4)-6
墌 00.5.31/68j/1sc4 墍
STARTER
2. Starter S109012
4) Remove air cleaner case stay.
S2M0900A
G6M0095

ture sensor. (MT vehicles)
S2M0901A
5) Disconnect connector and terminal from starter.
B2M2285
S6M0002A
(A) Terminal
(B) Connector
6) Remove starter from transmission.
B6M1221
G2M0309
SC(H4)-7
墌 00.5.31/68j/1sc4 墍
STARTER
B: INSTALLATION S109012A11 3) Remove yoke from magnetic switch.

Tightening torque:
50 N·m (5.1 kgf-m, 37 ft-lb)
B6M0423A
4) Remove screws securing end frame to brush

holder.
G2M0309
1) Disconnect lead wire from magnetic switch.
B6M0424A
5) Separate yoke from end frame.
B6M0421A
2) Remove through-bolts from end frame.
B6M0425A
6) Remove brush by lifting up positive (+) side

brush spring using long-nose pliers.
CAUTION:
Be careful not to damage brush and commuta-
B6M0422A
tor.
B6M0426A
SC(H4)-8
墌 00.5.31/68j/1sc4 墍
STARTER
7) Remove armature from yoke. 11) Take out steel ball from clutch.
CAUTION: CAUTION:
Be careful not to drop armature. Be careful not to lose steel ball.
B6M0427A B6M0431A
8) Remove screws securing magnetic switch to 12) Remove idle gear from housing.
housing.
B6M0432A
B6M0428A 13) Remove retainer and roller from housing.

9) Remove housing from magnetic switch. CAUTION:
Be careful not to drop retainer and roller.
B6M0429A
B6M0433A
10) Remove clutch from housing.
14) Remove coil spring from magnetic switch.
B6M0430A
B6M0434A
SC(H4)-9
墌 00.5.31/68j/1sc4 墍
STARTER
D: ASSEMBLY S109012A02 4) Installing brushes

Assemble brush holder to yoke as shown, then
Assemble in the reverse order of disassembly. assemble two yoke-side brushes to brush holder.
Observe the following:
1) Before assembling, lubricate disassembled
parts at the points shown in “COMPONENT
PARTS”. <Ref. to SC(H4)-3 STARTER,
COMPONENT, General Description.>
Grease:
ESSO BEACON 325
SHELL ALVANIA GREASE RA
or equivalent
2) Assembling magnetic switch, clutch, and hous- B6M0471A
ing
To assemble, first install clutch to magnetic switch, 5) Installing end frame
then install idle gear, and finally install clutch. When assembling end frame to yoke, align
notched portion of end frame with lead wire grom-
CAUTION:
met.
쐌 Do not forget to install steel ball and coil
spring to clutch.
쐌 Attach bearing to idle gear beforehand.
B6M0472A
6) Installing yoke
B6M0470A When installing yoke to magnetic switch, align
notch of yoke with protrusion of magnetic switch.
3) Installing armature to yoke
CAUTION:
Do not forget to put felt washer on armature
shaft bearing.
B6M0473A
B6M0427A
SC(H4)-10
墌 00.5.31/68j/1sc4 墍
STARTER
E: INSPECTION S109012A10 4) Armature short-circuit test

Check armature for short-circuit by placing it on
1. ARMATURE S109012A1001
growler tester. Hold a hacksaw blade against
1) Check commutator for any sign of burns of armature core while slowly rotating armature. A
rough surfaces or stepped wear. If wear is of a short-circuited armature will cause the blade to
minor nature, correct it by using sand paper. vibrate and to be attracted to core. If the hacksaw
2) Run-out test blade is attracted or vibrates, the armature, which
Check the commutator run-out and replace if it is short-circuited, must be replaced or repaired.
exceeds the limit.
Commutator run-out:
Standard
0.02 mm (0.0008 in), or less
Service limit
G6M0040
5) Armature ground test

Using circuit tester, touch one probe to the com-
mutator segment and the other to shaft. There
should be no continuity. If there is a continuity,
armature is grounded.
G6M0038 Replace armature if it is grounded.
3) Depth of segment mold
Check the depth of segment mold.
Depth of segment mold:
0.6 mm (0.024 in)
Limit
0.2 mm (0.008 in)
G6M0041
2. YOKE S109012A1002
Make sure pole is set in position.
G6M0039
B6M0435
SC(H4)-11
墌 00.5.31/68j/1sc4 墍
STARTER
3. OVERRUNNING CLUTCH S109012A1003 3) Insulation resistance of brush holder

Be sure there is no continuity between brush
Inspect teeth of pinion for wear and damage.
holder and its plate.
Replace if it is damaged. Rotate pinion in direction
of rotation (clockwise). It should rotate smoothly.
But in opposite direction, it should be locked.
CAUTION:
Do not clean overrunning clutch with oil to pre-
vent grease from flowing out.
B6M0438
4) Brush spring force

Measure brush spring force with a spring scale. If
it is less than the service limit, replace brush
spring.
B6M0436 Brush spring force:
Standard
4. BRUSH AND BRUSH HOLDER S109012A1004 18.6 N (1.9 kg, 4.2 lb) (when new)
Service limit
1) Brush length 6.9 N (0.7 kg, 1.5 lb)
Measure the brush length and replace if it exceeds
the service limit. 5. BEARING S109012A1005
Replace if abnormal wear or cracks are noticed. 1) Rotate bearing by hand; no binding should
Brush length: exist.
Standard 2) Rotate bearing rapidly; no abnormal noise
15 mm (0.59 in) should be heard.
Service limit
10 mm (0.39 in)
B6M0439
B6M0437 6. MAGNETIC SWITCH S109012A1006
2) Brush movement CAUTION:

Be sure brush moves smoothly inside brush 쐌 The following magnetic switch tests should
holder. be performed with specified voltage applied.
쐌 Each test should be conducted within 3 to 5
seconds. Power to be furnished should be one-
half the rated voltage.
SC(H4)-12
墌 00.5.31/68j/1sc4 墍
STARTER
1) Pull-in test fied capacity whenever testing the starter.

Connect two battery negative leads onto magnetic The starter should be checked for the following
switch body and terminal C respectively. Then con- three items:
nect battery positive lead onto terminal 50. Pinion 쐌 No-load test
should extend when lead connections are made. Measure the maximum rotating speed and current
under a no-load state.
쐌 Load test
Measure the magnitude of current needed to gen-
erate the specified torque and rotating speed.
쐌 Stall test
Measure the torque and current when the armature
is locked.
1) No-load test
Run single starter under no-load state, and mea-
sure its rotating speed, voltage, and current, using
B6M0415A the specified battery. Measured values must meet
the following standards:
2) Holding-in test
Disconnect lead from terminal C with pinion No-load test (Standard):
extended. Pinion should be held in the extended Voltage/Current
position. 11 V/90 A, or more
Rotating speed
TN128000-8311: 3,000 rpm, or more
TN128000-8321: 3,350 rpm, or more
B6M0416A
3) Return test
Connect two battery negative leads onto terminal B6M0418A
50 and onto switch body respectively. Then con-
nect battery positive lead onto terminal C. Next,
disconnect lead from terminal 50. Pinion should
return immediately.
B6M0417A
7. PERFORMANCE TEST S109012A1007
The starter is required to produce a large torque

and high rotating speed, but these starter charac-
teristics vary with the capacity of the battery. It is
therefore important to use a battery with the speci-
SC(H4)-13
墌 00.5.31/68j/1sc4 墍
STARTER
2) Load test (For reference) 3) Stall test

Perform this test to check maximum output of Using the same test equipment used for load test,
starter. Use test bench which is able to apply load apply brake to lock starter armature. Then mea-
(brake) to starter. Measure torque value and rotat- sure voltage, current, and torque values.
ing speed under the specified voltage and current Measured values must meet the following stan-
conditions while controlling braking force applied to dard.
starter. Stall test (Standard):
CAUTION: TN128000-8311
Change engagement position of overrunning Voltage/Current
clutch and make sure it is not slipping. 5 V/800 A, or less
Torque
Load test (Standard): 27.5 N·m (2.8 kgf-m, 20.3 ft-lb) min.
TN128000-8311 TN128000-8321
Voltage/Load Voltage/Current
8 V/9.8 N·m (1.0 kgf-m, 7.2 ft-lb) 5 V/1,050 A, or less
Current/Speed Torque
280 A max./900 rpm min. 27.5 N·m (2.8 kgf-m, 20.3 ft-lb) min.
TN128000-8321
Voltage/Load
8 V/13.7 N·m (1.4 kgf-m, 10.1 ft-lb)
Current/Speed
370 A, or less/880 rpm, or more
B6M0420A
NOTE:
Low rotating speed or excessive current during no-
load test may be attributable to high rotating resis-
tance of starter due to improper assembling.
B6M0419A Small current and no torque during stall test may
be attributable to excessive contact resistance
between brush and commutator; whereas, normal
current and insufficient torque may be attributable
to shorted commutator or poor insulation.
Starter can be considered normal if it passes no-
load and stall tests; therefore, load test may be
omitted.
SC(H4)-14
墌 00.5.31/68j/1sc4 墍
GENERATOR
3. Generator S109008
5) Remove bolts which install generator onto
bracket.
S6M0352
G6M0095 B: INSTALLATION S109008A11
2) Disconnect connector and terminal from gen- Install in the reverse order of removal.
erator. CAUTION:
Check and adjust V-belt tension. <Ref. to
B2M3105

S6M0352
1) Heat the portion (A) of rear cover to 50°C

(122°F) with heater drier.
B2M3106
4) Remove front side V-belt.
B6M0476B
G2M0286
SC(H4)-15
墌 00.5.31/68j/1sc4 墍
GENERATOR
2) Remove the four through bolts. Then insert the 5) Remove three screws from front cover and then
tip of a flat-head screwdriver into the gap between bearing retainer and ball bearing.
the stator core and front bracket. Pry then apart to
disassemble.
B6M0478A
G6M0065
6) Remove bolt which secure battery terminal bolt,
and remove rear cover. Remove nuts which secure
3) Hold rotor with a vise and remove pulley nut. diode plate, and remove stator and rear cover.
G6M0066 B6M0479A
CAUTION: 7) Separate diode plate from stator coil.

When holding rotor with vise, insert aluminum (1) Cut the connecting position (A) of stator coil
plates or wood pieces on the contact surfaces to diode.
of the vise to prevent rotor from damage. (2) Unsolder connection (B) and throughout the
lead wire of stator coil.
B6M0477A
B6M0480B
4) Remove rotor from front cover.
SC(H4)-16
墌 00.5.31/68j/1sc4 墍
GENERATOR
(3) Remove stator coil from diode plate. 쐌 Before installing rear cover, insert pin from
outside of rear cover so that holds brush. After
installing rear cover, remove pin.
B6M0481
8) Remove bolts which secure IC regulator, diode B6M0492

and brush holder.
CAUTION: 쐌 When installing rear cover, heat portion (A)
Do not apply a shock or load to IC regulator to 50°C (122°F) with heater drier.
cooling fins.
B6M0476B
B6M0482
1. ROTOR S109008A1001
Assemble in the reverse order of disassembly. 1) Slip ring surface

Inspect slip rings for contamination or any rough-
CAUTION: ness of the sliding surface.
쐌 When disassembling generator, replace rear Clean or polish with #500 to #600 emery paper if
ball bearing. defective.
G6M0077
B6M0769A
쐌 When soldering starter coil to diode, do not

touch lead wire with solder for more than 5
seconds.
SC(H4)-17
墌 00.5.31/68j/1sc4 墍
GENERATOR
2) Slip ring outside diameter 5) Ball bearing

Measure slip ring outside diameter. If slip ring is Check rear ball bearing. Replace it if it is noisy or
worn, replace rotor. if rotor does not turn smoothly.
Slip ring outside diameter:
Standard
27 mm (1.06 in)
Limit
26 mm (1.02 in)
B6M0486
2. STATOR S109008A1002
1) Continuity test
Inspect stator coil for continuity between its termi-
B6M0483A
nals. When there is no continuity between indi-
3) Continuity test vidual terminals, cable is broken. Replace stator
Check continuity between slip rings. If continuity coil.
does not exist, replace rotor.
G6M0078
B6M0484A
2) Insulation test
4) Insulation test Inspect stator coil for continuity between stator
Check continuity between slip ring and rotor core core and each terminal. If there is continuity,
or shaft. If continuity exists, replace rotor. replace stator coil.
G6M0079
B6M0485A
SC(H4)-18
墌 00.5.31/68j/1sc4 墍
GENERATOR
3. BRUSH S109008A1003 1) Diodes on “+” side

Continuity of proper diodes on “+” side
Measure brush length. If brush is worn, replace
brush holder assembly. Terminal N, U, V BAT side
Brush length (): and W (+) (−)
Standard Continuity must
(+) —
20.5 mm (0.807 in) not exist.
Limit Continuity must
(−) —
1.5 mm (0.059 in) exist.
B6M0487A B6M0489A
2) Diodes on “−” side

4. DIODE ASSEMBLY S109008A1004
Continuity of proper diodes on “−” side
CAUTION:
Never use a high tension insulation tester, Terminal N, U, V “E” side
such as a meggar as it will damage diodes with and W (+) (−)
its high tension. Continuity must
(+) —
exist.
The diode consists of eight diodes, four each being
Continuity must
located on the positive and negative sides. The (−) —
not exist.
diode is necessary to restrict current flow to one
direction.
Check all diodes, for continuity. If any diode is
faulty, replace diode assembly.
B6M0490A
B6M0488A
SC(H4)-19
墌 00.5.31/68j/1sc4 墍
GENERATOR
5. IC REGULATOR S109008A1005
1) Compose a circuit diagram as shown in figure.
B6M0491B
(1) Voltage meter: 0 to 30 V

(2) Switch 1
(3) Variable DC power supply: Variable 0 to 20 V, 1 A
or more
(4) Lamp 2
(5) Lamp 1
(6) Switch 3
(7) Switch 2
(8) Plus generator: Power supply 5 to 30 V, 1 kHz
2) Check operation as shown in chart below.

Switch operation Value of volt- Lamp operation
No. Remarks
1 2 3 age meter 1 2
1 ON OFF OFF 12 V DIM ON Check initial excitation.
2 ON ON OFF 12 V ON or BLINK OFF Check total excitation.
When value of voltage
OFF or DIM-
3 ON ON OFF 16 V OFF meter is between 12 V
BLINK
and 16 V.
Check connection for
4 OFF ON OFF 12 V ON or BLINK ON
S and B terminals.
Check for over loading
5 OFF ON ON 18 V ON ON
of voltage.
SC(H4)-20
墌 00.5.31/68j/1sc4 墍
BATTERY
4. Battery S109011 C: INSPECTION S109011A10
WARNING:
쐌 Electrolyte has toxicity; be careful handling
1) Remove battery cable holder (A) from battery the fluid.
rod. 쐌 Avoid contact with skin, eyes or clothing.
Especially at contact with eyes, blush with
water for 15 minutes and get prompt medical
attention.
쐌 Batteries produce explosive gasses. Keep
sparks, flame, cigarettes away.
쐌 Ventilate when charging or using in enclosed
space.
쐌 For safety, in case an explosion does occur,
wear eye protection or shield your eyes when
working near any battery. Never lean over a
B6M1183A
battery.
2) Disconnect the positive (+) terminal after dis- 쐌 Do not let battery fluid contact eyes, skin,
connecting the negative (−) terminal of battery. fabrics, or paint-work because battery fluid is
3) Remove flange nuts from battery rods and take corrosive acid.
off battery holder. 쐌 To lessen the risk of sparks, remove rings,
metal watch-bands, and other metal jewelry.
Never allow metal tools to contact the positive
battery terminal and anything connected to it
while you are at the same time in contact with
any other metallic portion of the vehicle
because a short circuit will be caused.
1. EXTERNAL PARTS: S109011A1001
Check for the existence of dirt or cracks on the

battery case, top cover, vent plugs, and terminal
B6M1506 posts. If necessary, clean with water and wipe with
a dry cloth.
4) Remove battery. Apply a thin coat of grease on the terminal posts
to prevent corrosion.
Install in the reverse order of removal. 2. ELECTROLYTE LEVEL: S109011A1002
Tightening torque: Check the electrolyte level in each cell. If the level
3.4 N·m (0.35 kgf-m, 2.5 ft-lb) is below MIN LEVEL, bring the level to MAX
LEVEL by pouring distilled water into the battery
NOTE: cell. Do not fill beyond MAX LEVEL.
쐌 Clean battery cable terminals and apply grease
to retard the formation of corrosion. 3. SPECIFIC GRAVITY OF
쐌 Connect the positive (+) terminal of battery and ELECTROLYTE: S109011A1003
then the negative (−) terminal of the battery.
1) Measure specific gravity of electrolyte using a
hydrometer and a thermometer.
Specific gravity varies with temperature of electro-
lyte so that it must be corrected at 20°C (68°F)
using the following equation:
SC(H4)-21
墌 00.5.31/68j/1sc4 墍
BATTERY
S20 = St + 0.0007 × (t − 20) 2. CHECK HYDROMETER FOR STATE OF

S20: Specific gravity corrected at electro- CHARGE S109011A1402
lyte temperature of 20°C
St : Measured specific gravity Hydrometer
State of charge Required action
t : Measured temperature (°C) indicator
Determine whether or not battery must Green dot Above 65% Load test
be charged, according to corrected spe- Dark dot Below 65% Charge battery
cific gravity. Replace battery*
Clear dot Low electrolyte
Standard specific gravity: 1.220 — 1.290 (If cranking complaint)
[at 20°C (68°F)] *: Check electrical system before replacement.
3. NORMAL CHARGING S109011A1403
Charge the battery at current value specified by

manufacturer or at approximately 1/10 of battery’s
ampere-hour rating.
4. QUICK CHARGING S109011A1404
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.
G6M0103 Since a large current flow raises electrolyte
temperature, the battery is subject to damage if the
2) Measuring the specific gravity of the electrolyte large current is used for prolonged time. For this
in the battery will disclose the state of charge of the reason, the quick charging must be carried out
battery. The relation between the specific gravity within a current range that will not increase the
and the state of charge is as shown in figure. electrolyte temperature above 40°C (104°F).
It should be also remembered that the quick charg-
D: MEASUREMENT S109011A14
ing is a temporary means to bring battery voltage
WARNING: up to a fair value and, as a rule, a battery should
쐌 Do not bring an open flame close to the bat- be charged slowly with a low current.
tery at this time. CAUTION:
CAUTION: 쐌 Observe the items in 1. NORMAL CHARG-
쐌 Prior to charging, corroded terminals should ING.
be cleaned with a brush and common baking 쐌 Never use more than 10 amperes when
soda solution. charging the battery because that will shorten
쐌 Be careful since battery electrolyte over- battery life.
flows while charging the battery.
쐌 Observe instructions when handling battery
charger.
쐌 Before charging the battery on vehicle, dis-
connect battery ground terminal. Failure to fol-
low this rule may damage alternator’s diodes
or other electrical units.
1. JUDGMENT OF BATTERY IN
CHARGED CONDITION S109011A1401
1) Specific gravity of electrolyte is held at a spe-
cific value in a range from 1.250 to 1.290 for more
than one hour.
2) Voltage per battery cell is held at a specific
value in a range from 2.5 to 2.8 volts for more than
one hour.
SC(H4)-22
墌 00.5.31/68j/1sc4 墍
GENERAL DESCRIPTION
Speed Control Systems
A: SPECIFICATION S107001E49
Free play At pedal pad 1 — 4 mm (0.04 — 0.16 in)

Accelerator pedal
Stroke At pedal pad 50 — 55 mm (1.97 — 2.17 in)
B4M2315A
(1) Accelerator bracket (6) Accelerator pedal spring (11) Accelerator plate
(2) Stopper (7) Accelerator pedal lever (12) Clip
(3) Bushing (8) Spring pin
(4) Clip (9) Accelerator pedal Tightening torque: N·m (kgf-m, ft-lb)
(5) Accelerator spring (10) Accelerator stopper T: 18 (1.8, 13.0)
C: CAUTION S107001A03 쐌 Be sure to tighten fasteners including bolts and

쐌 Wear work clothing, including a cap, protective 쐌 Place shop jacks or safety stands at the speci-
goggles, and protective shoes during operation. fied points.
쐌 Remove contamination, including dirt and 쐌 Before disconnecting electrical connectors of
corrosion, before removal, installation or disas- sensors or units, be sure to disconnect negative
sembly. terminal from battery.
tect them from dust and dirt.
ment.
SP(H4)-2
ACCELERATOR PEDAL
2. Accelerator Pedal S107005

2) Remove lock nut from accelerator cable
bracket.
3) Separate accelerator cable from bracket.
4) Remove accelerator cable end from throttle
cam.
5) Disconnect accelerator cable from throttle body. G4M0321
CAUTION: 10) Disconnect grommet from toe board.

Be careful not to kink accelerator cable.
NOTE:
From inside compartment, push grommet into
hole.
B4M2316A
(A) Lock nut

(B) Accelerator cable bracket B4M1740A
(C) Accelerator cable
(D) Throttle cam
11) Pull out the cable from the toe board hole.
12) Disconnect accelerator cable bushing from
6) Remove clip inside engine compartment. accelerator pedal lever.
B2M4143A B4M1741A
(A) Toe board 13) Disconnect accelerator cable stopper from

(B) Accelerator cable pedal bracket.
(C) To accelerator
(D) Brake booster
(E) Clip
7) Remove instrument panel lower cover from

instrument panel, and connector.
8) Remove brake and clutch pedal bracket. (MT
model) <Ref. to BR-60 REMOVAL, Brake Pedal.>
9) Remove accelerator pedal connecting bolt from
accelerator pedal bracket.
B4M1742A
14) Separate accelerator cable and bracket.
SP(H4)-3
墌 00.5.31/68j/1sp4 墍
ACCELERATOR PEDAL

CAUTION:
쐌 If cable clamp is damaged, replace it with a
new one.
쐌 Never fail to cover outer cable end with boot.
쐌 Be careful not to kink accelerator cable.
쐌 Always use new clevis pins.
2) Check pedal stroke and free play by operating
accelerator pedal by hand.
If it is not within specified value, adjust it by turn-
ing nut connecting accelerator cable to throttle
body.
Free play at pedal pad: L
1 — 4 mm (0.04 — 0.16 in)
Stroke at pedal pad: A
50 — 55 mm (1.97 — 2.17 in)
B4M2317A
(A) Bracket
(B) Stopper
(C) Bushing
(D) Clip
(E) Accelerator spring
(F) Accelerator pedal spring
(G) Accelerator pedal lever
(H) Spring pin
(I) Accelerator pedal

CAUTION:
Clean and apply grease to spacer and inside
bore of a accelerator pedal.
Lightly move pedal pad in lateral the direction to

B4M1739A
ensure pedal deflection is in specified range.
(A) Accelerator pedal CAUTION:
(B) Accelerator pedal bracket If excessive deflection is noted, replace bush-
Accelerator cable lock nut tightening torque: ing and clip with new ones.
12 N·m (1.2 kgf-m, 9 ft-lb) Deflection of accelerator pedal:
Service limit
5.0 mm (0.197 in) or less
1) Remove the clip, and then remove the accel-
erator pedal from the bracket.
2) Pull out the spring pin, and then remove the
accelerator pedal from the accelerator pedal lever.
SP(H4)-4
墌 00.5.31/68j/1sp4 墍
ACCELERATOR PEDAL
G4M0333
SP(H4)-5
墌 00.5.31/68j/1sp4 墍
ACCELERATOR CONTROL CABLE
3. Accelerator Control Cable S107007
1) Remove accelerator pedal. <Ref to SP(H4)-3

REMOVAL, Accelerator Pedal.>
2) Separate accelerator cable and accelerator
pedal.

CAUTION:
쐌 If cable clamp is damaged, replace it with a
new one.
쐌 Never fail to cover outer cable end with boot.
쐌 Be careful not to kink accelerator cable.
쐌 Do not apply grease to the throttle cable on
the engine side.
2) Adjustment after pedal installation <Ref. to
SP(H4)-4 INSTALLATION, Accelerator Pedal.>
1) Make sure the inner cable is not twisted or

frayed.
2) Make sure the outer cable is not cracked.
SP(H4)-6
FOREWORD
Foreword
1 . Foreword SAO,674
A: FOREWORD sAO,674.z,
These manuals are used when performing
maintenance, repair, or diagnosis of the Subaru
Legacy.
Applied model : BE*'`*** and BH***** from 2000MY
The additional manuals below are also available :

Pub. No. G0853ZE
The manuals contain the latest information at the

time of publication . Changes in specifications,
methods, etc. may be made without notice .
FVI/-2
HOW TO USE THIS MANUALS
How to Use This Manuals
1 . How to Use This Manuals SAOZ675

A: HOW TO USE THIS MANUALS
SA02675F69
1 . STRUCTURE SAOZ675F69o,
Each section consists of SCT that are broken down
into SC that are divided into sections for each com-
ponent. The specification, maintenance and other
information for the components are included, and
diagnosis information has also been added where
necessary.
2. INDEX SA02675F6902
The first page has an index with tabs . And at the

end of each section is an alphabetical index.
3. COMPONENTS SA02675F6903
For each component, a composition drawing is
included .
4. SPECIFICATIONS SA02675F6904
If necessary, specifications are also included

5. INSPECTION SA02675F6905
Inspections are included to be carried out before

and after maintenance .
6. MAINTENANCE SA02675F6906
Maintenance instructions are provided for each

component. When multiple components comprise
one process, refer to the instructions for that pro-
cess for each component.
7. DIAGNOSIS SAO2675F69o7
Tables showing a step-by-step process make it
easy to conduct diagnosis .
8. CAUTION, WARNING, NOTE sAO2675FS9o8

"CAUTION" is used to indicate points that must be
followed to protect the person doing the work and
people in the area from injury.
"WARNING" is used to indicate points that must be
followed to protect the vehicle or parts from dam-
age or from secondary physical injury.
"NOTE" is used to indicate additional information
that can improve the efficiency of doing a process .
9. SI UNITS SA02675F6909
Measurements in these manuals are according to

the SI units. Metric and yard/pound measurements
are also included .
HU-2
LEGACY
Specifications
1 . Legacy SA08704
A : DIMENSIONS SAO8~o4~ze
Model Sedan Station WAGON
AWD AWD
BRIGHTON L GT
Overall length mm (in) 4,685 (184.4) 4,760 (187 .4)
Overall width mm (in) 1,745 (68 .7) 1,745 (68 .7)
Overall height mm (in) 1,415 (55 .7) 1,435 (56 .5)
Compartment Leg room Front Max. mm (in) 1,101 (43 .3) 1,101 (43 .3)
Rear Min . mm (in) 868 (34.2) 871 (34.3)
Head room Front mm (in) 987 (38.9),
1,020 (40.2), 977 (38.5)'1
967 (38.1)'1
Rear mm (in) 930 (36 .6) 994 (39 .1), 945 (37 .2)'1
Shoulder Front mm (in) 1,368 (53.9) 1,368 (53.9)
room Rear mm (in) 1,362 (53.6) 1,362 (53.6)
Wheelbase mm (in) 2,650 (104 .3) 2,650 (104 .3)
Tread Front mm (in) 1,460 (57 .5) 1,460 (57 .5)
Rear mm (in) 1,460 (57.5) 1,455 (57 .3)
Minimum road clearance M.L .V.W. mm (in) 115 (4 .5) 120 (4 .7) 125 (4 .9)
C.W. mm (in) 155 (6 .1) 160 (6 .3)
'1 : with sun roof
B : ENGINE
Model Sedan/Station Wagon
Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Valve arrangement Overhead camshaft type
Bore x Stroke mm (in) 99 .5 x 79 .0 (3 .917 x 3 .110)
Displacement cm 3 (cu in) 2,457 (149 .9)
Compression ratio 10 .0
Firing order 1 -3-2-4
Idle speed at Park/Neutral
rpm 650 (MT), 700 (AT)
position
Maximum output kW (HP)/rpm 123 (165)/5,600
Maximum torque N~m (kgf-m, ft-Ib)/rpm 226 (23 .0, 166)/3,600
C: ELECTRICAL SA08704G30

Ignition timing at idling speed BTDC/rpm 10°±10°/650 (MT), 10°±10°/700 (AT)
Spark plug Type and manufacturer CHAMPION : RC10YC4 (Standard)
NGK: BKR6E-11
CHAMPION : RC8YC4
Alternator 12V - 90A
Battery Reserve capacity min 90 (MT), 110 (AT)
Cold cranking amperes amp. 430 (MT), 490 (AT)
SPC-2
LEGACY
Specifications
D: TRANSMISSION SA08704G31

AW D
Transmission type 5MT*1 4AT'2
Clutch type DSPD TCC
Gear ratio 1 st 3 .454 2 .7853, 3 .027'4
2nd 2.062 1 .545'3, 1 .619'4
3rd 1 .448 1 .000
4th 1 .088 0.694
5th 0.780 -
Reverse 3.333 2.272
Reduction gear 1st reduction Type of gear - Helical
(Front drive) Gear ratio - 1 .000
Final reduction Type of gear Hypoid Hypoid
Gear ratio 3 .900`3, 4 .111-4 4 .111'3, 4 .444'4
Reduction gear Transfer reduc- Type of gear Helical -
(Rear drive) tion Gear ratio 1 .000 -
Final reduction Type of gear Hypoid Hypoid
Gear ratio I 4.111 I 4.111 "3, 4.444'4
5MT'1 : 5-forward speeds with synchromesh and 1-reverse - with center differential and viscous coupling
4AT`2: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse - with hydraulically controlled transfer clutch
`3 : L
'4 : GT
DSPD : Dry Single Plate Diaphragm
TCC: Torque Converter Clutch
E : STEERING SA08704G32
Type Rack and Pinion

Turns, lock to lock 3.2
Minimum turning circle m (ft) Curb to curb : 10 .8 (35 .4), Wa l l to wall : 11 .4 (37 .4)
F: SUSPENSION SA08704G33
Front Macpherson strut type, Independent, Coil spring

Rear I Multi-link type, Independent, Coil spring 777 I
G : BRAKE
Model with ABS
Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Disc brake
Parking brake I Mechanical on rear brakes I
H : TIRE SA08704G35
Model 15 inch wheel 16 inch wheel

Size P195/60R15 87H P205/60R15 90H P205/55R16 89H
rType I Steel belted radial, Tubeless
SPC-3
LEGACY
Specifications
I : CAPACITY .........
Model AWD
5MT 4AT
Fuel tank f (US gal, Imp gal) 64 (16.9, 14 .1)
Engine oil Upper level P (US qt, Imp qt) 4.0 (4 .2, 3.5)
Lower level Z (US qt, Imp qt) 3.0 (3 .2, 2.6)
Transmission gear oil e (US qt, Imp qt) 3.5 (3 .7, 3.1) -
Automatic transmission fluid C (US qt, Imp qt) - 9.3 (9 .8, 8 .2)
AT differential gear oil 2 (US qt, Imp qt) - 12 (1 .3, 1 .1)
AWD rear differential gear oil e (US qt, Imp qt) 0.8 (0 .8, 0.7)
Power steering fluid 2 (US qt, Imp qt) 0.7 (0 .7, 0.6)
Engine coolant C (US qt, Imp qt) I 6.8 (7 .2, 6.0) I 6.7 (7 .1, 5.9)
J : WEIGHT SA08704G37
1 . U.S. SPEC. VEHICLE SA08704G3701
Model Sedan
AWD
L GT
5MT'2 4AT'2 5MT*3 4AT"3
Curb weight (C .W .) Front kgf (1b) 810 (1,785) 837 (1,845) 819 (1,805) 846 (1,865)
Rear kgf (1b) 642 (1,415) 644 (1,420) 651 (1,435) 653 (1,440)
Total kgf (1b) 1,451 (3,200) 1,481 (3,265) 1,469 (3,240) 1,499 (3,305)
Gross vehicle Front kgf (1b) 1,007 (2,220)
weight (G .V .W.) Rear kgf (1b) 989 (2,180)
Total kgf (1b) 1,995 (4,400)
'1 : Includes the weights of A/C.
*2 : Includes the weights of P/W, P/D, A/C and C/C.
'3 : Includes the weights of P/W, PID, A/C, C/C and Rear spoiler.
Model Station WAGON

AWD
BRIGHTON
5MT' 1 4AT' 1
Curb weight (C .W .) Front kgf (1b) 794 (1,750) 819 (1,805)
Rear kgf (1b) 667 (1,470) 671 (1,480)
Total kgf (1b) 1,460 (3,220) 1,490 (3,285)
Gross vehicle Front kgf (1b) 961 (2,120)
weight (G .V.W.) Rear kgf (1b) 1,016 (2,240)
Total kgf (Ib) 1,977 (4,360)
Model Station WAGON

AW D
L GT
5MT'2 4AT'2 5MT'3 4AT'3
Curb weight Front kgf (1b) 803 (1,770) 828 (1,825) 816 (1,800) 841 (1,855)
Rear kgf (1b) 689 (1,520) 694 (1,530) 705 (1,555) 710 (1,565)
Total kgf (1b) 1,492 (3,290) 1,522 (3,355) 1,522 (3,355) 1,551 (3,420)
weight (G .V.W.) Rear kgf (1b) 1,063 (2,345)
Total kgf (Ib)T 2,066 (4,555)
'1 : Includes the weight of A/C.
'2 : Includes the weights of P/W, PID, A/C and C/C.
*3 : Includes the weights of P/W, P/D, A/C, C/C and S/R.
SPC-4
LEGACY
Specifications
2. CANADA SPEC . VEHICLE SA08704G3702
Model Sedan
AW D
L GT
4A7'1 5MT`2 4AT`2
Curb weight (C .W.) Front kgf (1b) 837 (1,845) 819 (1,805) 846 (1,865)
Rear kgf (1b) 644 (1,420) 651 (1,435) 653 (1,440)
Total kgf (1b) 1,481 (3,265) 1,469 (3,240) 1,499 (3,305)
weight (G .V .W .) Rear kgf (1b) 989 (2,180)
Total kgf (1b) 1,995 (4,400)
Model Station WAGON

AWD
BRIGHTON L GT
5MT 4AT 5MT*1 4AT"1 4AT`2
Curb weight (C .W.) Front kgf (1b) 778 (1,715) 803 (1,770) 803 (1,770) 828 (1,825) 841 (1,855)
Rear kgf (1b) 664 (1,465) 669 (1,475) 689 (1,520) 694 (1,530) 710 (1,565)
Total kgf (1b) 1,442 (3,180) 1,472 (3,245) 1,492 (3,290) 1,522 (3,355) 1,551 (3,420)
Gross vehicle Front kgf (1b) 961 (2,120) 1,002 (2,210)
weight (G .V.W .) Rear kgf (1b) 1,016 (2,240) 1,063 (2,345)
Total kgf (1b) 1,977 (4,360) - - 2,066 (4,555)
'1 : Includes the weights of P/W, P/D, A/C and C/C.
'2 : Includes the weights of P/W, P/D, A/C, C/C and S/R.
SPC-5
OUTBACK
Spe cifications
2. OUTBACK SAas7oS
A : DIMENSIONS SA08705G28
Model Sedan Station Wagon

AWD AWD
4AT 5MT 4AT
Overall length mm (in) 4,685 (184 .4) 4,760 (187 .4)
Overall width mm (in) 1,745 (68 .7) 1,745 (68 .7)
Overall height mm (in) 1,480 (58.3) 1,580 (62.2)
Compartment Leg room Front Max . mm (in) 1,101 (43 .3) 1,101 (43 .3)
Rear Min. mm (in) 868 (34.2) 871 (34.3)
Head room Front mm (in) 987 (38.9), 967 (38.1)'1 1,020 (40.2), 977 (38.5)'1
Rear mm (in) 930 (36.6) 994 (39.1), 945 (37.2)`1
Shoulder Front mm (in) 1,368 (53 .9) 1,368 (53.9)
room Rear mm (in) 1,362 (53.6) 1,362 (53.6)
Wheelbase mm (in) 2,650 (104 .3) 2,650 (104 .3)
Tread Front mm (in) 1,470 (57 .9) 1,470 (57 .9)
Rear mm (in) 1,465 (57 .7) 1,465 (57 .7)
Minimum road clearance M .L .V.W. mm (in) 150 (5 .9) 150 (5.9)
C .W . mm (in) 185 (7 .3) 185 (7.3)
'1 : with sun roof
B : ENGINE
Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Valve arrangement Overhead camshaft type
Bore x Stroke mm (in) 99 .5 x 79 .0 (3 .917 x 3.110)
Displacement cm 3 (cu in) 2,457 (149 .9)
Compression ratio 10 .0
Firing order 1 -3-2-4
Idle speed at Park/Neutral
rpm 650 (MT), 700 (AT)
position
Maximum output kW (HP)/rpm 123 (165)/5,600
Maximum torque N~m (kgf-m, ft-Ib)/rpm 226 (23.0, 166)/3,600
C: ELECTRICAL .......3 .

Ignition timing at idling speed BTDC/rpm 10°±10°/650 (MT), 10°±10°/700 (AT)
Spark plug Type and manufacturer CHAMPION : RC10YC4 (Standard)
NGK: BKR6E-11
CHAMPION : RC8YC4
Alternator 12V - 90A
Battery Reserve capacity min 90 (MT), 110 (AT)
Cold cranking amperes amp. 430 (MT), 490 (AT)
SPC-6
OUTBACK
Specifications
D: TRANSMISSION SA08705G31

AW D
Transmission type 4AT
Clutch type TCC
Gear ratio 1 st 3.027
2nd 1 .619
3rd 1 .000
4th 0 .694
5th -
Reverse 2 .272
Reduction gear 1 st reduction Type of gear Helical
(Front drive) Gear ratio 1 .000
Final reduction Type of gear Hypoid
Gear ratio 4 .444
Reduction gear Transfer reduc- Type of gear -
(Rear drive) tion Gear ratio -
Final reduction Type of gear Hypoid
Gear ratio 4.444
4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse - with hydraulically controlled transfer clutch
TCC: Torque Converter Clutch
E : STEERING SAOe~o5~3z
Type Rack and Pinion
Turns, lock to lock 3.4
Minimum turning circle m (ft) ~ Curb to curb : 11 .2 (36.7), Wall to wall : 12 .0 (39.4) I
F : SUSPENSION SA08705G33
Front Macpherson strut type, Independent, Coil spring

I Rear I Multi-link type, Independent, Coil spring
G : BRAKE
Model with ABS
Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Disc brakes
Parking brake I Mechanical on rear brakes
H : TIRE SA08705G35
Model 16 inch wheel

Size P225/60R16 97H
I Type I Steel belted radial, Tubeless
SPC-7
OUTBACK
Specifications
I : CAPACITY SA08705G36
Model AWD
4AT
Fuel tank 2 (US gal, Imp gal) 64 (16.9, 14 .1)
Engine oil Upper level C (US qt, Imp qt) 4.0 (4 .2, 3.5)
Lower level f (US qt, Imp qt) 3.0 (3 .2, 2.6)
Transmission gear oil e (US qt, Imp qt) -
Automatic transmission fluid f (US qt, Imp qt) 9.3 (9 .8, 8.2)
AT differential gear oil F (US qt, Imp qt) 1 .2 (1 .3, 1 .1)
AWD rear differential gear oil 2 (US qt, Imp qt) 0.8 (0 .8, 0.7)
Power steering fluid e (US qt, Imp qt) 0.7 (0 .7, 0.6)
Engine coolant e (US qt, Imp qt) 6.7 (7 .1, 5.9)
J : WEIGHT
1 . U.S. SPEC. VEHICLE SA08705G3701
Model Sedan Wagon

AWD AWD
4AT'1 5MT'2 4AT`2
Curb weight Front kgf (1b) 873 (1,925) 830 (1,830) 855 (1,885)
Rear kgf (1b) 664 (1,465) 694 (1,530) 698 (1,540)
Total kgf (1b) 1,537 (3,390) 1,524 (3,360) 1,553 (3,425)
Gross vehicle Front kgf (1b) 1,007 (2,220) 1,002 (2,210)
weight (G .V.W.) Rear kgf (1b) 989 (2,180) 1,063 (2,345)
Total kgf (1b) 1,995 (4,400) 2,066 (4,555)
`1 : Includes the weights of P/W, P/D, A/C, C/C, Leather interior, Rear spoiler, Side A/B and S/R.
'2 : Includes the weights of P/W, P/D, A/C and C/C .
NOTE :
When following optional parts are installed, add the weight to the curb weight .
Weight of optional parts Built-in child restraint (B/R)
Front kgf (1b) 0.4 (0 .9)
Rear kgf (1b) 4.2 (9 .3)
Total kgf (1b) 4.6 ( 1 0 . 1)
2. CANADA SPEC. VEHICLE SA08705G3702
Model Sedan Wagon

AW D AW D
4AT'1 5MT'2 4AT'2
Curb weight Front kgf (1b) 873 (1,925) 832 (1,835) 857 (1,890)
Rear kgf (1b) 664 (1,465) 694 (1,530) 698 (1,540)
Total kgf (1b) 1,537 (3,390) 1,526 (3,365) 1,556 (3,430)
Gross vehicle Front kgf (1b) 1,007 (2,220) 1,002 (2,210)
weight (G .V.W.) Rear kgf (1b) 989 (2,180) 1,063 (2,345)
Total kgf (1b) 1,995 (4,400) 2,066 (4,555)
*1 : Includes the weights of P/W, P/D, A/C, C/C, Leather interior, Rear spoiler, Side A/B and S/R .
"`2: Includes the weights of P/W, P/D, A/C, C/C and C/W.
SPC-8
PRECAUTION
Precaution
1 . Precaution SA04677 7. AIRBAG MODULE SA04677F5907
Adhere to the following when handing and storing

A : PRECAUTION SA04677F59
the air bag module to prevent bodily injury from
Please clearly understand and adhere to the fol- unexpected deployment :
lowing general precautions . They must be strictly 9 Do not hold harnesses or connectors to carry
followed to avoid minor or serious injury to the per- the module .
son doing the work or people in the area. 9 Do not face the bag in the direction that it opens
towards yourself or other people .
1 . AB S SA04677F5901
* Do not face the bag in the direction that it opens
Handle the ABS as a total system . Do not disas- towards the floor or walls.
semble or attempt to repair individual parts. Doing
so could prevent the ABS system from operating 8. AIRBAG SPECIAL TOOLS SA04677F5908
when needed or cause it to operate incorrectly and To prevent unexpected deployment, only use spe-
result in injury. cial tools .
2. BRAKE FLUID SAO46»F59oz 9. WINDOW SA04677F5909
If brake fluid gets in your eyes or on your skin, do Always wear safety glasses when working around
the following: any glass to prevent glass fragments from damag-
9 Wash out your eyes and seek immediate medi- ing your eyes .
cal attention .
9 Wash your skin with soap and then rinse thor- 10. WINDOW ADHESIVE SA04677F5910
oughly with water. Always use the specified urethane adhesive when
attaching glass to prevent it from coming loose and
3 . ELECTRIC FAN SAO46»F59o3 falling, resulting in accidents and injury.
The electric fan may rotate without warning, even
when the engine is not on . Do not place your hand,
cloth, tools, or other items near the fan at any time .
4 . ROAD TESTS sAa46»F59o4
Always conduct road tests in accordance with traf-
fic rules and regulations to avoid bodily injury and
interrupting traffic.
5. AIRBAG SA04677F5905
To prevent bodily injury from unexpected deploy-

ment of air bags and unnecessary maintenance,
follow the instructions in this manual when per-
forming maintenance on air bag components or
nearby, and air bag wiring harnesses or nearby .
To prevent unexpected deployment, perform one
of the steps below and then wait at least ten sec-
onds to discharge electricity before beginning
work .
" Step 1 : Turn the ignition switch OFF.
" Step 2 : Remove the fuse for the air bag system .
" Step 3: Remove the negative battery terminal .
6. AIRBAG DISPOSAL sAO46»F59o6
To prevent bodily injury from unexpected airbag
deployment, do not dispose air bag 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
Note
1 . Note SA03676
A : NOTE SA03676A15
This is information that can improve efficiency of

maintenance and assure sound work .
1 . FASTENER NOTICE SA03676A7501
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 SAO3676A,5o2
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 SA03676A7503
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 SA03676AY504
Use authentic service parts for maximum perfor-

mance 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 SA03676A1505
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
e
O O
Without side sill cover I
With side sill cover
Pantograph jack
Lift
Safety stand
GIO100A
NT-3
NOTE
Note
NT-4
NOTE
Note
6. TIE DOWNS ,,.76A 1506
Tie downs are used when transporting vehicles and when using the chassis dynamo . Attach tie downs only
to the specified points on the vehicle .
~.-
7
I IF I I
11 ~ I I
Hook for towing Hook for towing

(Except OUTBACK) (OUTBACK)
`1
-~_
--
--
r
Hook for tie-down Hook for tie-down Hook for towing

and tie-down
allookt"_
for towing
,a nd
0 tie- down
Hook for tie-down
G10102A
NT-5
NOTE
Note
7. TOW ING SA03676A1507
Avoid towing vehicles except when the vehicle

cannot be driven . For vehicles with AWD, AT, or
VTD, use a loader instead of towing . When towing
other vehicles, to prevent excessive weight from
damaging the hook or vehicle :
* Do not tow other vehicles with a front towing
hook.
9 Make sure the vehicle towing is heavier that the
vehicle being towed .
8. TRAINING SA03676A 1508
For information about training, contact a dealer or

agent.
9. GENERAL SCAN TOOL SA03676A1509
Using general scan tools will greatly improve effi-

ciency of repairing engine electronic controls . The
Subaru Select Monitor can be used to diagnose
the engine and also the ABS, the air conditioner,
G10103 and other parts .
20'~ 20'
20 'W Y20'
0 0'
20
2 _V20'
0 0
45 45 45° 45°
0 : Tie-down range
G10104A
NT-6
IDENTIFICATION
Identification
1 . Identification SAO6679
A : IDENTIFICATION SA06679F70
1 . IDENTIFICATION NUMBER AND LABEL LOCATIONS SA06679F7001
The VIN (Vehicle Identification Numbers) is used to classify the vehicle .

Positioning of the plate label for identification
Emission control label Vehicle identification number plate
4~__ Vacuum hose
Radio noise label connections label
(CANADA spec . vehicle),
Vehicle identification number
. . .
O " ..
FMVSS label
(U .S .spec. vehicle)
CMVSS label
(CANADA spec . vehicle)
ly Tire inflation pressure label

(Driver side)
Model number plate GI0006A
ID-2
IDENTIFICATION
Identification
VA-type
Label 0
location
T-type
Stamp location
G10010A
ID-3
IDENTIFICATION
Identification
2. MEANING OF V.I . N. SA06679F7002
The meaning of the VIN is as follows:

North America
14S3BE635X17200001 [
The starting and ending brackets ( ][ ) are stop marks .
Digits Code Meaning Details
1 to 3 4S3 Manufacturer body Passenger car, SIA made, For US/Canada/Taiwan/Chile
area
4 B Car line Legacy/OUTBACK series
5 E Body type E: Sedan/OUTBACK Sedan
H: Station Wagon/OUTBACK
6 6 Displacement 6: 2.5 L AWD
8: 3.0 L AWD
7 3 Grade 2: Brighton
3:L
4: GT
5 : GT-LTD
6: OUTBACK
7 : OUTBACK-cold weather
8 : OUTBACK-LTD
9: OUTBACK-6 cylinders
0: OUTBACK-6 cylinders LL-bean
8 5 Restraint 5: Manual belts, dual airbag
6: Manual belts, dual airbag, side airbag
9 X Check digit
10 1 Model year 1: 2001 MY
2: 2002MY
11 7 Transmission type 6: Full-time AWD 5-speed MT
7: Full-time AWD 4-speed AT
12 to 17 200001 Manufacture number From 200001 : Sedan/OUTBACK Sedan
From 300001 : Station Wagon
From 600001 : OUTBACK
ID-4
IDENTIFICATION
Identification
3. MODEL NUMBER PLATE SA06679F7003
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 .
BE9BY3J

1 B Series B: Legacy/OUTBACK
2 E Body style E: Sedan/OUTBACK Sedan
H: Station Wagon/OUTBACK
3 9 Engine displacement 9: 2.5 L AWD
Drive system E: 3.0 L AWD
Suspension system
4 B Minor change SIA made
2001 MY (SIA made)
5 Y Destination K: Right-hand drive for general market
L: Left-hand drive for general market
Y: Left-hand drive for United States, Canada, and Taiwan
6 3 Grade SIA made
1 : Brighton
3: L
4: OUTBACK
5 : GT
6 : GT-LTD
9 : OUTBACK Sedan-LTD
A: OUTBACK-cold weather
B: OUTBACK-LTD
C: OUTBACK-6 cylinders
D: OUTBACK-6 cylinders LL-bean
7 J Transmission, fuel feed E: DOHC MPI 4-speed AT
system J : SOHC MPI center differential AWD
R: SOHC MPI 4-speed AT
The engine and transmission type are as follows :

Engine
EZ30DAXBBB

1 and 2 EZ Engine type EJ : 4 cylinders
EZ : 6 cylinders
3 and 4 30 Displacement 20 : 2.0 L
25 : 2.5 L
30 : 3.0 L
5 D Fuel feed system 1 : D-MPI SOHC-A phase-2 or-3
2 : D-MPI SOHC-B phase-2 or-3
3 : MPI SOHC phase-2 or-3
D: D-MPI DOHC 6 cylinders phase-3
6 A Exhaust regulations A: US Federal & California
C: US California
L: ADR (Australia)
M: Germany
N : Switzerland, Austria
R: Europe
7 X Transmission W: AWD MT
X: AWD AT
8 to 10 BBB Detailed specifications Used when ordering parts. See the parts catalog for details.
I D-5
IDENTIFICATION
Identification
Transmission
TVIA4YCAAA
1 T Transmission T: Transmission
2 V Transmission type Y: Full-time AWD MT center differential
V: Full-time AWD AT VTD
Z: Full-time AWD AT MPT
3 and 4 1A Classification 75: MT
1 A: New AT
5 4 Series 4: 3rd Generation Legacy
6 A Transmission specifica- V: Full-time AWD 5-speed MT with viscous coupling center
tions 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
7 C Mounted body C: US 2.5 L SOHC
M : US 3.0 L DOHC
R : General 2.0 L SOHC
F: General 2.5 L SOHC
P: General 3.0 L DOHC
8 to 10 AAA Detailed specifications Used when ordering parts. See the parts catalog for detail
9 Rear differential 1
VAIREF

1 V For AWD V: AED
2 A Type A: A type
3 1 Hypoid gear diameter 1: 152 dia.
2: 160 dia.
4 R Installation position R: Rear
5 E Reduction gear ratio E: 4.111
F: 4.444
6 F Specification differ- F: Case A
ences G: Case B
H: Case B with cooling fin
e Rear differential 2
T1
Code Reduction LSD

gear ratio
T1 3.900 No
T2 4.111 No
TP 4 .444 No
BK 4.111 Viscous
BP 4.111 Viscous strengthened type
BL 4.444 Viscous strengthened type
CD 4.444 Viscous
VB 3.700 I No I
ID-6
RECOMMENDED MATERIALS
Recommended Materials
1 . Recommended Materials SA05678
A : RECOMMENDED MATERIALS
SA05678G22
1 . GENERAL SA05678G2201
To insure the best performance, always use the

specified oil, gasoline, adhesive, sealant, etc. or
that of equivalent quality.
2 . FUEL SA05678G2202
Always use a gasoline of the same or higher
octane value than specified in the owner's manual .
Ignoring the specifications below will result in dam-
age or poor operation of the engine and fuel injec-
tion 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 gaso-
line with an octane value of 90 ROM or higher.
Methanol
Use gasoline with a methanol content of 5% or
less.
Ethanol
Use gasoline with an ethanol content of 10% or
less.
* MTBE
Use gasoline with an MTBE content of 15% or less.
California specifications
All Subaru vehicles are LEV, and thus can use
California specification gasoline .
Reformulated gasoline
Reformulated gasoline may be used.
R MI-2
3. LUBRICANTS SA05678G2203
Use either the lubricants in the table below or equivalent lubricants . See the table below to choose the cor-
rect SAE viscosity.
Lubricant Recommended Alternative
API Spec . CCMC Spec . ACEA Spec .
Engine oil SJ Grade "Energy conserving" G4 or G5 A1, A2 or A3 API : SH or SG
PQ~ $ERV/CF
sv
SAE
5W-30
.40
CONS
G10001
FOR
GASOLINE
r-Nuill,
WINES
G10002
Manual transmission oil GL-5 - - -
Front differential GL-5 - - -
Rear differential GL-5 - - -
SAE viscosity SAE viscosity No . and applicable temperature SAE J300

Engine oil
(°C) -30 -20 -10 0 10 20 30 40
(°F) -22 -4 14 32 50 68 86 104
10W-30 or 10W-40
5W-30 Recommend
<
G10003A
RM-3
SAE viscosity SAE viscosity No . and applicable temperature SAE J300

Manual transmission oil (°C) -30 -20 -10 0 10 20 30 40
(°F) -22 -4 14 32 50 68 86 104
90
85W
>
Rear differential
80W
75W-90
GI0004A
Front differential (°C) -30 -20 -10 0 10 20 30 40
(°F) -22 -4 14 32 50 68 86 104
90
85W
>
80W
80W-90
G10005A
4. FLUID SA05678G2204
Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid.
Fluid Recommended Alternative Remarks
Automatic transmission fluid DEXRON III -
Power steering fluid DEXRON III -
Brake fluid FMVSS No. 116 DOTS FMVSS No . 116 DOT4
Clutch fluid FMVSS No . 116 DOT3 FMVSS No . 116 DOT4 I
5. COOLANT SA05678G2205
Use genuine coolant to protect the engine . The table below shows the ratio of coolant to distilled water.
Coolant Recommended Item number Alternative
Coolant SUBARU coolant 000016218 None
Water for dilution Distilled water - Tap water I
6 . REFRIGERANT SA05678(32206
Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refriger-
ants . Also, do not use any air compressor oil except for ZXL200PG .
Air conditioner Recommended Item number Alternative
Refrigerant' HFC134a - None
Compressor oil ZXL200PG - None
RM-4
7. GREASE sAO5678G2207
Use the grease and supplementary lubricants shown in the table below.
Grease Application point Recommended Item number Alternative

Supplementary lubricants 9 02 sensor SUBARU CRC 004301003 -
Bolts, etc .
Grease MT main shaft FX clutch grease 000040901 -
Clutch master cylinder Slicolube G-40M 004404003 -
push rod
Steering shaft bear- SUNLIGHT2 003602010 -
ing
Gearshift bush
Steering gear box Valiant grease M-2 003608001 -
Disc brake Niglube RX-2 003606000 or -
725191040
Drum brake Molykote No . 7439 72519460 -
Brake pad Molykote AS-880N 26298AC000 -
. Brake shoe
Front axle SFJ SSG-6003 28093TA000 -
Rear axle BJ Molykote No . 2 723223010 -
Rear axle DOJ VU-3A702 23223GA050 -
Control cable Slicolube G-30M 004404002 -
Throttle linkage
Water pump
Door latch
Door striker
8 . ADHESIVES sAO56~e~ZZ,o
Use the adhesives shown in the table below, or equivalent.
Adhesive Application point Recommended Item number Alternative
Adhesive Windshield and body Essex Chemical Crop's Ure- - Sunstar 580
thane E
Weatherstrip, rubber Cemedine 5430L - 3M's EC-1770 EC-1368
parts
Soft vinyl Cemedine 540 - 3M's EC-776 EC-847 or EC-1022
(Spray type)
Momentary sealant Cemedine 3000 - Armstrong's Eastman 910
9 . SEAL MATERIAL SA05678G2209
Use seal material shown in the table below, or equivalent.

Seal material Application point Recommended Item number Alternative
Engine case Three Bond 1215 004403007 Dow Corning's No . 7038
Transmission Three Bond 12178 K0877YA020 -
Rear differential Three Bond 1324 004403042 -
Rear differential Three Bond 1105 004403010 Dow Corning's No . 7038
Weatherstrip Starcalking B-33A 000018901 Butyl Rubber sealant
Steering adjusting Three Bond 1102 004403006 -
screw
SOHC cam cap Three Bond 1280B K0877YA018 -
R M-5
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
1 . Pre-delivery Inspection SAO9.,9

A: GENERAL .......3.
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.
e Check if the vehicle before delivery is in a nor-
mal state.
* Check for any damage or missing parts that may
have taken place during transportation or storage.
* Make sure to provide a complete vehicle to 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 SAO9~,9~50

Follow the procedures shown in the table below.
Static Checks Just After Vehicle Receipt
Step Check point

1 . Appearance check (1) If the vehicle is covered with protective coating, visually check the
vehicle body for damage and dents. If the protective coating has been
removed, visually check the body paints for small areas of damage or
stains.
(2) Visually check the glass and light lenses for any damage and cracks
or excessive gaps to the body sheet metal.
(3) Visually check the plated parts for any damage .
2. Tire check (1) Check the tires for damage, abnormal conditions, and dents on the
wheels .
(2) Check the tire air pressure .
3. Check the doors for lock/unlock and open/ (1) Using the key, check if the door can be locked and unlocked normally .
close operations . (2) Open and close the all doors to see that there are no abnormal condi-
tions.
4. Power window operation check (1) Check the power window for correct operations .
5 . Operation check of trunk lock release lever (1) Operate the trunk lock release lever to check that the trunk opens nor-
mally.
6. Operation check of rear gate lock release lever (1) Operate the rear gate lock release lever to check that the rear gate is
unlocked normally.
7. Operation check of fuel lid opener lock release (1) Operate the fuel lid opener to check that the fuel lid is unlocked nor-
lever mally.
8. Accessory check Check the following accessories are provided :
Owner's manual
Warranty booklet
Service booklet
Spare key
Jack
Tool set
" Spare tire
9. Operation check of hood lock release system (1) Operate the hood lock release lever to check that the hood opens nor-
mally.
10 . Fuse installation (1) If the vehicle is about to be delivered to the customer, attach a room
lamp fuse .
11 . Connection of air conditioner harness (1) If the vehicle is about to be delivered to the customer, connect the air
conditioner harness.
12 . Battery (1) Check the battery for any abnormal conditions such as rust and trace
of battery fluid leaks.
13 . Brake fluid (1) Check the fluid amount .
14 . Engine oil (1) Check the oil amount .
15 . Transmission fluid (1) Check the fluid amount .
(2) For AT, check the front differential oil.
16 . AT front differential oil (1) Check the AT front differential oil amount .
17 . Coolant (1) Check the coolant amount .
18 . Clutch fluid (1) Check the clutch fluid amount .
19 . Window washer fluid (1) Check the window washer fluid amount .
20 . Hood latch check (1) Check that the hood is closed and latched securely.
21 . Keyless entry system (1) Check that the keyless entry system operates normally.
22 . Security system (1) Check that the security system operates normally.
23 . Seat (1) Check the seat surfaces for smears or dirt .
(2) Check the seat installation conditions and functionality.
24 . Seat belt (1) Check the seat belt installation conditions and functionality.
25 . Child seat (1) Check that an instruction tag for handling a child seat is attached.
26 . Wheel alignment ~(1) Check that the wheel alignments are properly adjusted .
PI-3
Checks with the Engine Running
Step Check point

1 . Test mode connector (1) Disconnect the test mode connector.
2. Operation check of shift lock system, key (1) For a MT vehicle, check the starter interlock system operations .
interlock, and starter interlock (2) For an AT vehicle, check the shift lock and key interlock system opera-
tions.
3. Starting condition (1) Start the engine and check that the engine starts smoothly.
4. Exhaust system (1) Check that the exhaust noise is normal and no leaks are found .
5. Indicator light (1) Check that all the indicator lights operate normally.
6. Clock (1) Check that the clock operate normally.
7. Radio (1) Check that the radio system operates normally.
8. Cigarette lighter (1) Check that the cigarette lighter operates normally.
9. Lighting system (1) Check that the lighting systems operate normally.
10 . Window washer (1) Check that the window washer system operates normally.
11 . Wiper 1 (1) Check that the wiper system operates normally. I
Dynamic Test with the Vehicle Running
Step Check point

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

1. ATF level (1) Check that the ATF level is normal .
2. Power steering fluid level (1) Cheek that the power steering fluid level is normal .
3. Fluid leak check (1) Check for fluid/oil leaks.
4. Water leak check (1) Spray the vehicle with water and check for water leaks.
5. Appearance check 2 (1) Remove the protective coating (if any) .
(2) Check the body paints for damage and smears .
(3) Check the plated parts for damage and rust .
PI-4
1 . APPEARANCE CHECK sAa9,,9G500, Vehicles with power door locks:

* If the vehicle is covered with protective coating, Sit in the driver seat, close the driver's door
visually check the vehicle body for damage and completely, and place the door lock knob (A) to the
dents. lock position. Then pull the all inside door handles
* If there is no protective coating, check the body (B) to ensure that the all doors will not open.
paints for small areas of damage or stains and For other doors, place the lock levers to the lock
repair as necessary. positions and then pull the inside door handles to
Check the window glass, door glass, and lights ensure that the doors will not open .
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.
2. TIRE CHECK SA09719G5002
" Check the tire outer faces for any damage .

" Check the tire air pressure by referring to the
following table.
Tire size Tire inflation pressure
kPa (kg/cm', psi)
4. POWER WINDOW OPERATION CHECK
Front Rear
SA09779G5004
P195/60R15 230 (2 .3, 33) 220 (2 .2, 32)
P205/60R15 220 (22, 32) 210 (2 .1, 30) Manipulate the power window switches one by one
R205/55R16 220 (2 .2, 32) 210 (2 .1, 30) to check that each of the power windows goes up
P225/60R16 210 (2 .1, 30) 200 (2 .0, 29) and down with no abnormal noises .
3. CHECK THE DOOR OPERATIONS, 5 . OPERATION CHECK OF TRUNK LOCK

LOCK/UNLOCK AND OPEN/CLOSE, AS RELEASE LEVER SA09719G5005
FOLLOWS . SA09719G5003 Operate the trunk lock release lever and verify that
Using the key, lock and unlock the door several the trunk lid opens .
times to check for normal operation . Open and
6. OPERATION CHECK OF REAR GATE
close the door several times for smooth move-
ment . LOCK RELEASE LEVER SA09719G5006
Operate the rear gate lock release lever and verify
that the rear gate is unlocked and opened
smoothly.
7. OPERATION CHECK OF FUEL LID
Unlock,~~ OPENER LOCK RELEASE LEVER SA09719G5007
'\ Lock
Operate the fuel lid opener and verify that the fuel
lid opens normally . Check that the filler cap is
securely closed .
GI0078A
Vehicles with manual door locks :

Sit in the driver seat, close the door completely,
and move the lock lever to the lock position . Then,
pull the inside door handle to ensure the door will
not open.
PI-5
8. ACCESSORY CHECK SA09719G5008 9. OPERATION CHECK OF HOOD LOCK

Check that the following accessories are provided RELEASE SYSTEM SA09719G5009
in the luggage compartment or cargo area . Unlatch and open the hood while checking that no
Owner's manual abnormal conditions are found. Then, support the
Warranty booklet hood with the hood stay.
Service booklet
Spare key
Jack
Tool set
" Spare tire
o~ I
(A) G10083A
10. FUSE INSTALLATION SA09719G5010
A vehicle just delivered has no fuses for the room

lamp circuit to prevent battery discharge. Attach a
15 A fuse as shown in the figure .
PI-6
11 . CONNECTION OF AIR CONDITIONER 14. ENGINE OIL SA09719G5074
HARNESS SA09779G5077 Check the engine oil amount. If the amount is

A vehicle just delivered has its air conditioner har- insufficient, check that no leaks are found. Then,
ness disconnected to protect the air conditioner add the necessary amount of the specified engine
compressor. Connect the harness as shown in the oil .
figure .
Oil level~gauge~ ~J

Engine oil filler cap Upper level
o About 1 .0Q
. o ~ (1 .1 US qt,
0.9 Imp qt)
. ~ o Lower level
J ~!
\ ~ U \
G10087A
15. TRANSMISSION FLUID SA09779G5075
12. BATTERY SA09719G5012

Check the transmission fluid amount. If the amount
Check the battery terminals to make sure that no is insufficient, check that no leaks are found . Then,
rust or corrosions due to fluid leaks are found . add the necessary amount of the specified fluid.
Check that the battery tent is securely tightened.
0
O Caps
Oil level gauge
i
--Upper level
~c , (\~ ~ J -Lower level
Upper level ". `
Lower level G10088A

G10086A
16. AT FRONT DIFFERENTIAL OIL SA09719G5016
13. BRAKE FLUID SA09719G5013

Check the AT front differential oil amount . If the
Check the brake fluid amount. If the amount is amount is insufficient, check that no leaks are
insufficient, carry out a brake line test to identify found. Then, add the necessary amount of the
brake fluid leaks and check the brake operation. specified AT front differential oil .
After that, refill the brake fluid tank with the speci-
fied type of fluid .
~` -Upper level
-Lower level
G10089A
PI-7
17. COOLANT SA09719G5077 * Press the "UNLOCK/DISARM" button on the

transmitter momentarily once and check if the driv-
Check the coolant amount on the reservoir. If the
er's door is unlocked, the horn chirps twice and the
amount is insufficient, check that no leaks are dome light illuminates .
found . Then, add the necessary amount of coolant
with the specified concentration.
18. CLUTCH FLUID SA09719G5018
Check the clutch fluid amount. If the amount is

insufficient, check that no leaks are found . Then,
add the necessary amount of the specified fluid.
C
LI
G10092
9 Press the "UNLOCK/DISARM" button on the

transmitter momentarily once again and check if all
the doors including the rear gate on wagon are
unlocked .
* Press the "LOCK/ARM" button on the transmit-
ter a little bit of time (approx . 1 .5 sec.) and check
if a panicking condition occurs ; the horn sounds
continuously. Also, check if that condition lasts for
19. WINDOW WASHER FLUID SAO97,9Gso,9 30 seconds or until any button of the transmitter is
Check the window washer fluid amount. If the pressed.
amount is insufficient, check that no leaks are * Press the "LOCK/ARM" button on the transmit-
ter momentarily once with one of the doors includ-
found . Then, add the necessary amount of washer
ing the rear gate (wagon) open and check if the
fluid commercially available.
horn chirps three times to warn of a door ajar .
20. HOOD LATCH CHECK SAO97,9G5o2o Then, bring all doors including the rear gate
(wagon) in closed condition and check if all the
Retract the hood stay and close the hood . Check doors are locked and the horn chirps once .
that the hood is securely latched. 9 Press the "LOCK" side of the power door lock-
ing switch with any one of the doors including the
21 . KEYLESS ENTRY SYSTEM SA09719G5027
rear gate (wagon) open. Then, bring all the doors
Check the keyless entry system operations as fol- including the rear gate (wagon) in the closed con-
lows . dition and check if all the doors are locked and the
Open all the door windows fully. horn chirps once .
Remove the key from the ignition switch and
close all the doors including rear gate (wagon) .
Press the "LOCK/ARM" button on the transmit-
ter momentarily once and check if all the doors are
locked and the horn chirps once .
j
LOCK
`~J
G 10093A I
G10091
PI-8
22. SECURITY SYSTEM SAO9~,9~5ozz Then, bring ail doors including the rear gate
(wagon) in closed condition and check if the arm-
Check the security system operations as follows .
ing condition is brought about; all the doors are
Open all the door windows fully.
locked, the horn chirps once and the parking lights
Remove the key from the ignition switch and
flash once .
close all the doors including rear gate (wagon) .
e Press the "LOCK" side of the power door lock-
9 Press the "LOCK/ARM" button on the transmit-
ing switch with any one of the doors including the
ter momentarily once and check if all the doors are
rear gate (wagon) open. Then, bring all the doors
locked, the horn chirps once, the parking lights
including the rear gate (wagon) in the closed con-
flash once and the security indicator light flashes
dition and check if all the doors are locked, the
slowly to ensure that the security system has been
horn chirps once and the parking lights flash once
brought into the arming state .
to ensure that the security system has been
brought into the arming state.
O ~\
J
i
LOCK
G10091
* Press the "UNLOCK/DISARM" button on the G10093A

transmitter momentarily once and check if the driv-
er's door is unlocked, the horn chirps twice, the Unlock a door using the inner lock knob or the
parking lights flash twice, the dome light illumi- key
* and open the door while the security system is
nates and the security indicator light goes off to in the arming state . Check to ensure that the
ensure that the system has been brought into the alarming condition occurs, i .e . the horn sounds
disarming state . continuously, the parking lights flash and the secu-
rity indicator light flashes rapidly, and that it lasts
for 30 seconds or until the "UNLOCK/DISARM"
O button on the transmitter is pressed . Also, check to
ensure that turning the ignition key to the "START"
position in the arming state does not cause the
starter motor to turn, thus the engine being pre-
vented from starting .
* Apply a shock to the vehicle body with the secu-
rity system in arming state, and check to ensure
that the alarming condition occurs .
G10092 * Troubleshoot the security system if any one of
the above-mentioned checks does not meet the
* Press the "UNLOCK/DISARM" button on the requirements .
transmitter momentarily once again and check if all
the doors including the rear gate on wagon are 23 . SEAT SA09719G5023
unlocked .
Check that each seat provides full functionality in
* Press the "LOCK/ARM" button on the transmit-
ter a little bit of time (approx. 1 .5 sec .) and check sliding and reclining . Check all available functions
if a panicking condition occurs ; the horn sounds of the rear seat such as a trunk-through center arm
continuously, the parking lights flash and the secu- rest.
rity indicator light flashes rapidly. Also, check if that
24 . SEAT BELT sA097,9G5024
condition lasts for 30 seconds or until any button of
the transmitter is pressed. Pull out the seat belt and then release it. Check
Press the "LOCK/ARM" button on the transmit- that the belt webbing retracts smoothly .
ter momentarily once with one of the doors includ-
ing the rear gate (wagon) open and check if the
horn chirps three times to warn of a door ajar.
PI-9
25. CHILD SEAT SA09779G5025 29. STARTING CONDITION SAO97,9G5029

Check that an instruction tag for handling a child Start the engine and check that the engine starts
seat is attached to the specified position . 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 .
30 . EXHAUST SYSTEM SA09719G5030
Listen to the exhaust noise to see if no abnormal

noises are observed .
31 . INDICATOR LIGHT
Operating instruction
SA09719G5031
for built-in child restr
G 10094A
Check that all the indicator lights are off .
26. WHEEL ALIGNMENT SA09779G5026

32 . CLOCK SA09779G5032
Check the wheel alignments . <Ref. to FS-6 Wheel Check the clock for normal operations and enough
Alignment.> and <Ref . to RS-8 Wheel Alignment.> accuracy.
27. TEST MODE CONNECTOR SA09719GSOD 33. RADIO SA09719G5033
Turn the ignition switch to ON and check that the Check the radio for full functionality and normal
check-engine light starts blinking . If the light blinks, noise level. Also check the CD unit operations .
return the ignition key to LOCK and disconnect the
test mode connector. Then, turn the ignition key to 34. CIGARETTE LIGHTER SA09719G5034
ON again. If the check-engine light blinks at that Check that the cigarette lighter operations .
time in spite of the disconnected test mode
connector, carry out an engine diagnosis . 35. LIGHTING SYSTEM SA09779G5035
Check the headlight operations .

Check the brake light operations .
Check the other lights for normal operations .
28. OPERATION CHECK OF SHIFT LOCK

SYSTEM, KEY INTERLOCK, AND
STARTER INTERLOCK SA09719G5028
For a MT vehicle, check the starter interlock sys-
tem
* operations .
* For an AT vehicle, check the shift lock and key
interlock system operations .
PI-10
Pre-delivery Inspe ction
36. WINDOW WASHER SA09719G5036 40 . AT SHIFT CONTROL SA09779G5041
Check that the window washer system injects Set the AT select lever to each gear position while
washer fluid to the specified area of the windshield checking that the demanded gear position is cor-
shown in the figure . rectly attained .
Front Selector lever gate pattern
200 mm 200 mm
(7 .87 in) 100 mm(3 .94 in)
X7 .87 in) N
350 mml
D
A-'Y
(13 .78 in)
~.f
2 ~
G10097A
Wagon Rear
Selector Gear Position
I
Position 1st 2nd 3rd 4th
42° 60 mm
D Yes Yes Yes Yes
(2 .36 in)
3 Yes Yes Yes
a 2 Yes
1 Yes
I I
41 . HEATER & VENTILATION SA09779G5042
G 10096A Operate the heater and ventilation system to check

for normal airflow and heating capacity .
3/ . WIPER SA09719G5037 42. AIR CONDITIONER SA09719G5043
Check the front and rear wipers for normal opera- Operate the air conditioner. Check that the A/C
tions . compressor operates normally and enough cooling
38 . BRAKE TEST SA09719G5038
is provided.
Check the foot brake for normal operations . 43 . CRUISE CONTROL SA09719G5044
39. PARKING BRAKE SA09719G5039

Operate the cruise control system . Check that the
system is activated and deactivated correctly.
Check the parking brake for normal operations .
44. ATF LEVEL SA09779G5045
Check that the ATF level is normal . If insufficient,

check that no leaks are found. Then add the nec-
essary amount of the specified ATE
PI-11
45. POWER STEERING FLUID LEVEL 47. WATER LEAK TEST SA09719G5048
SA09719G5046
Spray the vehicle with water and check that no
Check that the power steering fluid level is normal . water enters the passenger compartment.
If insufficient, check that no leaks are found. Then Before performing the water leakage test,
add the necessary amount of the specified power remove anything that may obstruct the operation or
steering fluid. which must be kept dry.
9 Close all of the windows completely, and then
close all of the doors tightly. Close the hood and
trunk lid before starting the test .
* Connect a hose to a tap, and spray water on the
vehicle. The rate of water discharge must be
approx . 20 to 25 liters (5 .3 to 6.6 US gal, 4 .4 to 5 .5
Imp gal) per minute .
When spraying water on areas adjacent to the floor
and wheel house, increase the pressure . When
directing water on areas other than the floor portion
and wheel house, decrease the pressure . But the
force of water must be made strong occasionally
by pressing the end of the hose .
46. FLUID LEAK CHECK SA09719G5047
NOTE :
Check the entire areas of the vehicle for any trace Be sure to keep the hose at least 10 cm (3.9 in)
of coolant/oil/fluid leaks. from the vehicle.
Check the following areas :
Front window and body framework mating
portion
Door mating portions
Glass mating portions
Rear quarter window mating portions
Rear window and body framework mating
portion
Around roof drips
" If any dampness in the compartments is discov-
ered after the water has been applied, carefully
check all areas that may have possibly contributed
to the leak.
48 . APPEARANCE CHECK 2 SA09719G5049
Check the vehicle body paints, plated faces, glass,

and lenses for any dirt or damage .
PI-12
GENERAL DESCRIPTION
Periodic Maintenance Services
1 . General Description sAO~oo,

A: GENERAL SA07ooiG23
Be sure to perform periodic maintenance in order

to maintain vehicle performance and find problems
before they become serious .
PM-2
SCHEDULE
2 . Schedule SA07682
A : MAINTENANCE SCHEDULE 1 SA07682G24
MAINTENANCE INTERVAL
[Number of months or km (miles), whichever occurs first]
Months 3 7.5 15 22 .5 30 37 .5 1 45 52 .5 60 67 .5 75 82 .5 90 97 .5 105 12 .5 120 Remarks
x 1,000 km 4 .8 12 24 36 48 60 72 81 .4 96 108 120 132 144 156 168 180 192
x 1,000 miles 3 7 .5 15 22 .5 30 37 .5 45 52 .5 60 67 .5 75 82 .5 90 97 .5 105 12 .5 120
1 Engine oil R R R R R R R R R R R R R R R R R
2 Engine oil filter R R R R R R R R R R R R R R R R R
3 Spark plugs R R R R For 2.5 L
R R For 3.0 L
4 Drive belt(s) I I I R
5 Camshaft Drive belt I I I R For 2.5 L
Note (1)
6 Valve clearance I
8 Fuel line (I) (I) (I) I Note (2)
9 Fuel filter (R) (R) (R) R Note (2)
10 Air cleaner element R R R R Note (3)
11 Cooling system I I I I
12 Coolant R R R R
13 Clutch system I I I I I I I I
14 Transmission oil I I I I
15 ATF I I I I Note (4)
16 Front & rear differen- I I I I
tial oil
17 Brake line I I I I I I I I
18 Brake fluid R R R R
19 Disc brake pads & I I I I
discs
20 Brake linings and I I I I
drums
21 Parking brake I I I I I I I I
22 Suspension I I I I I I I I
23 Wheel bearing (I) (I)
24 Axle boots & joints I I I I I I I I
25 Tire rotation I I I I I I I I I I I I I I I I Note (5)
26 Steering system I I I I I I I I
(Power steering)
27 Supplement restraint
system
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) This inspection is not required to maintain emission warranty eligibility and it does not affect the manufacturer's obligations
under EPA's in-use compliance program .
(3) When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often .
(4) ATF filter is maintenance free part . ATF filter needs replacement, when it has physically damaged or ATF leaked .
(5) A tire should be replaced when the tread wear indicator appears as a solid band across the tread. The indicators appear when
the remaining tread has been worn to 1 .6 mm (0 .063 in) or less .
PM-3
SCHEDULE
B : MAINTENANCE SCHEDULE 2 SA07682G25
Item Every Repeat short Repeat Extremely Salt or other High humidity Repeat tow-
distance drive rough/muddy cold weather corrosive or mountain ing trailer
road drive area used or area
coastal area
Engine oil 3.75 months R R R
6,000 km
3,750 miles
Engine oil filter 3.75 months R R R
6,000 km
3,750 miles
Fuel filter 15 months I
24,000 km
15,000 miles
Fuel line 15 months I
24,000 km
15,000 miles
Transmission oil 15 months R
24,000 km
15,000 miles
ATF 15 months R
24,000 km
15,000 miles
Front & rear differ- 15 months R
ential oil 24,000 km
15,000 miles
Brake line 15 months I I I I
24,000 km
15,000 miles
Brake fluid 15 months R
24,000 km
15,000 miles
Disc brake pads & 15 months I I I I
discs 24,000 km
15,000 miles
Brake linings and 15 months I I I I
drums 24,000 km
15,000 miles
Parking brake 15 months I I I I
24,000 km
15,000 miles
Suspension 7 .5 months I I I I
12,000 km
7,500 miles
Axle boots & 7.5 months I I I I I
joints 12,000 km
7,500 miles
Steering system 7.5 months I I I I I
(Power steering) 12,000 km
7,500 miles I __J
PM-4
ENGINE OIL
3. Engine Oil sAO7o» 5) Fill engine oil through filler pipe up to upper
point on level gauge. Make sure that vehicle is
A : REPLACEMENT SA.».,. placed level when checking oil level . Use engine oil
of proper quality and viscosity, selected in accor-
1) Drain engine oil by loosening engine oil drain dance with the table in figure .
plug .
Engine oil capacity:
Upper level
4.0 f (4.2 US qt, 3.5 Imp qt)
Lower level
3.0f (3.2 US qt, 2.6 Imp qt)
SAE Viscosity No . and Applicable Temperature

(°C) -30 -20-15 0 15 30 40
I ~ I I I I I
(°F) -22 --4 5 32 59 86 1 04
10W-30, 10W-40
5W-30 PREFERRED
2) Open engine oil filler cap for quick draining of
the engine oil .
G10015A
Engine oil filler cap
Oil level gauge- The proper viscosity helps vehicle get good cold
LL Upper level and hot starting by reducing viscous friction and
~O~ About 1 .01 thus increasing cranking speed .
'J (1 .1 US qt,
0.9 Imp qt) NOTE :
o - Lower level e 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 classifica-
tion and SAE viscosity No. designated by
G10013AI
SUBARU .
3) Replace drain plug gasket . * If vehicle is used in desert areas with very high
4) Tighten engine oil drain plug after draining temperatures or for other heavy duty applications,
engine oil . the following viscosity oils may be used :
API classification : SJ or SH
Tightening torque: SAE Viscosity No. : 30, 40, 10W-50, 20W-40,
44 N~m (4.5 kgf-m, 33 ft-Ib) 20W-50
6) Close engine oil filler cap.
7) Start engine and warm it up for a time .
8) After engine stops, recheck the oil level.
If necessary, add engine oil up to upper level on
level gauge.
Oil level gauge Notch mark
3P a Upper level
LL I About 1 .0 f
(1 .1 US qt,
0 .9 Imp qt)
J
o Lower level
G10016A
PM-5
ENGINE OIL
B : INSPECTION SA07077A10
1) Park vehicle on a level surface.

2) Remove oil level gauge and wipe it clean .
3) Reinsert the level gauge all the way. Be sure
that the level gauge is correctly inserted and in the
proper orientation .
4) Remove it again and note the reading . If the
engine oil level is below the "L" line, add oil to bring
the level up to the "F" line .
5) After turning off the engine, wait a few minutes
for the oil to drain back into the oil pan before
checking the level .
6) Just after driving or while the engine is warm,
engine oil level may show in the range between the
"F" line and the notch mark . This is caused by
thermal expansion of the engine oil.
7) To prevent overfilling the engine oil, do not add
oil above the "F" line when the engine is cold .
PM-6
ENGINE OIL FILTER
4. Engine Oil Filter SA07585
A : REPLACEMENT SA07585A20
1) Remove oil filter with ST.

2) Get a new oil filter and apply a thin coat of

engine oil to the seal rubber.
3) Install oil filter by turning it by hand, being care-
ful not to damage seal rubber.
4) Tighten more (approximately 2/3 to 3/4 turn)
after the seal rubber contacts the oil pump case .
Do not tighten excessively, or oil may leak.
5) After installing oil filter, run engine and make
sure that no oil is leaking around seal rubber .
NOTE :
The filter element and filter case are permanently
joined ; therefore, interior cleaning is not necessary.
6) Check the engine oil level . <Ref . to PI-7
ENGINE OIL, PDI PROCEDURE, Pre-delivery
Inspection .>
PM-7
SPARK PLUGS
5 . Spark Plugs SA07683
A : REPLACEMENT SA07683A20
1) Remove intake duct and intake chamber.

2) Remove washer tank and put it aside.
3) Disconnect spark plug cord .
4) Remove spark plug with a plug-wrench .
5) Set new spark plug .

Recommended spark plug:
CHAMPION RC10YC4
CHAMPION RCSYC4
NGK BKR6E-11
NIPPONDENSO K20PR-U11
Spark plug gap
1.0 - 1.1 mm (0.039 - 0.043 in)
6) Tighten spark plug lightly with hand, and then
secure with a plug-wrench to the specified torque .
Tightening torque:
20.6 N~m (2.10 kgf-m, 15.19 ft-Ib)
NOTE :
* Be sure to place the gasket between the cylin-
der head and spark plug .
* If torque wrench is not available, tighten spark
plug until gasket contacts cylinder head ; then
tighten further 1/4 to 1/2 turns.
PM-8
DRIVE BELT(S)
6 . Drive Belt(s) 5A°7684 B : REPLACEMENT sAO7684A2a

A: INSPECTION SA07684A10
1 . V-BELT COVER SA07684A2007
1) Replace belts, if cracks, fraying or wear is 1) Remove V-belt cover.

found.
2) Check drive belt tension and adjust it if neces-
sary by changing generator installing position
and/or idler pulley installing position .
Belt tension
(A)
replaced: 7 - 9 mm (0.276 - 0.354 in)
reused: 9.0 - 10.0 mm (0.354 - 0.394 in)
(B)*
replaced: 7.5 - 8.5 mm (0.295 - 0.335
in)
reused: 9.0 - 10.0 mm (0.354 - 0.394 in)
*: There is no belt (B) on models without an air 2. FRONT SIDE BELT (DRIVING POWER
conditioner. STEERING OIL PUMP AND GENERATOR)
SA07684A2002
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) .
as to obtain the specified belt tension .
5) Tighten the slider bolt (B).
6) Tighten the lock bolt (A).
Tightening torque:
C/P Crankshaft pulley Lock bolt, through bolt:
GEN Generator 25 N~m (2.5 kgf-m, 18 ft-Ib)
P/S Power steering oil pump pulley Slider bolt:
A/C Air conditioning compressor pulley 8 N~m (0.8 kgf-m, 5.8 ft-Ib)
I/P Idler pulley
PM_9
DRIVE BELT(S)
3. REAR SIDE BELT (DRIVING AIR

CONDITIONER) SA07684A2003
NOTE:
" Wipe off any oil or water on the belt and pulley.
Before removing the rear side belt, remove the
front side belt.
1) Loosen the lock nut (A) .
2) Loosen the slider bolt (B) .
3) Remove the rear side belt.
as to obtain the specified belt tension.
5) Tighten the slider bolt (B) .
6) Tighten the lock nut (A) .
Tightening torque:
22.6 N~m (2.3 kgf-m, 16 .6 ft-Ib)
PM-10
CAMSHAFT DRIVE BELT
7. Camshaft Drive Belt SA07685

9) Turn crankshaft and align alignment marks on
crankshaft, and left and right camshaft sprockets
A : REPLACEMENT ... with notches of belt cover and cylinder block:
1) Remove radiator fan <Ref. to CO(H4)-20
Radiator Main Fan and Fan Motor.> and air condi- Notch
tioner fan <Ref . to CO(H4)-23 Radiator Sub Fan
and Fan Motor .>. Alignment mark
(Ann
Alignment mark
> L°~ h'~
0v o
1
Notch
~o Alignment mark
3) Remove V-belts. <Ref . to ME(H4)-43 V-belt .>
4) Remove air conditioning compressor drive belt
tensioner.
5) Remove pulley bolt. To lock crankshaft use ST.
1
WRENCH G10025A
10) Remove belt idler.

11) Remove belt idler (No . 2) .
6) Remove crankshaft pulley.

7) Remove left side belt cover.
8) Remove front belt cover. 12) Remove timing belt.
13) Remove automatic belt tension adjuster
assembly.
PM-11
CAMSHAFT DRIVE BELT
B : INSTALLATION SA07685A17 C : INSPECTION SA07685Af0
To install, reverse order of removal procedures . 1) Remove left and right timing belt covers .
NOTE : 2) While cranking engine at least four rotations,
When installing the timing belt, be sure to align all check timing belt back surface for cracks or dam-
alignment marks on the belt with corresponding age . Replace faulty timing belt as needed .
marks on the sprockets . If incorrectly installed, 3) Measure timing belt width W. If it is less than 27
interference between pistons and valves may mm (1 .06 in), check idlers, tensioner, water pump
pulley and cam sprocket to determine idler align-
occur.
ment (squareness) . Replace worn timing belt.
4) Install left and right timing belt covers .
PM-12
VALVE CLEARANCE
8. Valve Clearance SA07083
A : INSPECTION SA07083Af0
For the inspection procedures of the valve clear-

ance : <Ref. to ME(H4)-53 Valve Rocker Assem-
bly.>
PM-13
FUEL LINE
9. Fuel Line sAO7686

A : INSPECTION SAO.
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(H4)-98 Fuel Delivery, Return and Evapora-
tion Lines.>
PM-14
FUEL FILTER
10 . Fuel Filter sAO7oz7 Unit : mm (in)
A : REPLACEMENT SAO1oz7Vo Fitting

Hose
WARNING :
" Place "No fire" signs near the working area . -- -Rri
Disconnect ground cable from battery.

CAUTION :
7
-.-~~-- 1 - 4 (0 .04 - 0 .16)
Be careful not to spill fuel on the floor.
1) Before removing the hose, filter, pump, etc., be When fitting length is specified
sure to release the fuel pressure, as follows:
Disconnect the wiring connector of the fuel
20 - 25 (0 .79 - 0.98)
pump .
* Crank the engine for more than five seconds . If
the engine starts, let the engine run until it stops . - - -,n-.
9 After turning IG switch OFF, connect the wiring ~y .
connector of the fuel pump.
Disconnect ground cable from battery.
1 - 4 (0 .04-0.16)
2) Loosen the screw of the hose clamp and pull off
the hose from the filter. When fitting length is not specified
3) Remove the filter from the holder. G 10030A
4) Replace fuel filter with a new one .
6) Install the fuel filter bracket to the vehicle body.
And tighten the bolts to the specified torque .
NOTE :
Make sure that the clamp screw is not loose .
Tightening torque:
7.35 N~m (0.75 kgf-m, 5.45 ft-Ib)
5) Install the hoses as shown in the figure .

Tightening torque:
1.0 - 1.5 N~m (0.1 - 0.15 kgf-m, 0.7 -
1.1 ft-Ib)
~I filter
CAUTION : G10029A
* If the hose is damaged at the clamping
portion, replace the hose with a new one.
9 If the hose clamp is deformed too much,
replace with a new one .
* Correct the hose position by removing any
twist so that it will not interfere with the filter
body or washer tank, before tightening the
screw of the hose clamp.
PM-15
AIR CLEANER ELEMENT
11 . Air Cleaner Element SAO7687

A : REPLACEMENT
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 penetra-
tion into the filter paper. If this filter paper is
cleaned, the filtration layer thus formed will be lost
along with the viscous liquid .
PM-16
COOLING SYSTEM
12 . Cooling System SAO7688

1) Check radiator for leakage, filling it with coolant

and attach radiator cap tester (A) to the filler neck .
Then apply a pressure of 157 kPa (1 .6 kg/cm2 , 23
psi) and check the following points :
" Each portion of radiator for leakage
Hose joints and other connections for leakage
NOTE:
* When attaching or detaching tester and when
operating tester, use special care not to deform
radiator filler neck.
3) If the coolant temperature exceeds 76.0 to

80.0°C (169 to 176°F) while radiator is not so hot,
check thermostat. If thermostat does not open at
* When performing this check, be sure to keep the 76.0 to 80 .0°C (169 to 176°F), replace it with a new
engine stationary and fill radiator with coolant. one .
Wipe off check points before applying pressure . 4) If electric fan does not operate when coolant
" Use care not to spill coolant when detaching temperature exceeds 90 to 94°C (194 to 201"F),
tester from radiator. check thermoswitch or fan motor.
2) Check the radiator cap valve open pressure
using radiator cap tester .
NOTE :
Rust or dirt on cap may prevent valve from func-
tioning normally : be sure to clean cap before test-
ing.
Raise the pressure until the needle of gauge stops
and see if the pressure can be retained for five to
six seconds. The radiator cap is normal if a pres-
sure above the service limit value has been main-
tained 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)
PM-17
COOLANT
13 . Coolant sAO7689 Next, add coolant into reservoir tank up to "FULL"

level.
A : REPLACEMENT SA.2o 12) After adding coolant, securely install radiator
and reservoir tank caps .
1 . REPLACEMENT OF COOLANT SAO7689AZOO,
WARNING : 2. RELATIONSHIP OF SUBARU COOLANT
The radiator is of the pressurized type . Do not CONCENTRATION AND FREEZING
attempt to open the radiator cap immediately TEMPERATURE SA07689A2002
after the engine has been stopped . The concentration and safe operating temperature
1) Lift up the vehicle. of the SUBARU coolant is shown in the diagram .
2) Remove under cover. Measuring the temperature and specific gravity of
3) Place a container under drain pipe . the coolant will provide this information.
[Example]
4) Loosen and remove drain screw (A) to drain
If the coolant temperature is 25°C (77°F) and its
engine coolant into container.
specific gravity is 1 .054, the concentration is 35%
(point A), the safe operating temperature is -14°C
(7°F) (point B), and the freezing temperature is
-20°C (-4°F) (point C) .
Safe operating temperature
Concentration
of coolant
1 .100 Z___L_
V
1 .090
%
,. 1 .080 - %
%
5) For quick draining, open radiator cap . 60%
o 1 .070 -
00 C
CAUTION : 1 .060 (1 .054) % 5 %
Be careful not to spill coolant on the floor. A
1 .050
40% N
416
6) Drain coolant from reservoir tank. -1 .040 -
7) Tighten radiator drain screw securely after .6 1 .030 - Freezing 300%/,
oo
0,
draining coolant. a)0- temperature)
.
8) Slowly pour prepared coolant from radiator filler W 1 .020 -
2 00X
port to neck of filler, then pour into reservoir tank 1 .010-
up to "FULL" level . 1 .000, 1 1 1
C\1 10%
0-3 0-2 0-1 0 0 1 0 20 3 0 40 50
Coolant capacity (fill up to "FULL" level) (-40)(-22)(-4)(14)
-4 (32) (50) (68)(86)(104)(122)
MT model: Coolant temperature 'C (T)
Approx. 6.8 f (7.2 US qt, 6.0 Imp qt)
G 10037A
AT model:
Approx. 6.7 f (7.1 US qt, 5.9 Imp qt)
NOTE :
The SUBARU Genuine Coolant containing anti-
freeze and anti-rust agents is especially made for
SUBARU engine, which has an aluminum crank-
case . Always use SUBARU Genuine Coolant,
since other coolant may cause corrosion .
9) Securely install radiator cap.
10) Run engine for more than five minutes at
2,000 to 3,000 rpm . (Run engine until radiator
becomes hot in order to purge air trapped in cool-
ing system.)
11) Stop engine and wait until coolant temperature
lowers . Then open radiator cap to check coolant
level and add coolant up to radiator filler neck .
PM-1 8
COOLANT
3. PROCEDURE TO ADJUST THE

CONCENTRATION OF THE COOLANT
SA07689A2003
To adjust the concentration of the coolant accord-

ing to temperature, find the proper fluid concentra-
tion in the above diagram and replace the neces-
sary 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 cool-
ant 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 cool-
ant 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.
Q
Necessary concentration
of coolant
3
~ (3 .2, 2.6)
aD 45%
c
----- ------ 40%
35%~
~ (2 .1, 1 .8) 30%
0 1 \ 25%
'J 20%
(1 .1, 1 .8) 15%
0 10%
o p
10 20 30 40 50
0
>, Concentration of coolant in the vehicle
cooling system
ro
Concentration of coolant in vehicle
and quantity to be drained
GI0038A
PM-19
CLUTCH SYSTEM
14. Clutch System SA07690
A : INSPECTION AND ADJUSTMENT

SA07690G26
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.
J
-Release lever
Push rod
J \
Operating cylinder L G 10039A
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-21 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 retighten-
ing their fitting bolt and/or replacing their parts.
5) Check the fluid level using the scale on the
outside of the clutch master cylinder tank (A). If the
level is below "MIN" (B), add clutch fluid to bring it
up to "MAX" (C) .
Recommended clutch fluid:
FMVSS No. 116, fresh DOT3 or DOT4
brake fluid
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 .
PM-20
TRANSMISSION OIL
15 . Transmission Oil SAO7s9,

A: REPLACEMENT SAO169,AZo
1 . MANUAL TRANSMISSION SA07691A2001
1) Drain gear oil by removing drain plug after

allowing the engine to cool for 3 to 4 hours .
NOTE :
Before starting work, cool off the engine well .
, _- \\\\
'3~ ~ 1` V
c~ \\ ~/
G10041
2) Reinstall drain plug after draining gear oil and

tighten it to the specified torque .
Tightening torque:
44 N~m (4.5 kgf-m, 32.5 ft-Ib)
NOTE :
* Be sure to place a gasket between the transmis-
sion case and drain plug .
Replace the gasket with a new one.
" Each oil manufacturer has its base oil and addi-
tives. 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:
4.0 f (4.2 US qt, 3.5 Imp qt)
PM-21
ATF
16. ATF SA07692 2. ATF FILTER SAO~69zA~ooz

NOTE :
A: REPLACEMENT .116.21
ATF filter is maintenance free part . ATF filter needs
1 . AUTOMATIC TRANSMISSION FLUID replacement, when it has physically damaged or
SA07692A2001 ATF leaked .
1) Drain ATF (Automatic Transmission Fluid) by For the replacement procedures of the ATF filter :
removing drain plug after allowing the engine to <Ref . to AT-38 ATF Filter.>
cool for 3 to 4 hours.
NOTE :
Before starting work, cool off the engine well .
\ATF drain plug

\ -
Front differential
o
drain plug
~ ~--~ ~-tea (~
o
G10043A
2) Reinstall drain plug after draining ATF, and

tighten it to the specified torque .
Tightening torque:
24 .5 N~m (2.5 kgf-m, 18.1 ft-Ib)
3) Fill ATF up to the middle of the "COLD" side on
level gauge by using the gauge hole .
Recommended fluid:
Dexron HE or 111 type automatic trans-
mission fluid
Fluid capacity:
9.3+o.s/_o P (9.S+o .s/_v US qt, 8.2'"o.s4o imp
qt)
4) Run the vehicle until the ATF temperature rises
to 60 to 80°C (140 to 176°F) and check the ATF
level.
"Hot"
side
Upper "COLD"
side
Upper
level
level Lower
level
G10044A
PM-22
FRONT & REAR DIFFERENTIAL OIL
17. Front & Rear Differential Oil

SA07693
A: REPLACEMENT SA07693A20
1 . FRONT DIFFERENTIAL (MANUAL

TRANSMISSION) SA07693A2001
For M/T vehicle, manual transmission oil works as
differential oil to lubricate differential . Refer to
"Transmission Oil". <Ref . to PM-21 MANUAL
TRANSMISSION, REPLACEMENT, Transmission
Oil .>
3. REAR DIFFERENTIAL SA07693A2003
2. FRONT DIFFERENTIAL (AUTOMATIC 1) Drain oil by removing drain plug .

TRANSMISSION) SA07693A2002 2) Remove filler plug for quick draining oil .
1) Drain differential gear oil by removing drain plug 3) Tighten drain plug after draining oil .
after allowing the engine to cool for 3 to 4 hours. NOTE :
NOTE : Apply fluid packing to drain plug threads before
Before starting work, cool off the engine well . installation .
Fluid packing:
Three Bond 1105
Tightening torque:
44.1 N-m (4.5 kgf-m, 32.5 ft-Ib)
4) After installing drain plug onto rear differential
gear case firmly, fill oil up fully to the mouth of filler
plug .
Filler plug
2) Reinstall drain plug after draining differential

gear oil and tighten it to the specified torque .
e '. .
Tightening torque: -
--' -
44 N~m (4.5 kgf-m, 32.5 ft-Ib)
NOTE:
Drain plug
9 Be sure to place a gasket between the transmis- G 10047A
sion case and drain plug .
9 Replace the gasket with a new one. Oil capacity:
* Each oil manufacturer has its base oil and addi- 0.8 f (0.8 US qt, 0.7 Imp qt)
tives . Thus, do not mix two or more brands . NOTE :
3) Fill differential gear oil through the oil level Each oil manufacturer has its base oil and addi-
gauge hole up to the upper point of level gauge. tives. Thus, do not mix two or more brands.
Differential gear oil capacity: 5) Install filler plug onto rear differential gear case
1.1-1 .3(1 .2-1.4USqt, 1.0-1,1 firmly.
Imp qt) NOTE :
Apply fluid packing to filler plug before installation .
Fluid packing:
Three Bond 1105
Tightening torque:
44.1 N~m (4.5 kgf-m, 32.5 ft-Ib)
PM-23
BRAKE LINE
18 . Brake Line SAO7694 B : CHECKING

1 . SERVICE BRAKE SA07694GD01
I Clevis pin
1 . BRAKE LINE SA07694A1001
1) Check the free play of brake pedal with a force
of less than 10 N (1 kgf, 2 Ib) .
1) Check scratches, swelling, corrosion and/or
traces of fluid leakage on brake hoses or pipe Brake pedal free play :
joints . 1-3mm(0.04-0.12 in)
2) Check the possibility of adjacent parts interfer-
ing with brake pipes/hoses during driving, and Lock nut
loose connections/clamps .
3) Check any trace of fluid leakage, scratches,
Brake boosters I Clevis
etc. on master cylinder, wheel cylinder and pres- operating rod
sure control valve . Pedal play
Play at pin 1 -3 mm
NOTE : (0 .04 - 0.12 in)
9 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. GIOOSOA
* Visually check brake hose (using a mirror where 2) If the free play is out of specifications above,
it is difficult to see) for any damage. adjust the brake pedal as follows :
(1) Be sure engine is off. (No vacuum is applied
to brake booster.)
(2) There should be play between brake
booster clevis and pin at brake pedal installing
portion.
[Depress brake pedal pad with a force of less
than 10 N (1 kgf, 2 Ib) to a stroke of 1 to 3 mm
(0.04 to 0.12 in) .]
(3) Depress the surface of brake pad by hand.
(4) If there is no free play between clevis pin
and clevis, turn brake switch adjusting nut until
the clearance between stopper and screw of
brake switch becomes 0.3 mm (0 .012 in) .
-~ Rear brake hose Brake switch
Adjusting nut
Lock nut
0.3 mm (0 .012 in)
J
G10049A i
1 \ Stopper
Brake booster
\Clevis pin
operating rod
\ Clevis
Play at pin
Pedal play
1-3mm
(0 .04 - 0.12 in)
G 10051 A
PM-24
BRAKE LINE
3) Check the pedal stroke .

While the engine is idling, depress the brake pedal
with a 490 N (50 kgf, 110 Ib) load and measure the
distance between the brake pedal and steering Engine side Brake booster side
wheel . With the brake pedal released, measure the
distance between the pedal and steering wheel 'ON ~ <= M1110.
again . The difference between the two measure-
ments must be less than 95 mm (3.74 in) . If the
distance is more than specified, there is a possibil-
ity air is in the inside of the hydraulic unit.
G10053A
Brake pedal reserve distance: A
more than 95 mm (3.74 in)/ 490 N (50 kgf, 5) Check vacuum hose for cracks or other dam-
110 Ib) age .
NOTE :
When installing the vacuum hose on the engine
and brake booster, do not use soapy water or lubri-
cating oil on their connections .
6) Check vacuum hose to make sure it is tight and
secure .
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 .
2 . BRAKE SERVO SYSTEM SA07694G2702
1) With the engine off, depress the brake pedal

several times applying the same pedal force: Make
sure the travel distance should not change.
2) With the brake pedal depressed, start the
engine : Make sure the pedal should move slightly
toward the floor.
3) With the brake pedal depressed, stop the
engine and keep the pedal depressed for 30 sec-
onds : Make sure the pedal height should not
change.
4) Check valve is built into vacuum hose . Discon-
nect vacuum hose to inspect function of check
valve .
Blow air into vacuum hose from its brake booster
side end : Air must flow out of engine side end of
hose . Next blow air into hose from engine side: Air
should not flow out of hose .
Replace both check valve and vacuum hose if
check valve is faulty. Engine side of vacuum hose
is indicated by marking "ENGINE" as shown .
PM-25
BRAKE FLUID
19. Brake Fluid SAO~,sz NOTE :

Cover bleeder with waste cloth, when loosening
A: REPLACEMENT SAO,,6ZAZo it, to prevent brake fluid from being splashed over
surrounding parts .
1) Either jack up vehicle and place a safety stand During bleeding operation, keep the brake
under it, or lift up vehicle . reserve tank filled with brake fluid to eliminate entry
2) Remove both front and rear wheels . of air.
3) Draw out the brake fluid from master cylinder " Brake pedal operation must be very slow.
with syringe. " For convenience and safety, it is advisable to
4) Refill reservoir tank with recommended brake have two men working.
fluid . 9 The amount of brake fluid required is approxi-
Recommended brake fluid: mately 500 mf (16.9 US fl oz, 17 .6 Imp fl oz) for
FMVSS No. 716, fresh DOT3 or 4 brake total brake system .
fluid 6) Instruct your co-worker to depress the brake
NOTE: pedal slowly two or three times and then hold it
depressed.
Avoid mixing different brands of brake fluid to
7) Loosen bleeder screw approximately 1/4 turn
prevent
'6 degrading the quality of the fluid.
until a small amount of brake fluid drains into
9 Be careful not to allow dirt or dust to get into the container, and then quickly tighten screw.
reservoir tank . 8) Repeat steps 6) and 7) above until there are no
Bleeding sequence (1) ---> (2) ---> (3) -4 (4) air bubbles in drained brake fluid and new fluid
flows through vinyl tube.
C1) (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 .
(5)~~
9) After completing the bleeding operation, hold
brake pedal depressed and tighten screw and
install bleeder cap.
Tightening torque:
(s) (2) 8 N~m (0.8 kgf-m, 5.8 ft-Ib)
G10054A
10) Bleed air from each wheel cylinder by follow-

(1) Front right
ing the previous 5 steps.
(2) Rear left
11) Depress brake pedal with a force of approxi-
(3) Front left
mately 294 N (30 kgf, 66 Ib) and hold it there for
(4) Rear right
approximately 20 seconds. At this time check
(5) Secondary
pedal to see if it makes any unusual movement .
(6) Primary
Visually inspect bleeder screws and brake pipe
5) Install one end of a vinyl tube onto the air joints to make sure that there is no fluid leakage.
bleeder and insert the other end of the tube into a 12) Install wheels, and drive vehicle for a short
container to collect the brake fluid. distance between 2 to 3 km (1 to 2 miles) to make
sure that brakes are operating properly.
PM-26
DISC BRAKE PADS AND DISCS
20. Disc Brake Pads and Discs NOTE :

SA°'695 When replacing a pad, always replace the pads for
both the left and right wheels at the same time.
A : INSPECTION SA07695A10 Also replace pad clips if they are twisted or worn .
1 . DISC BRAKE PAD AND DISC SAO~695A,oo,
1) Jack up vehicle and support with rigid racks.
Then remove wheels.
2) Visually check pad thickness through inspec-
tion hole of disc brake assembly. Replace pad if
necessary.
Pad thickness including back metal mm (in)

Front Rear
Standard 17 (0 .67) 14 (0 .55)
Service limit 7.5 (0 .295) 6.5 (0 .256)
Service limit 1 .5 (0 .059) 1 .5 (0 .059)
(exclusive back metal)
Thickness
of pad
Lining ~
\ I rBack
1, metal
G10057A
3) Check the disc rotor, and correct or replace if it

is damaged or worn .
Brake disc thickness mm (in)
Front Rear
Standard 24 (0 .94) 10(0 .39)
I Wear limit 22 (0 .87) 8.5 (0 .335)
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 runouf limit:
Front: 0.075 mm (0.0030 in)
Rear: 0.075 mm (0.0030 in)
PM-27
BRAKE LININGS AND DRUMS
21 . Brake Linings and Drums If deformation or wear of back plate, shoe, etc . is
noticeable, replace the affected parts .
SA07696
1 . REAR DRUM BRAKE SA,696A,oo, QA
1) Remove brake drum, and check that there is no A
fluid leakage from wheel cylinder. aOP

A Q
If there is fluid leakage from wheel cylinder, replace
it.
2) Inspect brake shoes for damage or deformities
and check brake linings for wear.
Measuring inside diameter
NOTE : G10060A
Always replace both leading and trailing brake

shoes for the left and right wheels at the same 2. PARKING BRAKE (REAR DISC BRAKE)
time . SA07696A1002
* When either the left or the right brake assembly

Inspect brake linings and drums of both sides of
is replaced, always replace the leading shoe and
the rear brake at the same time by removing brake
trailing shoe of the other.
drums .
The cotter pin, once removed, cannot be
1) Inspect brake shoes for damage or deformation
reused .
and check brake linings for wear .
Thickness of lining (except back metal)
NOTE :
Standard value: 4.1 mm (0.161 in)
Always replace both primary and secondary brake
Service limit: 1 .5 mm (0.059 in)
shoes for the left and right wheels at the same
(2) time .
(3)
C1) !7~___ Brake lining thickness excluding back metal
Standard value: 3.2 mm (0.126 in)
(4) Wear limit: 1.5 mm (0.059 in)
OO
0
~5)
o ~ o
(6)
G10059A 'o o~
(1) Rotational direction of drum (Forward)

(2) Wheel cylinder
Brake shoe ~ Brake shoe
(3) Upper shoe return spring (Primary) (Secondary)
(4) Adjusting lever
G10061 A
(5) Trailing shoe
(6) Lower shoe return spring
(7) Leading shoe
To replace trailing shoe, remove cotter pin. Clevis

pin should also be replaced if worn .
3) Check brake drum for wear, dents or other
damage.
If the inside surface of brake drum is streaked,
correct the surface with emery cloth (#200 or
more) . If it is unevenly worn, tapered, or the out-
side surface of brake drum is damaged, correct or
replace it.
Brake drum inner diameter
Standard value : 228.6 mm (9.000 in)
Service limit: 230.6 mm (9.079 in)
PM-28
BRAKE LININGS AND DRUMS
2) Check brake drum for wear, dents or other B : ADJUSTMENT SA07696A01
damage. If the inside surface of brake drum is

streaked, correct the surface with emery cloth 1 . REAR DRUM BRAKE SA07696A0101
(#200 or more) . If it is unevenly worn, tapered, or The main brake is adjusted automatically, and so
the outside surface of brake drum is damaged, there is no need to adjust it.
correct or replace it.
2. PARKING BRAKE (REAR DISC BRAKE)
Brake drum inside diameter
Standard value: 170 mm (6.69 in)
SA07696A0102
Wear limit: 171 mm (6.73 in) For rear disc brake, adjust parking brake after
bleeding the air.
1) Remove rear cover (rubber) installed at back
plate.
2) Turn adjuster toward arrow mark (upward) until
it is locked slightly, by using slot-type screwdriver
as shown in illustration .
Adjuster
Cover (rubber)
r , ~r Slot-type screwdriver

etc. is noticeable, replace them . / /
4) When the shoe return spring tension is exces- Back plate
upper and lower springs . G10063A
3) Turn back (downward) adjuster 3 to 4 notches.

4) Install cover (rubber) at original position cor-
rectly.
PM-29
SUSPENSION
22 . Suspension SA07697
A: INSPECTION SAO769.A,°
1 . SUSPENSION BALL JOINT SA07697A7007
1) Jack up vehicle until front wheels are off

ground.
2) Next, grasp bottom of tire and move it in and
out. If relative movement is observed between
brake disc cover and end of transverse link, ball
joint may be excessively worn .
3) Next, grasp end of transverse link and move it
up and down . Relative movement between hous- 2. TRANSVERSE LINK'S REAR BUSHING
ing and transverse link boss indicates ball joint SA07697A7002
may be excessively worn . Check oil leaks at around liquid-filled bushing. If oil
4) If relative movement is observed in the imme- leaks, replace bushing .
diately preceding two steps, remove and inspect
ball joint. If free play exceeds standard, replace
ball joint. <Ref . to FS-14 Front Ball Joint.> -Rear bushing
Housing
o
0
JTransverse link C
Disc cover G10067A

Transverse link ~~IIII""
^zlative movement
Ball joint
3. WHEEL ARCH HEIGHT SA07697A7003
G10064A
1) Unload cargoes and set vehicle in curb weight
(empty) condition .
2) Then, check wheel arch height of front and rear
Housing suspensions to ensure that they are within speci-
0 fied values .
0 3) When wheel arch height is out of standard,
visually inspect following components and replace
Relative movement
deformed parts.
Suspension components [Front strut assembly
Transverse link and rear shock absorber assembly]
Ball joint * Body parts to which suspensions are installed .
GI0065A 4) When no components are deformed, adjust
wheel arch height by replacing coil spring in the
5) Damage of dust seal suspension whose wheel arch height is out of stan-
Visually inspect ball joint dust seal . If it is damaged, dard. <Ref . to FS-6 Wheel Alignment.> <Ref . to
remove transverse link. <Ref . to FS-11 Front RS-8 Wheel Alignment.>
Transverse Link.> And measure free play of ball
joint. <Ref . to FS-14 Front Ball Joint.>
(1) When looseness exceeds standard value,
replace ball joint.
(2) If the dust seal is damaged, replace with the
new ball joint.
NOTE :
When transverse link ball joint has been removed
or replaced, check toe-in of front wheel . If front
wheel toe-in is not at specified value, adjust toe-in .
<Ref . to FS-6 Wheel Alignment.>
PM-30
SUSPENSION
4 . WHEEL ALIGNMENT OF FRONT 8. DAMAGE TO SUSPENSION PARTS

SUSPENSION SA07697A1004 SA07697A1008
1) Check alignment of front suspension to ensure 1) Check the following parts and the fastening por-
that following items conform to standard values . tion of the vehicle body for deformation or exces-
" Toe-in sive rusting which impairs the suspension . If
Camber angle necessary, replace damaged parts with new ones .
Caster angle If minor rust formation, pitting, etc . are noted,
Steering angle remove rust and apply remedial anti-corrosion
<Ref . to FS-6 Wheel Alignment.> measures .
2) When caster angle does not conform to stan- Front suspension
dard value, visually inspect following components Transverse link
and replace deformed parts . " Crossmember
Suspension components [Strut assembly, Strut
crossmember, transverse link, etc.] Rear suspension
* Body parts to which suspensions are installed . Sub frame
3) When toe-in and camber are out of standard " Link F
value, adjust them so that they conform to respec- " Link R
tive service standard . " Link UPR
4) When right-and-left turning angles of tire are 9 Arm R
out of standard, adjust to standard value. Shock absorber
" In the district where salt is sprayed to melt snow
5. WHEEL ALIGNMENT OF REAR on a road in winter, check suspension parts for
SUSPENSION SA07697A1005 damage caused by rust every 12 months after
1) Check alignment of rear suspension to ensure lapse of 60 months . Take rust prevention measure
that following items are within standard values . as required .
" Toe-in
Camber angle
Thrust angle
<Ref . to RS-8 Wheel Alignment.>
2) When camber angle does not conform to stan-
dard value, visually inspect parts listed below. If
deformation is observed, replace damaged parts.
Suspension components [Shock absorber, link
F, link R, link UPR, arm R, sub frame, etc.]
* Body parts to which suspensions are installed.
3) When toe-in and thrust angle are out of stan-
dard value, adjust them so that they conform to
respective service standard .
6. OIL LEAKAGE OF STRUT AND SHOCK
ABSORBER .,,.7A 1006
Visually inspect 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
SA07697A7007
Check bolts and nuts shown in the figure for loose-

ness . Retighten bolts and nuts to specified torque .
If self-lock nuts and bolts are removed, replace
them with new ones .
Front suspension : <Ref . to FS-2 General Descrip-
tion .>
Rear suspension : <Ref . to RS-2 General Descrip-
tion .>
PM-31
WHEEL BEARING
23. Wheel Bearing SAO7698 6) While supporting rear drive shaft horizontally
with one hand, turn hub COMPL with the other to
A : INSPECTION SA07698A70 check for noise or binding.
If hub COMPL is noisy or binds, disassemble rear
1 . FRONT WHEEL BEARING SA07698A1007
axle and check condition of oil seals, bearings, etc.
NOTE:
Inspect the condition of front wheel bearing Hub unit
Hub bolt
grease.
1) Jack up the front of vehicle .
o
2) While holding front wheel by hand, swing it in
and out to check bearing free play. 0
3) Loosen wheel nuts and remove front wheel .
4) If bearing free play exists in step 2) above,
attach a dial gauge to hub and measure axial dis- Hi
placement in axial direction.
G10069AI
Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove bolts and self-locking nuts, and extract
transverse link from front crossmember.
6) While lightly hammering spring pin which
secures S.F.J. to transmission spindle, remove it.
7) Extract S.F.J . from transmission spindle . <Ref .
to DS-16 Front Axle .>
8) While supporting front drive shaft horizontally
with one hand, turn hub with the other to check for
noise or binding.
If hub is noisy or binds, disassemble front axle and
check condition of oil seals, bearing, etc .
Inner oil seal

Hub bolt
1
Socket bolt
(With ABS only)
Snap ring
Bearing
Housing
Outer oil seal
e r<
Tone wheel
Hub
GI0068A
2 . REAR WHEEL BEARING SA07698A1002
1) Jack up the rear of vehicle.

2) While holding rear wheel by hand, swing if in
and out to check bearing free play.
3) Loosen wheel nuts and remove rear wheel .
4) If bearing free play exists in step 2) above,
attach a dial gauge to hub COMPL and measure
axial displacement in axial direction .
Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the DOJ of rear drive shaft from rear
differential . <Ref. to DS-33 Rear Drive Shaft.>
PM-32
AXLE BOOTS & JOINTS
24. Axle Boots & Joints sAO7699

A : INSPECTION SA07699A70
1 . FRONT AND REAR AXLE BOOTS SA07699A1001
Inspect front axle boots (A) and rear axle boots (B)
for deformation, damage or failure . If faulty, replace
them with new ones . <Ref . to DS-28 Front Drive
Shaft.> <Ref . to DS-33 Rear Drive Shaft.>
2. PROPELLER SHAFT SAa7699A,oo2

Inspect propeller shaft for damage or failure . If
faulty, replace with new one. <Ref. to DS-13 Pro-
peller Shaft.>
PM-33
TIRE ROTATION
25 . Tire Rotation SAO»oo

1) Replace the tire if the tread depth is less than

1 .6 mm (0 .063 in) or if wear indicators appear
across the tire tread . (It is recommended that both
right and left tires are replaced as a set.)
2) Adjust the wheel alignment if abnormally
uneven tire wear is found .
3) Also, rotate the tires between the front and rear
tires as illustrated, in order to ensure uniform tire
wear .
New tread Worn tread
Tread wear
indicator
~I I
-I I
G10073A
PM-34
STEERING SYSTEM (POWER STEERING)
26 . Steering System (Power 2 . STEERING SHAFT JOINT SA07707A7002
Steering) SAO»o, 1) When steering wheel free play is excessive,

disconnect universal joint of steering shaft and
A : INSPECTION SA07701A70 check it for any play and yawing torque (at the
1 . STEERING WHEEL SA07701A1001
point of the crossing direction) . Also inspect for any
damage to sealing or worn serrations . If the joint is
1) Set steering wheel in a straight-ahead position, loose, retighten the mounting bolts to the specified
and check wheel spokes to make sure they are torque .
correctly set in their specified positions .
2) Lightly turn steering wheel to the left and right Tightening torque:
to determine the point where front wheels start to 24±3 N~m (2.4±0.3 kgf-m, 17.4±2.2 ft-Ib)
move .
Measure the distance of the movement of steering
wheel at the outer periphery of wheel.
Steering wheel free play:
0- 17 mm (0-0 .67 in)
Free play
\ S U PS aRU _
I
3. GEARBOX SA07701A1003
1) With wheels placed on a level surface, turn

steering wheel 90° in both the left and right direc-
G 10074A
tions .
Move steering wheel vertically toward the shaft to While wheel is being rotated, reach under vehicle
ascertain if there is play in the direction . and check for looseness in gearbox.
Maximum permissible play: Tightening torque:
0.5 mm (0.020 in) 59±12 N~m (6.0-+1.2 kgf-m, 43.4±8.7 ft-Ib)
3) Drive vehicle and check the following items dur-
ing 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 . . . . . . .. .. . .. .. 2) Check boot for damage, cracks or deterioration .
Steering wheel should return to its original posi-
tion after it has been turned and then released .
Maximum permissible play:
0.5 mm (0.020 in)
PM-35
3) With vehicle on a level surface, quickly turn 3) Check lock nut on the tie-rod end for tightness.
steering wheel to the left and right. If it is loose, retighten it to the specified torque .
While steering wheel is being rotated, check the Tightening torque:
gear backlash . If any unusual noise is noticed, 83±5 N~m (8.5±0.5 kgf-m, 61.5±3.6 ft-Ib)
adjust the gear backlash in the following manner.
(1) Tighten adjusting screw to 7.4 N~m (0 .75 5 . POWER STEERING FLUID LEVEL
kgf-m, 5.4 ft-Ib) and then loosen . Repeat this SA07701A1005
operation twice . NOTE :

(2) Retighten adjusting screw to 7.4 N~m (0 .75 The fluid level must be checked when the tempera-
kgf-m, 5.4 ft-Ib) and back off 25° . ture of the reservoir tank surface is approximately
(3) Apply liquid packing to at least 1/3 of entire 20°C (68°F) .
perimeter of adjusting screw thread . 1) Place vehicle with engine "off" on the flat and
level surface .
2) Check the fluid level using the scale on the
outside of the reservoir tank (A) . If the level is
below "MIN" (B), add fluid to bring it up to "MAX"
Apply liquid packing (C) .
`;;f to at least 1/3 of entire
perimeter
GI0077A
(4) Install lock nut. While holding adjusting

screw with a wrench, tighten lock nut using ST.
ST 926230000 SPANNER
Tightening torque (Lock nut) :
39±10 N~m (4.0±1 .0 kgf-m, 29±7 ft-Ib)
NOTE :
Hold the adjusting screw with a wrench to pre- If fluid level is at MAX level or above, drain fluid to
vent it from turning while tightening the lock nut .
keep the level in the specified range of indicator by
4. TIE-ROD sA0770,A,004 using a syringe or the like .
1) Check tie-rod and tie-rod ends for bends, Recommended fluid:
scratches or other damage . Dexron 111
Fluid capacity:
0.7 f (0.7 US qt, 0.6 Imp qt)
6. POWER STEERING FLUID FOR LEAKS
SA07701A1006
Inspect the underside of oil pump and gearbox for

power steering system, hoses, piping and their
couplings for fluid leaks.
If fluid leaks are found, correct them by retighten-
ing their fitting bolts (or nuts) and/or replacing their
parts.
NOTE :
2) Check connections of knuckle ball joints for Wipe the leakage fluid off after correcting fluid
play, inspect for damage on dust seals, and check leaks, or a wrong diagnosis is taken later.
free play of ball studs . If castle nut is loose, * Also pay attention to clearances between hoses
retighten it to the specified torque, then tighten fur- (or pipings) and other parts when inspecting fluid
ther up to 60° until cotter pin hole is aligned . leaks.
Tightening torque:
27±2.5 N~m (2.75±0.25 kgf-m, 19 .9±1 .8
ft-Ib)
PM-36
7. HOSES OF OIL PUMP FOR DAMAGES 10. FITTING BOLTS AND NUTS SA07707A7070
SA07701A1007
Inspect fitting bolts and nuts of oil pump and
Check pressure hose and return hose of oil pump bracket for looseness, and retighten them if neces-
for crack, swell or damage . Replace hose with new sary.
one if necessary. Inspect and/or retighten them when engine is cold .
NOTE:
Prevent hoses from revolving and/or turning when
installing hoses.
8. POWER STEERING PIPES FOR

DAMAGE SA07707A7008
Check power steering pipes for corrosion and
damage .
Replace pipes with new one if necessary.
9. GEARBOX BOOTS SA07707A1009
Inspect both sides of gearbox boots as follows, and

correct the defects if necessary.
1) (A) and (B) positions of gearbox boot are fitted
correspondingly in (A) and (B) grooves of gearbox
and the rod.
2) Clips are fitted outside of (A) and (B) positions
of boot.
3) Boot does not have crack and hole .
NOTE :
Rotate (B) position of gearbox boot against twist of
it produced by adjustment of toe-in, etc.
PM-37
SUPPLEMENTAL RESTRAINT SYSTEM
27. Supplemental Restraint System SAO»oZ

A : INSPECTION SA07702A10
Check the airbag system in accordance with the result of the self-diagnosis . <Ref . to AB-2 Basic Diagnos-
tic Procedure.>
1) Ensure that airbag connectors are connected . If not, properly connect (also double lock the connector) .
When the ignition switch is turned ON with the connector(s) disconnected, the airbag warning light blinks
to identify the fault.
AIR BAG
o0 0 0
G10031A
2) Turn the ignition switch ON, and connect the airbag diagnosis terminal of the service connector (located
below lower cover) to the ground terminal .
3) The warning light blinks to indicate a trouble code (a fault is identified) . When the airbag system is in
good order (no trouble codes are stored in the memory), the warning light blinks on and off at 0.6 second
intervals (as long as the diagnosis terminal is connected to the ground terminal) .
4) When the warning light indicates a trouble code, check the airbag system in accordance with the
troubleshooting procedure . <Ref. to AB-2 Basic Diagnostic Procedure .>
PM-38
HVAC System (Auto A/C) (DIAGNOSTICS)

1 START INSPECTIONS. Dose self-diagnosis oper- Go to step 2. <Ref. to AC-16
1) Perform pre-inspection. ate? A/C AND/OR
2) Perform self-diagnosis. <Ref. to AC-12 SELF-DIAGNO-
SELF-DIAGNOSIS MODE, Diagnostics Chart SIS SYSTEMS
for Diagnosis System.> DO NOT
OPERATE, Diag-
nostics for A/C
System Failure.>
2 CHECK TROUBLE CODE. Is trouble code indicated? <Ref. to AC-26 Go to step 3.
Check trouble code. Diagnostic Proce-
dure with Trouble
Code.>
3 CHECK BLOWER MOTOR OPERATION. Is blower motor rotated? Go to step 4. <Ref. to AC-18
1) Turn blower switch ON. BLOWER
2) Check blower motor operation. MOTOR IS NOT
ROTATED, Diag-
nostics for A/C
System Failure.>
4 CHECK FRESH/RECIRC MODE. Is FRESH/RECIRC mode Go to step 5. <Ref. to AC-20
Change FRESH/RECIRC mode by pushing changed? FRESH/RECIRC
mode switch. IS NOT
CHANGED, Diag-
nostics for A/C
System Failure.>
5 CHECK COMPARTMENT TEMPERATURE. Is the compartment tem- Go to step 6. <Ref. to AC-22
1) Turn A/C switch ON. perature changed? COMPARTMENT
2) Set temperature at 18°C (65°F) (MAX TEMPERATURE
COOL). IS NOT
3) Check compartment temperature changes. CHANGED OR
A/C SYSTEM
DOES NOT
RESPOND
QUICKLY, Diag-
nostics for A/C
System Failure.>
6 CHECK A/C SYSTEM RESPONSE. Dose A/C system respond A/C system is OK. <Ref. to AC-22
Change the temperature setting, and check quickly? COMPARTMENT
response of A/C system. TEMPERATURE
IS NOT
CHANGED OR
A/C SYSTEM
DOES NOT
RESPOND
QUICKLY, Diag-
nostics for A/C
System Failure.>
AC-2
GENERAL DESCRIPTION
Before performing diagnosis, check the following
items which might affect engine problems.
1) Never connect the battery in reverse polarity.
쐌 The Auto A/C control module will be destroyed 1. BATTERY S001001A1001
instantly.
1) Measure battery voltage and specific gravity of
2) Do not disconnect the battery terminals while
the engine is running. electrolyte.
쐌 A large counter electro motive force will be gen- Standard voltage: 12 V
erated in the alternator, and this voltage may dam-
Specific gravity: Above 1.260
age electronic parts such as A/C control module.
3) Before disconnecting the connectors of each 2) Check the condition of the fuses for A/C, heater
sensor and the A/C control module, be sure to turn and other fuses.
off the ignition switch. 3) Check the condition of the harnesses and har-
쐌 Otherwise, the Auto A/C control module may be ness connectors connection.
damaged.
4) Every Auto A/C-related part is a precision part.
Do not drop them.
5) Airbag system wiring harness is routed near the
A/C control panel (A/C control module) and junc-
tion box.
CAUTION:
쐌 Be careful not to damage Airbag system wir- B4M1361B
ing harness when servicing the A/C control
panel (A/C control module) and junction box. (a) Main fuse box
2. ASPIRATOR HOSE S001001A1002
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 nec-
essary.
3) Push “DEF” switch and then blower fan switch
to turn the blower fan to maximum speed.
B4M1561
AC-3
墌 00.5.31/68j/0ac 墍
GENERAL DESCRIPTION
4) Firmly hold a thin thread (b) in front of the in- 3. REFRIGERANT LINE S001001A1003
vehicle sensor suction port (a) for the auto A/C

Check contact for refrigerant line (A).
control unit and check that the thread moves
towards the port indicating that air is being sucked
into the port.
NOTE:
쐌 Ensure the thread does not get sucked into the
port.
쐌 Hold the thread approximately 5 mm (0.02 in)
away from the port when the suction force is not
very strong.
B4M1548A
4. CONTROL LINKAGE S001001A1004
1) Check state of mode door control rod and link-

age.
2) Check state of air mix door control rod and link-
age.
3) Check state of intake door control rod and link-
B4M2289A age.
5) If the thread does not move at all, remove the

auto A/C control unit <Ref. to AC-30 AUTO A/C,
REMOVAL, Control Unit.> and check for improper
connection of the aspirator hose (a) and auto A/C
control unit and secure as necessary.
B4M1549B
(a) Control rod
B4M2290A
AC-4
墌 00.5.31/68j/0ac 墍
GENERAL DESCRIPTION
5. CONTROL SWITCHES S001001A1006
Start and warm up engine completely.

1) Inspection using switches.
No. Point to check Switch operation Judgement standard
“SET” temperature display go out.
쐌 Air flow → OFF
1 OFF switch OFF switch “ON” 쐌 Outlet → HEAT
쐌 Inlet → FRESH
쐌 Compressor → OFF
a. AUTO switch display illuminates.
b.
쐌 Outlet air → Cool
A. AUTO switch “ON”
쐌 Air flow → HI (AUTO)
B. Temp. control switch 18°C (65°F) (Max. Cold)
쐌 Outlet → VENT
쐌 Inlet → AUTO
쐌 Compressor → AUTO
c. Air and air outlet mode change as follows:
2 AUTO switch 쐌 Outlet air: cool → hot
C. TEMP control switch is gradually set from
쐌 Air flow: AUTO
18°C (65°F) to 32°C (85°F).
쐌 Outlet: VENT → BI-LEVEL → HEAT
쐌 Inlet: AUTO
d. Outlet air → Hot
쐌 Air flow → HI (AUTO)
D. Temp. control switch 32°C (85°F) (Max. Hot) 쐌 Outlet → HEAT
쐌 Inlet → FRESH (AUTO)
쐌 Compressor → AUTO
a. DEF switch display illuminates.
b.
쐌 Outlet air temperature (AUTO control)
A. DEF switch “ON”
3 DEF switch 쐌 Air flow (AUTO control)
B. Temp. control switch 18 — 32°C (65 — 85°F)
쐌 Outlet → DEF
쐌 Inlet → FRESH
쐌 Compressor → ON
FRESH/RECIRC Changes from RECIRC → FRESH, or FRESH
4 FRESH/RECIRC switch “ON”
switch → RECIRC.
Outlet changes from VENT → BI-LEVEL →
5 MODE switch MODE switch “ON” HEAT → DEF/HEAT each time MODE switch is
pushed.
Fan speed changes from LO → M1 → M2 → HI
6 FAN switch FAN switch “ON”
each time FAN switch is pushed.
Ambient temperature flashes on “set” tempera-
7 OUT-TEMP switch OUT-TEMP switch “ON”
ture display, and “set” temperature appears.
2) Compressor operation inspection

No. Point to check Switch operation Judgement standard Remarks
A. AUTO switch “ON” a. Compressor ON
Compressor turns OFF several seconds
1 Compressor B. A/C switch “ON” b. Compressor ON
after AUTO switch is turned ON.
C. DEF switch “ON” c. Compressor ON
3) Illumination control inspection

No. Point to check Switch operation Judgement standard Remarks
Illumination light illuminates and both switch
light and “set” temperature display dim. Green lights remain on
1 Illumination switch Lighting switch “ON” 쐌 Switch lights: although OFF and OUT-
OFF → Green light illuminates. TEMP switches are ON.
ON → Green light illuminates.
AC-5
墌 00.5.31/68j/0ac 墍
B4M1550A
(1) Ambient sensor (5) Evaporator sensor (9) A/C relay

(2) Power transistor (6) Auto A/C control module (10) A/C fuse
(3) In-vehicle sensor (7) Air mix door motor (11) Mode door motor
(4) Sunload sensor (8) Intake door motor
AC-6
墌 00.5.31/68j/0ac 墍
A/C CONTROL MODULE I/O SIGNAL
4. A/C Control Module I/O Signal S001518
B4M1368B
Connector &
Content Signal (V)
Terminal No.
BATT voltage,
BATT voltage (Memory back-up) b1—b12
13 — 14 (engine running)
Battery voltage (ignition switch ON),
IGN power supply a8—b12
13 — 14 (engine running)
ACC power supply
(OFF: ignition in START or diag- b2—b12 BATT voltage, 0 (engine cranking), BATT voltage (during engine starts)
nosis system reset)
A/C control module ground circuit b12—body 0 (ignition switch ON) — circuit constantly grounded
Sensor ground circuit b17—body 0 (ignition switch ON) — continuity exists
Ambient sensor b6—b17
Evaporator sensor b7—b17 Approx. 3.3 (disconnect connector, and ignition switch ON)
Thermometer b15—b12
Sunload sensor b16—b17 Approx. 4.2 (disconnect connector, and ignition switch ON)
BATT voltage (AUTO mode) positive “+” at terminal “a4” and negative “–”
Air mix door motor a4—a3 at “a3” [temperature set at 18°C (65°F)]; negative “–” at terminal “a4” and
positive “+” at “a13” [temperature set at 32°C (85°F)]
Approx. 0.5 [temperature set at 18°C (65°F) in AUTO mode]
Air mix door motor P.B.R. a12—b17
Approx. 4.5 [temperature set at 32°C (85°F) in AUTO mode]
BATT voltage (ignition switch ON in MANUAL mode); positive “+” at termi-
Mode actuator VENT a5—b17 nal “a5” and negative “–” at “b17” (VENT); negative “–” at “a5” and positive
“+” at “b17” (DEF)
BATT voltage (ignition switch ON in MANUAL mode)
Mode actuator DEF a6—b17
Approx. 4.5 (VENT); approx. 0.5 (DEF)
Intake door FRS voltage a7—a15 BATT voltage (CIRC switch OFF)
Intake door CIRC voltage a15—a7 BATT voltage (CIRC switch ON)
Blower fan relay b14—body BATT voltage (ignition switch ON)
0 (ignition and A/C switches ON)
A/C relay b3—b12
BATT voltage (A/C switch OFF)
Illumination control signal b10—b20 BATT voltage (ignition and lighting switches ON)
Rear defogger a13—b12 0 (IGN ON, R Def SW ON)
AC-7
墌 00.5.31/68j/0ac 墍
1. AIR CONDITIONER AUTO A/C S001518A2103
BU46-20A
AC-8
墌 00.5.31/68j/0ac 墍
BU46-20B
AC-9
墌 00.5.31/68j/0ac 墍
BU46-20C
AC-10
墌 00.5.31/68j/0ac 墍
BU46-20D
AC-11
墌 00.5.31/68j/0ac 墍
DIAGNOSTICS CHART FOR DIAGNOSIS SYSTEM
5. Diagnostics Chart for Diagnosis System S001624
A: SELF-DIAGNOSIS MODE S001624F36
B4M2343A
(1) Temperature select dial (3) REC switch (5) MODE switch
(2) AUTO switch (4) DEF switch
AC-12
墌 00.5.31/68j/0ac 墍

1 SELECT CONTROL PANEL TO SELF-DIAG- Can it be moved to the Go to step 2. <Ref. to AC-16
NOSIS MODE. self-diagnosis mode? A/C AND/OR
1) Turn ignition switch to OFF. SELF-DIAGNO-
2) While pushing “AUTO” and “REC” SIS SYSTEMS
switches, start the engine. DO NOT
OPERATE, Diag-
nostics for A/C
System Failure.>
2 CHECK INDICATOR AND BUZZER. Does each character illumi- Go to step 3. Go to step 7.
1) Turn temperature select dial clockwise by nate and buzzer sound?
one click.
2) Make sure that all characters illuminate on
the display, and that the buzzer continuously
sounds.
3 CHECK EACH SENSOR AND EACH Is the code “20” indicated Go to step 4. Repair each
POTENTION METER. on indicator? trouble code.
1) Turn temperature select dial clockwise by
one click.
2) If system has the trouble for each sensor
and/or each potention meter, trouble code is
indicated on indicator.
3) If system has no trouble, code “20” is indi-
cated on indicator.
NOTE:
When the sunload sensor is checked inside
the passenger compartment or in the shade,
code “25” may appear on the indicator.
Always check the sunload sensor in a place
where it senses direct sunlight.
4 CHECK DOOR MOTOR POSITION SWITCH. Is the code “30” indicated Go to step 5. Repair each
1) Turn temperature select dial clockwise by on indicator? trouble code.
one click.
2) If system has the trouble for each door
position switch, trouble code is indicated on
indicator.
3) If system has no trouble, code “30” is indi-
cated on indicator.
5 CHECK OPERATION OF EACH ACTUATOR, Does each mode displayed Go to step 6. Go to step 7.
BLOWER FAN AND COMPRESSOR match the operating mode
CLUTCH. table? <Ref. to AC-14
1) Turn temperature select dial clockwise by OPERATING MODE
one click. TABLE, SELF-DIAGNOSIS
2) Select operating mode by pushing every MODE, Diagnostics Chart
“DEF” switch. for Diagnosis System.>
3) Check the operation for each mode.
쐌 Air inlet:
쐌 Air outlet:
쐌 Air mix door:
쐌 Blower fan:
쐌 A/C compressor:
AC-13
墌 00.5.31/68j/0ac 墍

6 CHECK INDICATED VALUE OF EACH SEN- Is a proper input signal End Go to step 7.
SOR. value displayed in each
1) Turn temperature select dial clockwise by sensor?
one click.
2) Each time the “DEF” switch is pressed, the
value indicated on the display changes to cor-
respond with the ambient sensor, in-vehicle
sensor and intake sensor, in that order.
3) Make sure there is no big difference
between the temperature indicated on the dis-
play and the measured temperature.
NOTE:
If a large temperature difference is noted,
check for ECM standard voltage and sensor
function using the performance characteristic
diagram.
7 CHECK POOR CONTACT. Is there poor contact in A/C Repair poor con- Contact with your
Check poor contact in A/C control module. control module? tact in A/C control Subaru distributor.
module.
1. OPERATING MODE TABLE S001624F3601
Mode display 41 42 43 44 45 46 47 48
Air inlet REC REC REC FRE FRE FRE FRE FRE
Air outlet VENT VENT B/L B/L B/L HEAT D/H DEF
FULL FULL FULL
Air mix door FULL HOT FULL HOT FULL HOT FULL HOT FULL HOT
COOL COOL COOL
Power sup- Power sup-
Blower fan 5V 5V 8.5V 8.5V 8.5V 8.5V
ply voltage ply voltage
A/C compressor ON ON ON OFF OFF OFF ON ON
AC-14
墌 00.5.31/68j/0ac 墍
MEMO:
AC-15
墌 00.5.31/68j/0ac 墍
DIAGNOSTICS FOR A/C SYSTEM FAILURE
6. Diagnostics for A/C System Failure S001625
A: A/C AND/OR SELF-DIAGNOSIS SYSTEMS DO NOT OPERATE S001625F37
TROUBLE SYMPTOM:
쐌 “Set” temperature is not indicated on display, switch LEDs are faulty and switches do not operate.
쐌 Self-diagnosis system does not operate.
WIRING DIAGRAM:
B4M2371
AC-16
墌 00.5.31/68j/0ac 墍

1 CHECK FUSE. Is the fuse blown-out? Replace fuse. Go to step 2.
2) Remove fuse No. 2 from main fuse box.
3) Check condition of fuse.
2) Remove fuses No. 4 and No. 17 from joint
box.
3 CHECK A/C CONTROL MODULE POWER Is the voltage more than 10 Go to step 4. Repair short cir-
CIRCUIT. V? cuit in harness for
1) Pull out A/C control module connector. power supply line.
2) Measure voltage between A/C control mod-
ule connector terminal and chassis ground
when turning ignition switch to OFF.
Measure voltage between A/C control module power supply line.
turning ignition switch to ACC.
Measure voltage between A/C control module power supply line.
turning ignition switch to ON.
6 CHECK A/C CONTROL MODULE GROUND Is the resistance less than Go to step 7. Repair short cir-
CIRCUIT. 5 Ω? cuit in harness for
Measure resistance of harness between A/C ground line.
control module and chassis ground.
(i49) No. 12 — Chassis ground:
module.
AC-17
墌 00.5.31/68j/0ac 墍
B: BLOWER MOTOR IS NOT ROTATED S001625F38
TROUBLE SYMPTOM:
쐌 Blower motor is not rotated.
쐌 Blower motor is not rotated in “HI”.
WIRING DIAGRAM:
B4M2372
AC-18
墌 00.5.31/68j/0ac 墍

1 CHECK FUSE. Are any of the fuses blown- Replace fuse. Go to step 2.
1) Remove No. 2 and No. 17 fuses in joint out?
box.
2) Check condition of fuses.
2 CHECK POWER SUPPLY TO BLOWER FAN Is the voltage more than 10 Go to step 3. Repair open cir-
MOTOR. V? cuit in harness for
1) Turn ignition switch to ON. blower fan motor
2) Turn blower switch to ON. power supply line.
3) Measure voltage between blower fan motor
and chassis ground.
3 CHECK BLOWER FAN MOTOR RELAY. Is the resistance less than Go to step 4. Replace blower
1) Turn ignition switch to OFF. 1 Ω? fan motor relay.
2) Remove blower fan motor relay.
3) Connect battery to No. 1 and No. 3 termi-
nals of blower fan motor connector.
4) Measure resistance between No. 2 and No.
4 terminals.
Terminals:
No. 2 — No. 4
4 CHECK BLOWER FAN MOTOR. Does the blower fan motor Go to step 5. Replace blower
1) Disconnect connector from blower fan operate? fan motor.
motor.
2) Connect battery to connector terminals of
blower fan motor.
3) Make sure that blower fan motor is oper-
ated.
module.
AC-19
墌 00.5.31/68j/0ac 墍
C: FRESH/RECIRC IS NOT CHANGED S001625F39
TROUBLE SYMPTOM:
FRESH/RECIRC mode door is not changed.
WIRING DIAGRAM:
B4M2373
AC-20
墌 00.5.31/68j/0ac 墍

1 CHECK SWITCH OPERATION. Does the mode selection Go to step 7. Go to step 2.
Make sure that the mode selection on display change?
is changed when pushing the “MODE” switch.
1) Remove No. 17 fuse in joint box.
3 CHECK SIGNAL VOLTAGE. Is the voltage less than 1 Go to step 4. Repair short cir-
1) Change display to RECIRC by pushing V? cuit in harness for
MODE switch. power supply line.
ule and chassis ground.
4 CHECK SIGNAL VOLTAGE. Is the voltage less than 1 Go to step 5. Repair short cir-
1) Change display to FRESH with pushing V? cuit in harness for
MODE switch. power supply line.
ule and chassis ground.
5 CHECK HARNESS CONNECTOR Is the resistance less than Go to step 6. Repair open cir-
BETWEEN A/C CONTROL MODULE AND 1 Ω? cuit in harness
FRESH/RECIRC ACTUATOR. between A/C con-
1) Turn ignition switch to OFF. trol module and
2) Disconnect connector from A/C control FRESH/RECIRC
module and mode door motor. actuator.
A/C control module and FRESH/RECIRC
actuator.
(i48) No. 15 — (B91) No. 1
FRESH/RECIRC ACTUATOR. between A/C con-
Measure resistance of harness between A/C trol module and
control module and FRESH/RECIRC actuator. FRESH/RECIRC
Connector & terminal: actuator.
(i48) No. 7 — (B91) No. 2
module.
AC-21
墌 00.5.31/68j/0ac 墍
D: COMPARTMENT TEMPERATURE IS NOT CHANGED OR A/C SYSTEM

DOES NOT RESPOND QUICKLY S001625F40
WIRING DIAGRAM:
B4M2374
AC-22
墌 00.5.31/68j/0ac 墍

2) Remove No. 2 fuse in main fuse box.
2 CHECK POWER SUPPLY TO MAGNET Is the voltage more than 10 Go to step 3. Repair open cir-
CLUTCH OF A/C COMPRESSOR. V? cuit in harness for
1) Start the engine, and turn A/C switch to power supply line
ON. of the A/C com-
2) Set the compartment temperature at 18°C pressor.
(65°F) (MAX COOL).
3) Measure voltage between magnet clutch
3 CHECK SIGNAL VOLTAGE TO A/C RELAY. Is the voltage more than 10 Go to step 4. Repair open cir-
1) Turn ignition switch to ON. V? cuit in harness for
2) Turn A/C switch to ON. power supply line.
3) Measure signal voltage to A/C relay and
chassis ground.
4 CHECK A/C RELAY. Is the operation of each Go to step 5. Replace A/C relay.
1) Remove A/C relay in main fuse box. relay OK?
2) Check A/C relay. <Ref. to AC-39
INSPECTION, Relay and Fuse.>
5 CHECK OPERATION OF MAIN FAN Does the radiator main fan Go to step 10. Go to step 6.
MOTOR. operate?
2) Turn A/C switch to ON.
3) Check operation of main fan motor.
6 CHECK POWER SUPPLY TO MAIN FAN Is the voltage more than 10 Go to step 7. Repair open cir-
CAUTION: power supply cir-
Be careful not to overheat engine during cuit.
repair.
2) Disconnect connector from main fan motor.
3) Start the engine, and warm it up until
engine coolant temperature increases over
95°C (203°F).
4) Stop the engine and turn ignition switch to
ON.
5) Measure voltage between main fan motor
(F17) No. 1, 2 (+) — Chassis ground
(−):
7 CHECK GROUND CIRCUIT OF MAIN FAN Is the resistance less than Go to step 8. Repair open cir-
MOTOR. 1 Ω? cuit in harness
1) Turn ignition switch to OFF. between main fan
2) Measure resistance between main fan motor connector
motor connector and chassis ground. and chassis
Check poor contact in main fan motor con- main fan motor connector? tact in main fan
nector. motor connector.
AC-23
墌 00.5.31/68j/0ac 墍

9 CHECK MAIN FAN MOTOR. Does the main fan rotate? Repair poor con- Replace main fan
Connect battery positive (+) terminal to termi- tact in main fan motor with a new
nal No. 1, 2, and negative (−) terminal to ter- motor connector. one.
minal No. 4 of main fan motor connector.
10 CHECK OPERATION OF SUB FAN MOTOR. Does the radiator sub fan Go to step 15. Go to step 11.
Check operation of sub fan motor. operate?
11 CHECK POWER SUPPLY TO SUB FAN Is the voltage more than 10 Go to step 12. Repair open cir-
CAUTION: power supply cir-
Be careful not to overheat engine during cuit.
repair.
2) Disconnect connector from sub fan motor.
3) Start the engine, and warm it up until
engine coolant temperature increases over
100°C (212°F).
4) Stop the engine and turn ignition switch to
ON.
5) Measure voltage between sub fan motor
(F16) No. 1, 2 (+) — Chassis ground
(−):
12 CHECK GROUND CIRCUIT OF SUB FAN Is the resistance less than Go to step 13. Repair open cir-
MOTOR. 1 Ω? cuit in harness
1) Turn ignition switch to OFF. between sub fan
2) Measure resistance between sub fan motor motor connector
connector and chassis ground. and chassis
13 CHECK POOR CONTACT. Is there poor contact in sub Repair poor con- Go to step 14.
Check poor contact in sub fan motor connec- fan motor connector? tact in sub fan
tor. motor connector.
14 CHECK SUB FAN MOTOR. Does the sub fan rotate? Repair poor con- Replace sub fan
Connect battery positive (+) terminal to termi- tact in sub fan motor with a new
nal No. 1, 2, and negative (−) terminal to ter- motor connector. one.
minal No. 4 of sub fan motor connector.
15 CHECK EACH SENSOR AND POTENTION Is the operation of each Go to step 16. Replace sensor
METER. sensor and potention meter and/or potention
Check the sensors and potention meter for normal? meter.
proper operation using the self-diagnostic
function. <Ref. to AC-12 Diagnostics Chart for
Diagnosis System.>
16 CHECK CONNECTION OF ASPIRATOR Is the connection of aspira- Repair aspirator Go to step 17.
DUCT. tor duct correct? duct connection.
Make sure that the connection of aspirator
duct is correct.
17 CHECK EACH ACTUATOR. Is the operation of each Go to step 18. Replace actuator.
Check the actuators for proper operation actuator normal?
using the self-diagnostic function. <Ref. to
AC-12 Diagnostics Chart for Diagnosis Sys-
tem.>
module.
AC-24
墌 00.5.31/68j/0ac 墍
LIST OF DIAGNOSTIC TROUBLE CODE
7. List of Diagnostic Trouble Code S001511
A: LIST S001511A12
1. TROUBLE CODE FOR SENSOR AND POTENTION METER S001511A1201
Trouble Code Trouble Unit Contents

20 No Trouble —
21 Open
Ambient sensor
–21 Short
22 Open
In-vehicle sensor
–22 Short
24 Open
Evaporation sensor
–24 Short
25 Open
Sunload sensor
–25 Short
26 Open
Air mix door motor
–26 Short
2. TROUBLE CODE FOR MODE DOOR POSITION SWITCH S001511A1202
Trouble Code 30 31 32 33 34 35
Faulty Door No Trouble VENT B/L HEAT D/H DEF
AC-25
DIAGNOSTIC PROCEDURE WITH TROUBLE CODE
8. Diagnostic Procedure with Trouble Code S001509
A: TROUBLE CODE 21 OR –21 (AMBIENT SENSOR) S001509F41
TROUBLE SYMPTOM:
Fan speed, outlets and inlets are not switched when AUTO or ECON switch is ON.
WIRING DIAGRAM:
B4M2375
AC-26
墌 00.5.31/68j/0ac 墍

1 CHECK AMBIENT SENSOR. Is the resistance approx. Go to step 2. Replace ambient
1) Turn ignition switch to OFF. 2.2 kΩ at 25°C (77°F)? sensor.
2) Disconnect connector from ambient sensor.
terminals of ambient sensor.
Terminals:
No. 1 — No. 2
2 CHECK INPUT SIGNALS FOR AMBIENT Is the voltage approx. 4.5 Go to step 6. Go to step 3.
SENSOR. V?
1) Turn ignition ON.
2) Measure voltage between (F78) connector
terminals.
(F78) No. 1 — No. 2
3 CHECK OUTPUT SIGNALS FROM A/C Is the voltage approx. 4.5 Go to step 6. Go to step 4.
CONTROL MODULE. V?
2) Pull out A/C control panel.
3) Disconnect connector from ambient sensor.
5) Measure voltage between connector termi-
nals of A/C control module.
(i49) No. 6 — No. 17
AMBIENT SENSOR. between A/C con-
2) Disconnect connectors from A/C control ambient sensor.
module.
A/C control module and ambient sensor.
(F78) No. 1 — (i49) No. 6
AMBIENT SENSOR. between A/C con-
control module and ambient sensor. ambient sensor.
(F78) No. 2 — (i49) No. 17
module.
AC-27
墌 00.5.31/68j/0ac 墍
B: TROUBLE CODE 22 OR –22 (IN-VEHICLE SENSOR) S001509F42
TROUBLE SYMPTOM:
When turning AUTO switch to ON, blower fan speed, outlet port and inlet port is not changed.
If trouble code 22 or −22 appears on the display, 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-28
墌 00.5.31/68j/0ac 墍
MEMO:
AC-29
墌 00.5.31/68j/0ac 墍
C: TROUBLE CODE 24 OR –24 (EVAPORATOR SENSOR) S001509F43
WIRING DIAGRAM:
B4M2376
AC-30
墌 00.5.31/68j/0ac 墍

1 CHECK EVAPORATOR SENSOR. Is the resistance approx. Go to step 2. Replace evapora-
1) Turn ignition switch to OFF. 1.8 — 2.0 kΩ at 20°C tor sensor.
2) Remove glove box. (68°F)?
3) Disconnect connector from evaporator sen-
sor.
terminals of evaporator sensor.
Terminals:
No. 1 — No. 3
2 CHECK INPUT SIGNALS FOR EVAPORA- Is the voltage approx. 4.5 Go to step 3. Replace evapora-
TOR SENSOR. V? tor sensor.
1) Turn ignition switch to “ON”.
2) Measure voltage between (B88) connector
3 CHECK OUTPUT SIGNALS FROM A/C Is the voltage approx. 4.5 Go to step 4. Go to step 6.
CONTROL MODULE. V?
2) Pull out A/C control module.
3) Turn ignition switch to “ON”.
ule connector terminals.
(i49) No. 7 — No. 17
EVAPORATOR SENSOR. between A/C con-
2) Disconnect connectors from A/C control evaporator sen-
module. sor.
A/C control module and evaporator sensor.
(B88) No. 1 — (i49) No. 7
EVAPORATOR SENSOR. between A/C con-
control module and evaporator sensor. evaporator sen-
Connector & terminal: sor.
(B88) No. 3 — (i49) No. 17
module.
AC-31
墌 00.5.31/68j/0ac 墍
D: TROUBLE CODE 25 OR –25 (SUNLOAD SENSOR) S001509F44
TROUBLE SYMPTOM:
쐌 Sensor identified that sunlight is at maximum. Then, A/C system is controlled to COOL side.
쐌 Sensor identified that sunlight is at minimum. Then, A/C system is controlled to HOT side.
NOTE:
When the sunload sensor is checked inside the passenger compartment or in the shade, code “25” may
appear on the indicator. Always check the sunload sensor in a place where it senses direct sunlight.
AC-32
墌 00.5.31/68j/0ac 墍
WIRING DIAGRAM:
B4M2377
AC-33
墌 00.5.31/68j/0ac 墍

1 CHECK SUNLOAD SENSOR. Is the resistance less than Go to step 2. Replace sunload
1) Turn ignition switch to OFF. 1 Ω? sensor.
2) Remove sunload sensor. <Ref. to AC-43
REMOVAL, Sun-load Sensor (Auto A/C).>
3) Measure resistance between sunload sen-
sor terminals.
Terminals:
No. 2 — No. 1
2 CHECK SUNLOAD SENSOR. Is the resistance more than Go to step 3. Replace sunload
Make sure that there is no resistance in the 1 MΩ? sensor.
reverse side terminals.
Terminals:
No. 1 — No. 2
3 CHECK INPUT VOLTAGE TO SUNLOAD Is the voltage approx. 4.5 Go to step 6. Go to step 4.
SENSOR. V?
2) Measure input voltage to sunload sensor.
(i51) No. 2 — No. 1
SUNLOAD SENSOR. between A/C con-
2) Disconnect connectors from A/C control sunload sensor.
module.
A/C control module and sunload sensor.
(i51) No. 2 — (i49) No. 16
SUNLOAD SENSOR. between A/C con-
control module and sunload sensor. sunload sensor.
(i51) No. 1 — (i49) No. 17
module.
AC-34
墌 00.5.31/68j/0ac 墍
SYMPTOM RELATED DIAGNOSTIC
9. Symptom Related Diagnostic S001519
A: GENERAL DIAGNOSTICS TABLE S001519F45
B4M1644A
AC-35
墌 00.5.31/68j/0ac 墍
SYMPTOM RELATED DIAGNOSTIC
MEMO:
AC-36
墌 00.5.31/68j/0ac 墍
GENERAL DESCRIPTION
HVAC System (Heater, Ventilator and A/C)
1. HEATER SYSTEM S701001E4901
Item Specifications Condition

쐌 Mode selector switch: HEAT
쐌 Temperature control switch: FULL HOT
5.0 kW (4,300 kcal/h, 17,062 BTU/h) 쐌 Temperature difference between hot
Heating capacity
or more water and inlet air: 65°C (149°F)
쐌 Hot water flow rate: 360 (95.1 US gal,
79.2 Imp gal)/h
Air flow rate 300 m3 (10,593 cu ft)/h Heat mode (FRESH), FULL HOT at 12.5 V
쐌 Temperature control switch: FULL COLD
Max air flow rate 500 m3 (17,655 cu ft)/h 쐌 Blower fan speed: 4th position
쐌 Mode selector lever: RECIRC
Heater core size 193.5 × 152 × 35.0 mm
—
(height × length × width) (7.62 × 5.98 × 1.378 in)
Type Magnet motor 220 W or less at 12 V
Blower motor Fan type and size Sirocco fan type
—
(diameter × width) 150 × 75 mm (5.91 × 2.95 in)
AC-2
墌 00.5.31/68j/7ac 墍
GENERAL DESCRIPTION
2. A/C SYSTEM (4 CYLINDER) S701001E4903
Item Specifications
Type of air conditioner Reheat air-mix type
5.2 kW
Cooling capacity
(4,471 kcal/h, 17,741 BTU/h)
HFC-134a (CH2FCF3)
Refrigerant
[0.65±0.05 kg (1.43±0.11 lb)]
Type 5-vane rotary, fix volume (DKV-14G)
Compressor Discharge 140 cm3 (8.54 cu in)/rev
Max. permissible speed 7,000 rpm
Type Dry, single-disc type
Power consumption 45 W
Magnet clutch Type of belt V-Ribbed 4 PK
Pulley dia. (effective dia.) 125 mm (4.92 in)
Pulley ratio 1.064
Type Corrugated fin (Multi-flow)
Core face area 0.21 m2 (2.26 sq ft)
Condenser
Core thickness 24 mm (0.94 in)
Radiation area 6.52 m2 (70 sq ft)
Receiver drier Effective inner capacity 250 cm3 (15.26 cu in)
Expansion valve Type Internal equalizing
Type Single tank
Evaporator 235 × 224 × 60 mm
Dimensions (W × H × T)
(9.25 × 8.82 × 2.36 in)
Fan type Sirocco fan
Blower fan Outer diameter × width 150 × 75 mm (5.91 × 2.95 in)
Power consumption 220 W at 12 V
Motor type Magnet
Condenser fan (Sub fan) Power consumption 75 W at 12 V
Fan outer diameter 300 mm (11.81 in)
Motor type Magnet
Radiator fan (Main fan) Power consumption 75 W at 12 V
Idling speed (A/C ON) MPFI model 850±100 rpm
177±25 kPa
ON → OFF
Low-pressure switch oper- (1.80±0.25 kg/cm2, 25.6±3.6 psi)
ating pressure 216+39/−25 kPa
OFF → ON
Dual switch (2.2+0.4/−0.25 kg/cm2, 31+5.7/−3.6 psi)
(Pressure switch) 2,942±196 kPa
ON → OFF
High-pressure switch (30±2 kg/cm2, 427±28 psi)
operating pressure 588±196 kPa
DIFF
(6±2 kg/cm2, 85±28 psi)
Thermo control amplifier working temperature

(Evaporator outlet air)
B4M2237A
AC-3
墌 00.5.31/68j/7ac 墍
GENERAL DESCRIPTION
3. A/C SYSTEM (6 CYLINDER) S701001E4904
Item Specifications
Type of air conditioner Reheat air-mix type
5.2 kW
Cooling capacity
(4,471 kcal/h, 17,741 BTU/h)
HFC-134a (CH2FCF3)
Refrigerant
[0.65±0.05 kg (1.43±0.11 lb)]
Type 5-vane rotary, fix volume (DKV-14G)
Compressor Discharge 140 cm3 (8.54 cu in)/rev
Max. permissible speed 7,000 rpm
Type Dry, single-disc type
Power consumption 38 W
Magnet clutch Type of belt V-Ribbed 6 PK
Pulley dia. (effective dia.) 125 mm (4.92 in)
Pulley ratio 1.064
Type Corrugated fin (Multi-flow)
Core face area 0.22 m2 (2.37 sq ft)
Condenser
Core thickness 24 mm (0.94 in)
Radiation area 6.52 m2 (70 sq ft)
Receiver drier Effective inner capacity 250 cm3 (15.26 cu in)
Expansion valve Type Internal equalizing
Type Single tank
Evaporator 235 × 224 × 60 mm
Dimensions (W × H × T)
(9.25 × 8.82 × 2.36 in)
Fan type Sirocco fan
Blower fan Outer diameter × width 150 × 75 mm (5.91 × 2.95 in)
Power consumption 220 W at 12 V
Motor type Magnet
Condenser fan (Sub fan) Power consumption 120 W at 12 V
Motor type Magnet
Radiator fan (Main fan) Power consumption 120 W at 12 V
Idling speed (A/C ON) MPFI model 850±100 rpm
177±25 kPa
ON → OFF
Low-pressure switch oper- (1.80±0.25 kg/cm2, 25.6±3.6 psi)
ating pressure 216+39/−25 kPa
OFF → ON
Dual switch (2.2+0.4/−0.25 kg/cm2, 31+5.7/−3.6 psi)
(Pressure switch) 2,942±196 kPa
ON → OFF
High-pressure switch (30±2 kg/cm2, 427±28 psi)
operating pressure 588±196 kPa
DIFF
(6±2 kg/cm2, 85±28 psi)
Thermo control amplifier working temperature

(Evaporator outlet air)
B4M2237A
AC-4
墌 00.5.31/68j/7ac 墍
GENERAL DESCRIPTION
1. HEATER UNIT S701001A0501
B4M2211A
(1) Vent door actuator (7) Case B (13) Heater core

(2) Side link (8) Foot duct (14) Foot door lever
(3) Vent door lever (9) Foot door
(4) Case A (10) Case D Tightening torque: N·m (kgf-m, ft-lb)
(5) DEF door (11) Mix door T: 7.35 (0.750, 5.421)
(6) Vent door (12) Case C
AC-5
墌 00.5.31/68j/7ac 墍
GENERAL DESCRIPTION
2. INTAKE UNIT S701001A0502
B4M1699A
(1) Intake door actuator (8) Lever (B) (15) Intake unit case lower
(2) Lever (A) (9) Lever (C) (16) Aspirator pipe
(3) Door (A) (10) Blower plate (17) Blower motor
(4) Intake unit case upper (11) Resistor (18) Fan
(5) Thermistor (With A/C model) (12) Evaporator (With A/C model)
(6) Block expansion valve (With A/C (13) Evaporator case (With A/C Tightening torque: N·m (kgf-m, ft-lb)
model) model) T: 7.4 (0.75, 5.4)
(7) Door (B) (14) Drain hose
AC-6
墌 00.5.31/68j/7ac 墍
GENERAL DESCRIPTION
3. CONTROL UNIT (MANUAL A/C) S701001A0507
B4M2454A
(1) Switch (4) Base unit (7) Fan switch ASSY

(2) Control dial knob (5) Cover (8) Circuit ASSY
(3) Control panel ASSY (6) Temperature control cable (9) Bulb
AC-7
墌 00.5.31/68j/7ac 墍
GENERAL DESCRIPTION
4. CONTROL UNIT (AUTO A/C) S701001A0508
B4M2408A
(1) Control panel (3) Electronic control unit (5) Incar sensor
(2) Circuit ASSY (4) Control case (6) Aspirator hose
AC-8
墌 00.5.31/68j/7ac 墍
GENERAL DESCRIPTION
5. AIR CONDITIONING UNIT S701001A0504
B4M1807A
(1) Condenser (5) Hose (Low-pressure) Tightening torque: N·m (kgf-m, ft-lb)
(2) Pipe (Condenser — Receiver (6) Compressor
T1: 7.4 (0.75, 5.4)
drier) (7) Hose (High-pressure)
T2: 15 (1.5, 10.8)
(3) Receiver drier
(4) Pipe (Receiver drier — C/unit)
AC-9
墌 00.5.31/68j/7ac 墍
GENERAL DESCRIPTION
6. INTAKE UNIT WITH EVAPORATOR

S701001A0505
B4M1699A
(1) Intake door actuator (8) Lever (B) (15) Intake unit case lower
(2) Lever (A) (9) Lever (C) (16) Aspirator pipe
(3) Door (A) (10) Blower plate (17) Blower motor
(4) Intake unit case upper (11) Resistor (18) Fan
(5) Thermistor (With A/C model) (12) Evaporator (With A/C model)
(6) Block expansion valve (With A/C (13) Evaporator case (With A/C Tightening torque: N·m (kgf-m, ft-lb)
model) model) T: 7.35 (0.750, 5.421)
(7) Door (B) (14) Drain hose
AC-10
墌 00.5.31/68j/7ac 墍
GENERAL DESCRIPTION
7. COMPRESSOR S701001A0506
B4M1809A
(1) Idler pulley bracket (7) V-belt Tightening torque: N·m (kgf-m, ft-lb)
(2) Idler pulley adjuster (8) Compressor belt cover
T1: 7.4 (0.75, 5.4)
(3) Idler pulley
T2: 23 (2.3, 17)
(4) Compressor bracket upper
T3: 23.0 (2.35, 17.0)
(5) Compressor
(6) Compressor bracket lower T4: 28.9 (2.95, 21.3)
T5: 35 (3.6, 26)
AC-11
墌 00.5.31/68j/7ac 墍
GENERAL DESCRIPTION
C: CAUTION S701001A03 4. HANDLING OF REFRIGERANT S701001A0304
1. HFC-134a A/C SYSTEM S701001A0301

쐌 The refrigerant boils at approx. −30°C (−22°F).
When handling it, be sure to wear safety goggles
쐌 Unlike the old conventional HFC-12 system and protective gloves. Direct contact of the refrig-
components, the cooling system components for erant with skin may cause frostbite.
the HFC-134a system such as the refrigerant and If the refrigerant gets into your eye, avoid rubbing
compressor oil are incompatible. your eyes with your hands. Wash your eye with
쐌 Vehicles with the HFC-134a system can be plenty of water, and receive medical treatment
identified by the label “A” attached to the vehicle. from an eye doctor.
Before maintenance, check which A/C system is 쐌 Do not heat a service can. If a service can is
installed in the vehicle. 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 40°C (104°F) max.
쐌 Do not drop or impact a service can. (Observe
the precautions and operation procedure
described on the refrigerant can.)
쐌 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.
B4M1817A 쐌 The refrigerant is non-toxic and harmless under
normal operating circumstance, but it may change
2. COMPRESSOR OIL S701001A0302
to phosgene (a noxious fume) under open flames
or high temperatures (caused by a cigarette or
쐌 HFC-134a compressor oil has no compatibility heater).
with that for R12 system. 쐌 Provide good ventilation and do not work in a
쐌 Use only the manufacturer-authorized compres- closed area.
sor oil for the HFC-134a system; only use 쐌 Never perform a gas leak test using a halide
ZXL200PG. torch-type leak tester.
쐌 Do not mix multiple compressor oils. 쐌 In order to avoid destroying the ozone layer, pre-
If HFC-12 compressor oil is used in a HFC-134a vent HFC-134a from being released into the atmo-
A/C system, the compressor may become stuck sphere. Using a refrigerant recovery system, dis-
due to poor lubrication, or the refrigerant may leak charge and reuse it.
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.
쐌 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.
3. REFRIGERANT S701001A0303
쐌 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.
쐌 If an incorrect or no refrigerant is used, poor
lubrication will result and the compressor itself may
be damaged.
G4M0979
AC-12
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GENERAL DESCRIPTION
5. O-RING CONNECTIONS S701001A0305 쐌 Use the oil specified in the service manual to
lubricate the O-rings.
쐌 Use new O-rings. Apply the oil to the top and sides of the O-rings
쐌 In order to keep the O-rings free of lint which will before installation.
cause a refrigerant gas leak, perform operations Apply the oil to the area including the O-rings and
without gloves and shop towels. tube beads.
쐌 Apply the compressor oil to the O-rings to avoid
sticking, then install them.
쐌 Use a torque wrench to tighten the O-ring fit-
tings: Over-tightening will damage the O-ring and
tube end distortion.
쐌 If the operation is interrupted before completing
a pipe connection, recap the tubes, components,
and fittings with a plug or tape to prevent contami-
nation from entering.
G4M0581
쐌 Visually check the surfaces and mating surfaces

G4M0583
of O-rings, threads, and connecting points. If a fail-
ure is found, replace the applicable parts. 쐌 When connecting hoses or pipes, use 2
쐌 Install the O-rings at right angle to the tube wrenches (a torque wrench for tightening). While
beards. securing one side with a wrench, tighten the other
side to the specified torque with a torque wrench.
If only one wrench is used to tighten, the tighten-
ing torque will be excessive or insufficient. This
may cause a pipe distortion or gas leak, resulting
in damage to hoses and pipes.
쐌 After tightening, using a clean shop towel to
remove excess oil from the connections and any oil
which may have run on the vehicle body or other
parts.
쐌 If any leakage is suspected after tightening, do
G4M0582
not retighten the connections, Disconnect the
connections, remove the O-rings, and check the
O-rings, threads, and connections.
G4M0584
AC-13
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GENERAL DESCRIPTION
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 com-
pressor 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.
HFC-134a CFC-12
Tool & screw type Millimeter size Inch size
Valve type Quick joint type Screw-in type
Tools and Equipment Description

Wrench
Various WRENCHES will be required to service any A/C system. A 7

to 40 N·m (0.7 to 4.1 kg-m, 5 to 30 ft-lb) torque wrench with various
crowfoot wrenches will be needed. Open end or flare nut wrenches
will be needed for back-up on the tube and hose fittings.
G4M0571
Applicator bottle
A small APPLICATOR BOTTLE is recommended to apply refrigerant

oil to the various parts. They can be obtained at a hardware or drug
store.
G4M0572
Manifold gauge set
A MANIFOLD GAUGE SET (with hoses) can be obtained from

either a commercial refrigeration supply house or from an auto shop
equipment supplier.
G4M0573
AC-14
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GENERAL DESCRIPTION

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
Syringe
A graduated plastic SYRINGE will be needed to add oil back into the
system. The syringe can be found at a pharmacy or drug store.
G4M0575
Vacuum pump
A VACUUM PUMP (in good working condition) is necessary, and

may be obtained from either a commercial refrigeration supply house
or an automotive equipment supplier.
G4M0576
Can tap
A CAN TAP for the 397 g (14 oz) can is available from an auto sup-
ply store.
G4M0577
AC-15
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GENERAL DESCRIPTION

Thermometer
Pocket THERMOMETERS are available from either industrial hard-

ware store or commercial refrigeration supply houses.
G4M0578
Electronic leak detector
An ELECTRONIC LEAK DETECTOR can be obtained from either a

specialty tool supply or an A/C equipment supplier.
G4M0579
Weight scale
A WEIGHT SCALE such as an electronic charging scale or a bath-

room scale with digital display will be needed if a 13.6 kg (30 lb)
refrigerant container is used.
G4M0580
AC-16
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REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET
2. Refrigerant Pressure with Manifold Gauge Set S701631
1) Place the vehicle in the shade and draftless condition.

2) Connect the manifold gauge set.
3) Open the front windows and close all doors.
4) Open the hood.
5) Increase engine rpm to 1,500.
6) Turn ON the A/C switch.
7) Turn the temperature control switch to MAX COOL.
8) Put in RECIRC position.
9) Turn the blower control switch to HI.
10) Read the gauge.
Standard:
Low pressure: 127 - 196 kPa (1.3 - 2.0 kg/cm2, 18 - 28 psi)
High pressure: 1,471 - 1,667 kPa (15 - 17 kg/cm2, 213 - 242 psi)
Ambient temperature: 30 - 35°C (86 - 95°F)
Symptom Probable cause Repair order

쐌 Defective condenser fan motor 쐌 Replace the fan motor.
쐌 Clogged condenser fan 쐌 Clean the condenser fin.
High-pressure side is unusually high. 쐌 Too much refrigerant 쐌 Discharge refrigerant.
쐌 Air inside the system 쐌 Replace the receiver drier.
쐌 Defective receiver drier
쐌 Defective compressor 쐌 Replace the compressor.
쐌 Not enough refrigerant 쐌 Check for leaks.
High-pressure side is unusually low. 쐌 Clogged expansion valve 쐌 Replace the expansion valve.
쐌 Expansion valve frozen temporarily by
moisture
쐌 Defective compressor 쐌 Replace the compressor.
Low-pressure side is unusually high. 쐌 Defective expansion valve 쐌 Replace the expansion valve.
쐌 Too much refrigerant 쐌 Discharge refigerant.
쐌 Not enough refrigerant 쐌 Check for leaks.
쐌 Clogged expansion valve 쐌 Replace the expansion valve
Low-pressure side is unusually low. 쐌 Expansion valve frozen temporarily by 쐌 Replace the receiver drier.
moisture
쐌 Saturated receiver drier
AC-17
REFRIGERANT RECOVERY PROCEDURE
3. Refrigerant Recovery 6) Follow the operation manual to activate the

refrigerant recovery system.
Procedure S701291
CAUTION:
쐌 During operation, be sure to wear safety
goggles and protective gloves.
쐌 Connect the refrigerant recovery system
with the manifold gauge set to discharge the
refrigerant from the A/C system and reuse it.
쐌 When reusing the discharged refrigerant,
keep service cans on hand. Because the dis-
charge rate with the recovery system is approx.
90%, service cans are necessary to charge the
refrigerant.
쐌 Follow the detailed operation procedure
described in the operation manual attached to
the refrigerant recovery system.
1) Turn the A/C switch ON.
Leave the engine running for approx. 5 minutes to
activate the compressor. Perform the refrigerating
cycle with the refrigerant to discharge the com-
pressor oil remaining on the functional parts into
the compressor as much as possible.
2) Stop the engine.
3) Close the valves on the low-/high-pressure
sides of the manifold gauge set.
G4M0585
4) Install the low-/high-pressure hoses to the ser-

vice ports on the low-/high-pressure sides of the
vehicle respectively.
G4M0586
5) Connect the center hose to the refrigerant

recovery system.
AC-18
REFRIGERANT CHARGING PROCEDURE
4. Refrigerant Charging 4) Carefully open the valves on the low-/high-

pressure sides to activate the vacuum pump.
Procedure S701292
CAUTION:
쐌 During operation, be sure to wear safety
goggles and protective gloves.
쐌 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 G4M0597
level. The minimum vacuum level affects the
temperature in the system. 5) After the low-pressure gauge reaches 100.0
쐌 The list below shows the vacuum values kPa (750 mmHg, 29.5 inHg) or higher, evacuate
necessary to boil water in various temperature. the system for approx. 15 minutes.
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
1.7°C (35°F) 100.9 kPa (757 mmHg, 29.8 inHg)
7.2°C (45°F) 100.5 kPa (754 mmHg, 29.7 inHg)
12.8°C (55°F) 99.8 kPa (749 mmHg, 29.5 inHg)
G4M0598
18.3°C (65°F) 99.2 kPa (744 mmHg, 29.3 inHg)
23.9°C (75°F) 98.5 kPa (739 mmHg, 29.1 inHg) 6) After 15 minutes of evacuation, if the reading
29.4°C (85°F) 97.2 kPa (729 mmHg, 28.7 inHg) shows 100.0 kPa (750 mmHg, 29.5 inHg) or
35°C (95°F) 95.8 kPa (719 mmHg, 28.3 inHg) higher, close the valves on the both sides to stop
the vacuum pump.
1) Close the valves on low-/high-pressure sides of
the manifold gauge.
G4M0599
G4M0596 7) Note the low-pressure gauge reading.
2) Install the low-/high-pressure hoses to the cor-

responding service ports on the vehicle respec-
tively.
3) Connect the center hose of the manifold gauge
set with the vacuum pump.
G4M0600
AC-19
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8) Leave it at least 5 minutes, and then check the 15) Carefully open the high-pressure valve with
low-pressure gauge reading for any changes. the engine OFF.
When a gauge indicator shows near to zero point, CAUTION:
this is a sign of leakage. Check pipe connector
Do not open the low-pressure valve.
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.
G4M0604
CAUTION:
G4M0980 Never run the engine during charging from the
high-pressure side.
10) Disconnect the center manifold hose from the
vacuum pump, and connect the hose to the tap 16) Close the high-pressure valve when the low-
valve. pressure gauge reaches 98 kPa (1 kg/cm2, 14 psi).
11) When a 13.6 kg (30 lb) refrigerant container is Using a leak tester, check the system for leaks.
used, measure the refrigerant amount in use using If any leakage is found after the refrigerant recov-
a weighting scale. ery is completed, repair the applicable area.
17) After confirming that there are no leaks with
the leak test, charge the required amount of refrig-
erant.
CAUTION:
Never run the engine during charging from the
high-pressure side.
18) Close the high-pressure valve when;
쐌 the readings of low- and high-pressure gauges
become almost equal, after the charging speed is
G4M0981
reduced,
쐌 the HFC-134a source becomes empty, or
12) Confirm that all the 3 hoses are tightly con- 쐌 the system is filled with the gas.
nected 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-20
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19) If the HFC-134a source is empty, close the Refrigerant amount

high-pressure valve, close the valve on the can Refrigerant Minimum Maximum
tap, and replace the HFC-134a source with a new LHD 0.6 kg (1.3 lb) 0.7 kg (1.5 lb)
one to restart the operation. HFC-134a
RHD 0.4 kg (0.9 lb) 0.5 kg (1.1 lb)
27) Disconnect the hose from the service port,

and install the service port cap.
G4M0606
20) Confirm that both the low- and high-pressure

valves can be closed. Start the engine with the A/C
switch OFF.
21) Quickly repeat ON-OFF cycles a few times to
prevent initial compressor damage.
22) Set up the vehicle to the following status:
쐌 A/C switch ON
쐌 Engine running at 1,500 rpm
쐌 Blower speed setting to “HI”
쐌 Temperature setting to “MAX COOL”
쐌 Air inlet setting to “RECIRC”
쐌 Windows open
23) While reading the low-pressure gauge, care-
fully open the low-pressure valve with the refriger-
ant source connected and the service hose
purged.
CAUTION:
Never open the high-pressure valve with the
engine running.
G4M0608
24) Adjust the refrigerant flow to maintain the

pressure on the low-pressure side at 276 kPa (2.81
kg/cm2, 40 psi) max.
25) After the system is fully charged, close the
low-pressure valve.
26) Close the valve on the refrigerant source.
AC-21
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REFRIGERANT LEAK CHECK
5. Refrigerant Leak Check S701293

5) Check the joint between the compressor and
hoses.
A: INSPECTION S701293A10 6) Check the machined area of compressor and
1) Operate the A/C system for approx. 10 minutes, other joints on the compressor.
and confirm that the high-side pressure shows at 7) Check the thermal limiter (if equipped) on the
least 690 kPa (7.03 kg/cm2, 100 psi). Then stop compressor housing.
the engine to start the leak test. 8) Check the compressor shaft seal at the area
2) Starting from the connection between the high- near the center of compressor clutch pulley.
pressure tube and evaporator, check the system Some shaft seals show a slight amount of leakage
for leaks along the high-pressure side through the about 28 g (1.0 oz) per year. This is not a problem.
compressor. The following items must be checked 9) Starting from the connection between the low-
thoroughly. pressure tube and evaporator, check the system
쐌 Connection between the tube and tube fitting for leakage along the high-pressure side through
the compressor. The following items must be
checked thoroughly.
쐌 Connection between the tube and tube fitting
쐌 Connection between 2 parts
쐌 Connection between the tube and nut
G4M0612
쐌 Connection between 2 parts
S4M0038
10) Visually check the rubber area of the flexible

hose for cracks.
Check the entire length of the flexible hose, espe-
cially the connection with the metal hose end.
CAUTION:
Carefully check the external surface of hoses
G4M0613 and tubes at approx. 25 mm (0.98 in) per sec-
ond.
쐌 Connection between the tube and nut
G4M0617
G4M0614
3) Check the joint and seam between the pressure 11) Disconnect the drain hose from the evaporator
switch (dual switch) and receiver dryer. case, and check the hose end for at least 10 sec-
4) Check the connections between the condenser onds.
and tubes, and welded joints on the condenser. After the test is finished, reconnect the drain hose.
The leak tester may detect the oil on the condenser
fins as a leak.
AC-22
墌 00.5.31/68j/7ac 墍
REFRIGERANT LEAK CHECK
12) Turn the ignition key to ON position, and run

the blower at high speed for 1 minute. Stop the
blower to check the ventilation grill on the instru-
ment panel. While moving the tester closer to the
grill, run the blower for 1 or 2 seconds, then stop
it. Check the grill at that point for at least 10 sec-
onds.
G4M0618
13) Check the valve in the service port.

14) Visually check the rubber seal in the service
port cap.
G4M0619
AC-23
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COMPRESSOR OIL
6. Compressor Oil S701294 B: REPLACEMENT S701294A20
NOTE:
쐌 If a component is replaced, add an appropriate
NOTE: amount of compressor oil.
Before making repairs, conduct the oil return 쐌 When replacing the compressor, the new com-
operation to return the compressor oil in circulation pressor will already have the specified amount of
with the refrigerant to the compressor. oil in it. Install the new compressor after removing
1) Increase engine rpm to 1,500. the same amount of oil that is remaining in the
2) Turn ON the A/C switch. compressor removed.
3) Turn the temperature control switch to MAX
Replacement parts Amount of oil replenishment
COOL.
Evaporator 114 m (3.9 US fl oz, 4.0 Imp fl oz)
4) Put in RECIRC position.
5) Turn the blower control switch to HI. Receiver drier 5 m (0.2 US fl oz, 0.2 Imp fl oz)
6) Leave in this condition for 10 minutes. Condenser 2 m (0.07 US fl oz, 0.07 Imp fl oz)
Hose 1 m (0.03 US fl oz, 0.04 Imp fl oz)
AC-24
HEATER UNIT
7. Heater Unit S701290

7) Disconnect connector of airbag main harness
near steering support beam.

2) Pull out LLC.
4) Release heater hose clamps in engine com-
partment to remove the hoses.
B4M2299
5) Remove A/C unit. <Ref. to INTAKE UNIT.>

6) Using a Torx wrench, remove airbag control
unit.
B5M0684
8) Loosen bolts and nuts of support beam to

remove support beam.
9) Disconnect servo connector.
10) Loosen bolts and nuts of heater unit to remove
heater unit.
B5M0682
G4M0554
AC-25
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BLOWER MOTOR ASSEMBLY
8. Blower Motor Assembly S701295

7) Disconnect motor connector.

Glove Box.>
3) Remove mounting bolts of harness stay.
B4M2304
8) Remove 3 screws.
9) Disconnect aspirator pipe (A) and remove
blower motor.
B4M2301
4) Remove nuts of keyless unit stay and CRU unit

stay.
S4M0033A
B4M2302 C: INSPECTION S701295A10
5) Disconnect connector of sunroof. Connect motor connector terminal 1 from the bat-
6) Disconnect servo connector. tery to the positive (+) lead and terminal 2 to the
negative (−) lead. Make sure the motor runs
smoothly.
B4M2303
B4M2404
AC-26
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POWER TRANSISTOR (HEATER BLOWER RESISTOR)
9. Power Transistor (Heater

Blower Resistor) S701553

Glove Box.>
2) Disconnect power transistor connector.
3) Loosen 2 screws to remove power transistor.
B4M2305
AC-27
POWER TRANSISTOR (HEATER BLOWER RESISTOR)
1. MANUAL A/C S701553A1002
B4M2463A

Tester connection Condition Specified condition
4—3 Constant Approx. 0.46 Ω
If NG, replace the blower resistor.
AC-28
HEATER CORE
10. Heater Core S701554
1) Remove heater unit. <Ref. to AC-25

REMOVAL, Heater Unit.>
2) Remove screws to separate heater unit case.
3) Remove heater core.
B4M2306
AC-29
CONTROL UNIT
11. Control Unit S701285

5) Loosen screws to pull control unit slightly out of
center console.
1. AUTO A/C S701285A1801

3) Loosen 2 screws (B) to remove center panel
(C).
B4M1702
6) Disconnect connector from antenna cable to

remove control unit.
1. AUTO A/C S701285A1101

4) Loosen screws to pull control unit slightly out of 2. MANUAL A/C S701285A1102
center console.
2) Before installation, set temperature control
switch to “FULL HOT”.
B6M1210
5) Disconnect connector to remove control unit.

2. MANUAL A/C S701285A1802

3) Loosen 2 screws (B) to remove center panel
(C).
B6M1209A
4) Set temperature control switch to “FULL HOT”,

and disconnect temperature control cable from
heater unit.
AC-30
墌 00.5.31/68j/7ac 墍
COMPRESSOR
12. Compressor S701281 B: REMOVAL S701281A18
1) Perform oil return operation. <Ref. to AC-24
OPERATION, Compressor Oil.>
1. MAGNETIC CLUTCH CLEARANCE 2) Turn A/C switch OFF and stop the engine.
S701281A1001
3) Using refrigerant recovery system, discharge
1) Check the clearance of the entire circumfer- refrigerant. <Ref. to AC-18 OPERATION, Refriger-
ence around the drive plate and pulley. ant Recovery Procedure.>
Standard: 4) Disconnect ground cable from battery.
0.45±0.15 mm (0.0177±0.0059 in) 5) Remove duct (A).
2. MAGNETIC CLUTCH OPERATION

S701281A1002
1) Disconnect the compressor connector.

2) Connect the No. 3 terminal of the compressor
connector from the battery to the positive (+) lead.
Ground the negative (−) lead to the body.
B6M1186A
6) Disconnect low-pressure hose (A) and high-

pressure hose (B).
CAUTION:
Be careful not to lose O-rings on hose. Imme-
diately seal hose with a plug or vinyl tape to
B4M2407 prevent the entry of contamination.
3) Make sure the magnet clutch engages.
If NG, replace the compressor.
B4M2246A

REMOVAL, V-belt.>
8) Remove generator. <Ref. to SC(H4)-15
REMOVAL, Generator.>
9) Disconnect compressor harness from body har-
ness.
AC-31
墌 00.5.31/68j/7ac 墍
COMPRESSOR
10) Remove bolts from compressor bracket. C: INSTALLATION S701281A11

4 CYLINDERS:
2) Replace O-rings on low-/high-pressure hoses
with new ones, then apply compressor oil.
3) When replacing compressor, adjust amount of
compressor oil. <Ref. to Compressor Oil.>
4) Charge refrigerant. <Ref. to AC-19
OPERATION, Refrigerant Charging Procedure.>
B4M2311
6 CYLINDERS:
B4M2336
11) Loosen bolts to remove compressor from

bracket.
B4M2312
AC-32
墌 00.5.31/68j/7ac 墍
CONDENSER
13. Condenser S701282

6) Remove 2 bolts. While lifting condenser, pull it
out through the space between the radiator and the
A: REMOVAL S701282A18 radiator panel.
refrigerant. <Ref. to AC-18 OPERATION, Refriger-
ant Recovery Procedure.>
3) Remove duct (A).
B4M1821
CAUTION:
Be careful not to damage condenser fins. If a
damaged fin is found, repair it using a thin
screwdriver.
B6M1186A If condenser is replaced, add appropriate
amount of compressor oil to the compressor.
4) Disconnect high-pressure hose (A) and low- <Ref. to AC-24 REPLACEMENT, Compressor
pressure hose (B) from condenser. Oil.>

CAUTION:
Replace O-rings on hoses or pipes with new
ones, and then apply compressor oil. Confirm
that lower guide of condenser has been fitted
into holes on radiator panel.
B4M2247A
5) Remove radiator bracket (A).
B4M1822A

B4M1820A C: INSPECTION S701282A10
1) Confirm that no dust or insects are found on the

condenser fins. Air-blow or flush fins with water as
needed.
2) Confirm that no oil leaks from condenser. If a
failure is found, replace condenser with a new one.
AC-33
墌 00.5.31/68j/7ac 墍
RECEIVER DRIER
14. Receiver Drier S701283

3) Disconnect pressure switch harness (A).
4) Disconnect pipe (B).
5) Loosen mounting bolts (C) to remove receiver
drier.
H4M1263A
CAUTION:
The receiver drier contains a desiccant. After
disconnecting receiver drier, plug it to avoid
moisture.
If receiver drier is replaced, add appropriate
amount of compressor oil to the compressor.
<Ref. to AC-24 REPLACEMENT, Compressor
Oil.>

CAUTION:
Replace O-rings with new ones, and apply
compressor oil.
AC-34
INTAKE UNIT
15. Intake Unit S701632

10) Disconnect in-vehicle temperature sensor
connector.

3) Remove bolts securing expansion valve and
pipe in engine compartment.
B4M2307
11) Remove bolts and nuts on the unit.
S4M0211
4) Remove instrument panel. <Ref. to EI-37

REMOVAL, Instrument Panel.>
5) Remove keyless unit and CRU unit.
B4M2337
12) Disconnect drain hose.

13) Remove the unit.

CAUTION:
Replace O-rings with new ones, and apply
compressor oil.
B4M2302
6) Disconnect sunroof connector. OPERATION, Refrigerant Charging Procedure.>
7) Disconnect servo motor connector.
B4M2303
8) Disconnect heater blower power transistor con-

nector.
9) Disconnect heater blower motor connector.
AC-35
墌 00.5.31/68j/7ac 墍
INTAKE UNIT
1) Remove resistor (A) and thermistor (B) from Assemble in the reverse order of disassembly.
intake unit. CAUTION:
2) Remove screws and clips to separate intake Replace O-rings with new ones, and then apply
unit. compressor oil.
B4M1811A
3) Remove expansion valve (A) from evaporator.
B4M1813A
CAUTION:
If evaporator is replaced, add appropriate
amount of compressor oil to evaporator. <Ref.
to AC-24 REPLACEMENT, Compressor Oil.>
AC-36
墌 00.5.31/68j/7ac 墍
FLEXIBLE HOSE
16. Flexible Hose S701286

11) Disconnect high-pressure hose (B) from the
vehicle.
CAUTION:
쐌 When disconnecting/connecting hoses, do
not apply excessive force them. Confirm that
no torsion and excessive tension exist after
installing.
쐌 Seal the disconnected hose with a plug or
vinyl tape to prevent contamination from enter-
ing.
3) Remove duct (A).
B4M1824B
B6M1186A CAUTION:
When disconnecting/connecting hoses, do not
4) Remove hose attaching bolts (C). apply an excessive force them. Confirm that no
5) Disconnect hose from evaporator unit. torsion and excessive tension exist after
6) Disconnect hose from compressor. installing. Seal the disconnected hose with a
7) Remove low-pressure hose (A) from the plug or vinyl tape to prevent contamination
vehicle. from entering.
8) Remove hose attaching bolts (D).
9) Disconnect hose from compressor. 1) Install in the reverse order of removal.
10) Disconnect hose from condenser.
NOTE:
If cracking, damage, or swelling is found on a hose,
replace it with a new one.
AC-37
墌 00.5.31/68j/7ac 墍
RELAY AND FUSE
17. Relay and Fuse S701287
B4M2464A
4 cylinder engine model 6 cylinder engine model

Main fan relay F —
Sub fan relay B —
A/C relay A A
Main fan relay 1 — F
Sub fan relay 1 — G
Main fan relay 2 — B
Sub fan relay 2 — H
A/C fuse C C
Main fan fuse E (20 A) E (30 A)
Sub fan fuse D (20 A) D (30 A)
AC-38
RELAY AND FUSE
B4M2308A
(3) — (4): Continuity exists.

(1) — (2): No continuity
While applying battery voltage to the cable
between (3) and (4), check continuity between (1)
and (2).
If no continuity exists, replace the relay with a new
one.
AC-39
墌 00.5.31/68j/7ac 墍
PRESSURE SWITCH (DUAL SWITCH)
18. Pressure Switch (Dual

Switch) S701555
1) Connect the manifold gauge to the service

valve on the high-pressure side.
2) Remove the pressure switch harness connec-
tor. Using a circuit tester, inspect the ON-OFF
operation of the pressure switch.
G4M0654
Specified condition
Tester connection Operation
kPa (kg/cm2, psi)
Increasing to 2,942±196 (30±2, 427±28)
Turns OFF.
High and low pressure Decreasing to 177±20 (1.8±0.2, 26±3)
1—2
switch Increasing to 216 (2.2, 31) or less
Turns ON.
Decreasing to 2,354±196 (24±2, 341±28)
AC-40
PRESSURE SWITCH (TRIPLE SWITCH)
19. Pressure Switch (Triple

Switch) S701633
1) Connect the manifold gauge to the service

manifold on the high-pressure side.
2) Remove the pressure switch harness connec-
tor. Using a circuit tester, inspect the ON-OFF
operation of the pressure switch.
B4M2405
Specified condition
Tester connection Operation
kPa (kg/cm2, psi)
Increasing to 2,940±196 (29.98±2.00, 426±28)
Turns OFF.
High and low pressure Decreasing to 177±20 (1.8±0.2, 26±3)
1—2
switch Increasing to 216 or less (2.2, 31)
Turns ON.
Decreasing to 2,350±196 (23.97±2.00, 341±28)
Turns OFF. 1,370±120 (13.97±1.22, 199±17)
Middle pressure switch 3—4
Turns ON. 1,770±100 (18.05±1.02, 257±15)
AC-41
AMBIENT SENSOR (AUTO A/C)
20. Ambient Sensor (Auto A/C)

S701289
1) Open front hood.

3) Disconnect ambient sensor connector.
4) Remove ambient sensor from radiator lower
panel.
B4M2338
<Ref. to AC-26 TROUBLE CODE 21 OR -21

(AMBIENT SENSOR), Diagnostic Procedure with
Trouble Code.>
AC-42
SUN-LOAD SENSOR (AUTO A/C)
21. Sun-load Sensor (Auto A/C)

S701279

2) Insert a slotted screwdriver to remove sunload
sensor.
B4M1828A
3) Disconnect sunload sensor connector.
B4M1829
CAUTION:
Be careful not to damage sensors and interior
trims when removing them.
<Ref. to AC-32 TROUBLE CODE 25 OR -25 (SUN-

LOAD SENSOR), Diagnostic Procedure with
Trouble Code.>
AC-43
AIR VENT GRILLE
22. Air Vent Grille S701284

2. AIR VENT GRILLE PASSENGER SIDE
S701284A1802
1) Remove grille using sharp-edged screwdriver.
1. AIR VENT GRILLE DRIVER SIDE S701284A1801

2) Set tilt steering to the lowest position.
3) Disconnect each electrical connector to remove
front cover (A) and switch panel (B).
4) Loosen screw (C) to remove center panel (D).
5) Remove meter visor (E).
B4M2314
CAUTION:
Wrap screwdriver with vinyl tape to prevent
damage to interior parts.
The direction and amount of air should be adjusted

smoothly.
The adjustment should be kept in each position.
B6M1204A
6) Loosen screws to remove grille.
B4M2313
AC-44
墌 00.5.31/68j/7ac 墍
HEATER DUCT
23. Heater Duct S701556
1) Remove heater unit. <Ref. to AC-25

REMOVAL, Heater Unit.>
2) Remove front seat. <Ref. to SE-6 REMOVAL,
Front Seat.>
3) Remove front side sill cover.
4) Pull off floor mat to remove heater duct.
B4M2309
AC-45
HEATER VENT DUCT
24. Heater Vent Duct S701557
1) Remove instrument panel. <Ref. to EI-37

REMOVAL, Instrument Panel.>
2) Remove nine screws.
3) Remove heater vent duct.
B4M2310
AC-46
GENERAL DIAGNOSTICS
25. General Diagnostics S701278

Fuse
Blower motor relay
Blower motor
Doesn’t move.
Blower motor Blower motor resister
Blower switch
Wire harness
Strange noise. Blower motor
Refrigerant
Fuse
Air conditioning relay
Magnet clutch
Doesn’t move. Compressor
Pressure switch
Compressor
A/C switch
Blower switch
Wire harness
V-Belt
Strange noise Magnet clutch
Compressor
Refrigerant
V-Belt
Magnet clutch
Compressor
Pressure switch
Cold air not emitted.
A/C switch
Blower switch
Wire harness
Heater duct
Heater vent duct
Engine coolant
Warm air not emitted. Blower switch
Heater core
Engine coolant
Temperature of air from vents does not change. Mode actuator
Wire harness
Mode actuator
Unable to switch blow vents. Air flow switch
Wire harness
Air inlet select switch
Unable to switch suction vents. FRESH/RECIRC actuator
Wire harness
AC-47
GENERAL DIAGNOSTICS
MEMO:
AC-48
SYSTEM OVERVIEW
1 . System Overview
ThPrP arP thrPP Pmissinn cnntrnl systems which are as follows :
" Crankcase emission control system
" Exhaust emission control system
" Three-way catalyst system
" Air/fuel (A/F) control system
" Ignition control system
" Evaporative emission control system
" On-board refueling vapor recovery (ORVR) system
EC-2
SYSTEM OVERVIEW
Item Main components Function

Crankcase emission control Positive crankcase Draws blow-by gas into intake manifold from crankcase and burns it
system ventilation (PCV) together with air-fuel mixture. Amount of blow-by gas to be drawn in
valve is controlled by intake manifold pressure .
Exhaust Catalyst Front Three-way catalyst Oxidizes HC and CO contained in exhaust gases as well as reducing
emission system NOx.
control Rear
system A/F control Engine control mod- Receives input signals from various sensors, compares signals with
system ule (ECM) stored data, and emits a signal for optimal control of air-fuel mixture
ratio.
Front oxygen (A/F) Detects quantity of oxygen contained exhaust gases.
sensor
Rear oxygen sensor Detects density of oxygen contained exhaust gases.
Throttle position Detects throttle position .
sensor
Intake manifold Detects absolute pressure of intake manifold .
pressure sensor`1
Intake air tempera- Detects intake air temperature of air cleaner case .
ture sensor's
Intake air tempera- Detects absolute pressure of intake manifold .
ture and pressure
sensor"2 Detects intake air temperature of intake manifold .
Ignition control ECM Receives various signals, compares signals with basic data stored in
system memory, and emits a signal for optimal control of ignition timing .
Crankshaft position Detects engine speed (Revolution) .
sensor
Camshaft position Detects reference signal for combustion cylinder discrimination .
sensor
Engine coolant tem- Detects coolant temperature .
perature sensor
Knock sensor Detects engine knocking .
Evaporative emission control Canister Absorbs evaporative gas which occurs in fuel tank when engine
system stops, and releases it to combustion chambers for a complete burn
when engine is started. This prevents HC from being discharged into
atmosphere .
Purge control Receives a signal from ECM and controls purge of evaporative gas
solenoid valve absorbed by canister.
Pressure control Receives a signal from ECM and controls evaporative gas pressure
solenoid valve in fuel tank .
ORVR system Vent valve Controls evaporation pressure in fuel tank .
Drain valve Closes the evaporation line by receiving a signal from ECM to check
the evaporation gas leak .
*1 : MT vehicles
*2 : AT vehicles
EC-3
SCHEMATIC DIAGRAMS
Emission Control (Aux . Emission Control Devices)
2. Schematic Diagrams
A: MT VEHICLES
(34)
(35)
kc 11 <<vj
B2H3445A
EC-4
SCHEMATIC DIAGRAMS
(1) Engine control module (ECM) (23) Radiator fan relay

(2) Ignition coil and ignitor assembly (24) Knock sensor
(3) Crankshaft position sensor (25) Front oxygen (A/F) sensor
(4) Camshaft position sensor (26) Rear oxygen sensor
(5) Throttle position sensor (27) A/C compressor
(6) Fuel injectors (28) Neutral switch
(7) Pressure regulator (29) CHECK ENGINE malfunction indicator lamp (MIL)
(8) Engine coolant temperature sensor (30) Tachometer
(9) Intake air temperature sensor (31) A/C relay
(10) Intake manifold pressure sensor (32) A/C control module
(11) Idle air control solenoid valve (33) Ignition switch
(12) Purge control solenoid valve (34) Vehicle speed sensor
(13) Fuel pump (35) Data link connector
(14) PCV valve (36) Fuel tank pressure sensor
(15) Air cleaner (37) Pressure control solenoid valve
(16) Canister (38) Fuel temperature sensor
(17) Main relay (39) Fuel level sensor
(18) Fuel pump relay (40) Drain filter
(19) Fuel filter (41) Vent valve
(20) Front catalytic converter (42) Shut-off valve
(21) Rear catalytic converter (43) Drain valve
(22) Radiator fan
EC-5
SCHEMATIC DIAGRAMS
B: AT VEHICLES
(35)
(36)
(37)
B2H3446A
EC-6
SCHEMATIC DIAGRAMS
Emission Control (Aux. Emission Co ntro l Devices)
(1) Engine control module (ECM) (24) Knock sensor

(2) Ignition coil and ignitor assembly (25) Front oxygen (A/F) sensor
(3) Crankshaft position sensor (26) Rear oxygen sensor
(4) Camshaft position sensor (27) Air assist injector solenoid valve
(5) Throttle position sensor (28) A/C compressor
(6) Fuel injectors (29) Inhibitor switch
(7) Pressure regulator (30) CHECK ENGINE malfunction indicator lamp (MIL)
(8) Engine coolant temperature sensor (31) Tachometer
(9) Intake air temperature and pressure sensor (32) A/C relay
(10) Idle air control solenoid valve (33) A/C control module
(11) Purge control solenoid valve (34) Ignition switch
(12) Fuel pump (35) Transmission control module (TCM)
(13) PCV valve (36) Vehicle speed sensor
(14) Air cleaner (37) Data link connector
(15) Canister (38) Fuel tank pressure sensor
(16) Main relay (39) Pressure control solenoid valve
(17) Fuel pump relay (40) Fuel temperature sensor
(18) Fuel filter (41) Fuel level sensor
(19) Front catalytic converter (42) Drain filter
(20) Rear catalytic converter (43) Vent valve
(21) Radiator fan (44) Shut-off valve
(22) Radiator fan relay (45) Drain valve
(23) Atmospheric pressure sensor
EC-7
CRANKCASE EMISSION CONTROL SYSTEM
3. Crankcase Emission Control System

a Tha nn--,itiva r.rankraqP vPntilatinn IPr\/1 .-,v-,tPm nrPVPnt.-, air nnllutinn which will he caused by
blow-by gas being emitted from the crankcase .
The system consists of a sealed oil filler cap, rocker covers with fresh air inlet, connecting hoses,
a PCV valve and an air intake duct .
" In a part-throttle condition, the blow-by gas in the crankcase flows into the intake manifold
through the connecting hose of crankcase and PCV valve by the strong vacuum created in the
intake manifold . Under this condition, fresh air is introduced into the crankcase through the con-
necting hose of the rocker cover.
" In a wide-open-throttle condition, a part of blow-by gas flows into the air intake duct through the
connecting hose and is drawn into the throttle chamber, because under this is condition, the intake
manifold vacuum is not strong enough to introduce through the PCV valve all blow-by gases that
increase in the amount with engine speed .
Part-throttle condition Air cleaner case

--- Fresh air
Mixture of air and
blow-by gas
--Blow-by gas
Throttle body
PCV valve
PCV I __,,,Intake
0 Intakegmanifold
man fol,
PCV
valve Oil filler cap Case
0 0
Crankcase
Wide-open-throttle condition Air cleaner case

. Fresh air
Mixture of air and
blow-by gas
-Blow-by gas
Oil filler cap
B2H3534C
EC-8
THREE-WAY CATALYST
4 . Three-way Catalyst
" The basic material of three-way catalyst is platinum (Pt), rhodium (Rh) and palladium (Pd), and
a thin coat of their mixture is applied onto honeycomb or porous ceramics of an oval shape (carri-
er) . To avoid damaging the catalyst, only unleaded gasoline should be used .
" The catalyst reduces HC, CO and NOx in exhaust gases through chemical reactions (oxidation
and reduction) . These harmful components are reduced most efficiently when their concentra-
tions are in a certain balance . These concentrations vary with the air-fuel ratio. The ideal air-fuel
ratio for reduction of these components is the stoichiometric ratio .
" Therefore, the air-fuel ratio needs to be controlled to around the stoichiometric ratio to purify the
exhaust gases most efficiently.
EC-9
A/F CONTROL SYSTEM
5 . A/F Control System

w The air/fuel (A/F) control system makes a correction to the basic fuel injection duration in accor-
dance with the signal from the front oxygen sensor so that the stoichiometric ratio is maintained,
thus ensuring most effective exhaust gas purification by the three-way catalyst . Different basic fuel
injection durations are preset for various engine speeds and loads, as well as the amount of intake
air.
" This system also has a "learning" control function which stores the corrected data in relation to
the basic fuel injection in the memory map . This allows an appropriate air-fuel ratio correction to
be added automatically in quick response to any situation that requires such an effect . Thus, the
air-fuel ratio is optimally maintained under various conditions while purifying exhaust gases most
effectively, improving driving performance and compensating for changes in sensors' perfor-
mance over time .
EC-10
IGNITION CONTROL SYSTEM
6. Ignition Control System

A : MT VEHICLES
" The ignition system is controlled by the ECM .
The ECM monitors the operating condition of the engine using the signals from the sensors and
switches shown below and determines the ignition timing most appropriate for each engine oper-
ating condition . Then it sends a signal to the ignitor, commanding generation of a spark at that
timing .
" The ECM uses a preprogrammed map for a "closed-loop" control which provides its ignition tim-
ing control with excellent transient characteristics, i .e., highly responsive ignition timing control .
Battery
r---~
~/y' "UI--~I I
1 L___J
Ignition switch
-------------------
i ECM -, i ~ Crankshaft
position sensor
i Ignition coil and
11
~ - -----------'~ i:1 ~ ~ i9nitor assembly
~I~~I ` I
I1~~1 I
~I~II I
I ~ I ~ L
1~1~
III I
I
I I
~~I I
I~I~ I I
-_--
Camshaft position J ---
sensor .,
i ~ L ---------~
_ ~ ~ Spark plug
I I
L-_- -------- --- Engine coolant
temperature sensor
Intake air temperature sensor

Knock sensor Pressure sensor
B2H3535A
EC-11
B : AT VEHICLES
e ThP innitinn q\/ .-,tPm i.-, r.nntrnIIPd h\i the FC~M
timing .
ing control with excellent transient characteristics, i .e ., highly responsive ignition timing control .
Battery
r---1
L---J
Ignition switch
--- ;
-,
---- ECM
~II~I~
Crankshaft position sensor
~ r-----------''~ I ~ ~ ~
I ~ Ignition coil and ignitor assembly
r------------~
~r-----------' ~ ~
I I ~ r-----------~ i
I
~I~II~
L
II r - -
I~I~ r- V
Camshaft position i I
sensor
I I
I Spark plug
~ i ~`_------JJ I'
I
__________~ Engine coolant
temperature sensor
Intake air temperature and
Knock sensor pressure sensor
B2H3536A
EC-12
EVAPORATIVE EMISSION CONTROL SYSTEM
7 . Evaporative Emission Control System

A : GENERAL
" The evaporative emission control system prevents fuel vapors from escaping into atmosphere .
This system includes a canister, purge control solenoid valve, fuel cut valve, and the lines connect-
ing them .
" Fuel vapors in the fuel tank is introduced into the canister through the evaporation line, and are
absorbed by activated carbon in it . The fuel cut valve is also incorporated in the fuel tank line .
" The purge control solenoid valve is controlled optimally by the ECM according to the engine
condition .
" The pressure control solenoid valve incorporated in the fuel tank evaporation line regulates the
pressure/vacuum in the fuel tank under the control of the ECM which uses the signal from the fuel
tank pressure sensor.
B2H3422A
(1) Fuel gauge (7) Pressure control solenoid valve (13) Fuel tank
(2) Intake manifold (8) Drain valve (14) Fuel cut valve
(3) Throttle body (9) Drain filter (15) Fuel tank pressure sensor
(4) Purge control solenoid valve (10) Shut-off valve (16) Vent valve
(5) Engine control module (ECM) (11) Fuel temperature sensor
(6) Canister (12) Fuel level sensor
EC-13
B : FUEL CUT VALVE

The fuel rat valve is built onto the evaporation pipe of the fuel tank cap . The rising level of the fuel
in the fuel tank causes the float to move up and close the cap hole so that no fuel can enter the
evaporation line .
To car
Valve open I Valve closed
B2H3342B
C : FUEL TANK CAP

The fuel tank cap has a relief valve which prevents development of vacuum in the fuel tank in the
event of a problem with the fuel vapor line .
When there is no problem with the fuel vapor line, the filler pipe is sealed at the portion (A) and
by the seal pressed against the filler pipe end . If vacuum develops in the fuel tank, the atmospheric
pressure forces the spring down to open the valve ; consequently outside air flows into the fuel tank,
thus controlling the inside pressure .
eal
gyring
B2H0395A
EC-14
D : CANISTER
The charcoal filled in the canister temporarily stores fuel vapors . When the purge control solenoid
valve is opened icy a signal from the ECM, the external fresh air entering the canister carries the
fuel vapors into the collector chamber .
Grid Filter Charcoal
To purge control solenoid valve
From fuel tank
Spring
Air
H2H1164B
E : PURGE CONTROL SOLENOID VALVE

The purge control solenoid valve is on the evaporation line between the canister and throttle body.
It is installed at the underside of intake manifold :
le body
B2H0426
EC-15
F: PRESSURE CONTROL SOLENOID VALVE

The fuel tank pressure control solenoid valve is located in the evaporation line between the shut-off
valve on fuel filler pipe and the fuel tank. It adjusts the fuel tank inside pressure under the control
of the ECM .
When the tank inside pressure becomes higher than the atmospheric pressure, the valve is
opened allowing fuel vapors to be introduced into the canister.
On the other hand, when the tank inside pressure becomes lower than the atmospheric pressure,
external air is taken from the drain valve into the canister .
The pressure control solenoid valve can also be electrically closed for the system diagnosis pur-
poses .
Atmospheri
pressure
;onnector
erminal
From shut-off valve C> To fuel tank
Pin hole
B2H1719D
G : DRAIN FILTER
The drain filter is installed at the air inlet port of the vent control solenoid valve . It cleans the air taken
in the canister through the vent control solenoid valve .
To drain valve To atmosphere
Dement
Case
S2H0874
EC-16
H : VENT VALVE
The vent valve is located on the fuel tank . During filling the fuel tank, fuel vapors are introduced
into the canister through the vent valve.
When the fuel vapor pressure becomes higher than the atmospheric pressure and overcomes the
spring force which is applied to the back side of the diaphragm, the port toward the canister is
opened . The vent valve also has a float which blocks the fuel vapor passage when the tank is filled
up. Increasing fuel level raises the float to close the port toward the canister.
Spring
m
To filler
To canister to cover
B2H3424A
I : SHUTOFF VALVE
The shut-off valve is located at the top of the fuel filler pipe . When a filler gun is inserted into the
filler pipe, the shut-off valve closes the evaporation line .
Valve
Spring
B2H3423A
EC-17
J : DRAIN VALVE
The drain valve is located on the line connecting the drain filter and canister, lust below the drain
filter. The drain valve is forcibly closed by a signal from the ECM while the evaporation system diag-
nosis is being conducted .
eat
B2H1770
EC-18
ON-BOARD REFUELING VAPOR RECOVERY (ORVR) SYSTEM
8. On-board Refueling Vapor Recovery (ORVR) System

A: GENERAL
The on-board refueling vapor recovery system allows the fuel vapors in the fuel tank to be
introduced directly into the canister through the vent valve when the fuel tank inside pressure in-
creases as a result of refueling .
The diagnosis of the system is performed by monitoring the fuel tank inside pressure data from
the fuel tank pressure sensor while forcibly closing the drain valve .
B : OPERATION
" While driving
Since the back side of the diaphragm in the pressure control solenoid valve is open to the atmo-
sphere, the diaphragm is held pressed by the atmospheric pressure in the position where only the
external air is introduced into the canister. When the fuel vapor pressure acting on the other side
of the diaphragm increases and overcomes the atmospheric pressure, it pushes the diaphragm
and opens the port through which the fuel vapors make their way to the canister.
(4)
B2H3537A
(1) Canister (4) Intake manifold

(2) Pressure control solenoid valve (5) Shut-off valve: opened
(3) Purge control solenoid valve
EC-19
" While refueling

As the fuel enters the fuel tank, the tank inside pressure increases . When the inside pressure be-
comes higher than the atmospheric pressure, the port of the vent ~.ra!~~e opens, allowing the fuel
vapors to be introduced into the canister through the vent line. The fuel vapors are absorbed by
charcoal in the canister, so the air discharged from the drain valve contains no fuel . When a filler
gun is inserted, the shut-off valve closes the evaporation line .
B2H3538A
(1) Canister (4) Shut-off valve: closed

(2) Pressure control solenoid valve (5) Filler gun
(3) Vent valve
EC-20
VACUUM CONNECTIONS
9 . Vacuum Connections
The hose and pipe connections of the intake manifold, throttle body and other related parts are
as shown in the illustration .
A : MT VEHICLES
HOSE
o :PIPE
FRONT OF VEHICLE
B2H3539A
(1) Pressure regulator

(2) Throttle body
EC-21
VACUUM CONNECTIONS
Emi ssion Contr ol (Aux . Emission Control Devices)
B : AT VEHICLES
:HOSE
o : PIPE
(3)
FRONT OF VEHICLE
B2H3540A
(1) Pressure regulator

(2) Throttle body
(4) Air assist injector solenoid valve
EC-22
SYSTEM OVERVIEW
1 . System Overview
There
e are
e iiiie`c~ eiiiissivii ir'.viiiivi sysie i'iis vv iii~ii aieasfviiovvs .
" Crankcase emission control system

" Exhaust emission control system
" Three-way catalyst system
" Air/fuel (A/F) control system
" Ignition control system
" Evaporative emission control system
" On-board refueling vapor recovery (ORVR) system
EC-2
SYSTEM OVERVIEW
Item Main components Function

Crankcase emission control Positive crankcase Draws blow-by gas into intake manifold from crankcase and burns it
system ventilation ;PCV) together with air-fuel mixture. Amount of blow-by gas to be drawn in
valve is controlled by intake manifold pressure .
Exhaust Catalyst Front Three-way catalyst Oxidizes HC and CO contained in exhaust gases as well as reducing
emission system NOx.
control Rear
system A/F control Engine control mod- Receives input signals from various sensors, compares signals with
system ule (ECM) stored data, and emits a signal for optimal control of air-fuel mixture
ratio.
Front oxygen (A/F) Detects quantity of oxygen contained exhaust gases.
sensor
Rear oxygen sensor Detects density of oxygen contained exhaust gases.
Throttle position Detects throttle position .
sensor
Intake manifold Detects absolute pressure of intake manifold .
pressure sensor
Intake air tempera- Detects intake air temperature of air cleaner case .
ture sensor
Ignition control ECM Receives various signals, compares signals with basic data stored in
system memory, and emits a signal for optimal control of ignition timing .
Crankshaft position Detects engine speed (Revolution) .
sensor
Camshaft position Detects reference signal for combustion cylinder discrimination .
sensor
Engine coolant tem- Detects coolant temperature .
perature sensor
Evaporative emission control Canister Absorbs evaporative gas which occurs in fuel tank when engine
system stops, and releases it to combustion chambers for a complete burn
when engine is started . This prevents HC from being discharged into
atmosphere .
Purge control Receives a signal from ECM and controls purge of evaporative gas
solenoid valve absorbed by canister.
Pressure control Receives a signal from ECM and controls evaporative gas pressure
solenoid valve in fuel tank.
ORVR system Vent valve Controls evaporation pressure in fuel tank .
Drain valve Closes the evaporation line by receiving a signal from ECM to check
the evaporation gas leak .
EC-3
SCHEMATIC DIAGRAMS
2 . Schematic Diagrams
B2H3968A
EC-4
SCHEMATIC DIAGRAMS
(1) Engine control module (ECM) (19) Fuel filter (37) Data link connector
(2) Ignition coil and ignitor assembly (20) Front catalytic converter LH (38) Transmission control module
/TIER A\
1 I lrlVq
(3) Crankshaft position sensor (21) Front catalytic converter RH (39) Fuel tank pressure sensor
(4) Camshaft position sensor (22) Rear catalytic converter (40) Pressure control solenoid valve
(5) Throttle position sensor (23) Radiator fan (41) Fuel temperature sensor
(6) Fuel injectors (24) Radiator fan relay (42) Fuel level sensor
(7) Pressure regulator (25) Knock sensor (43) Drain filter
(8) Engine coolant temperature (26) Front oxygen (A/F) sensor LH (44) Vent valve
sensor
(9) Intake air temperature sensor (27) Front oxygen (A/F) sensor RH (45) Shut-off valve
(10) Intake manifold pressure sensor (28) Rear oxygen sensor (46) Drain valve
(11) Idle air control solenoid valve (29) A/C compressor (47) Induction valve
(12) Purge control solenoid valve (30) Inhibitor switch (48) Check valve
(13) Fuel pump (31) CHECK ENGINE malfunction (49) Induction valve control solenoid
indicator lamp (MIL)
(14) PCV valve (32) Tachometer (50) Vacuum tank
(15) Air cleaner (33) A/C relay (51) EGR valve
(16) Canister (34) A/C control module (52) Fuel damper
(17) Main relay (35) Ignition switch (53) Atmospheric pressure sensor
(18) Fuel pump relay (36) Vehicle speed sensor
EC-5
CRANKCASE EMISSION CONTROL SYSTEM
3. Crankcase Emission Control System

The positive crankcase ventilation (PCV) system prevents air pollution which will be caused by
blow-by gas being emitted from the crankcase .
The system consists of rocker covers with fresh air inlet, connecting hoses, a PCV valve and a
chamber .
(;hamhPr
Connecting hose
PCV valve
J valve
To intake Blow-by
manifold gas
Valve
CIP
Spring V
Rocker cover RH
Case
Rock
B2H3969A
EC-6
THREE-WAY CATALYST
4. Three-way Catalyst
" The basic material of three-way catalyst is platinum (Pt), rhodium (Rh) and palladium (Pd), and
a thin coat of their mixture is applied onto honeycomb or porous ceramics of an oval shape (carri-
er) . To avoid damaging the catalyst, only unleaded gasoline should be used .
" The catalyst reduces HC, CO and NOx in exhaust gases through chemical reactions (oxidation
and reduction). These harmful components are reduced most efficiently when their concentra-
tions are in a certain balance . These concentrations vary with the air-fuel ratio . The ideal air-fuel
ratio for reduction of these components is the stoichiometric ratio .
" Therefore, the air-fuel ratio needs to be controlled to around the stoichiometric ratio to purify the
exhaust gases most efficiently.
EC-7
A/F CONTROL SYSTEM
5. A/F Control System

=
Th e
/f
Q~air//
I /l~ lC\ i,i,n+rl,I m I~ nc+ ntion
co , irvu
fn
the
hacvil~ fl IC I ~i ior~t IIlYI HulYutin
iniJvvuv~ ,n, i,n, arrn,r-
In/I ~ lrVl IU VI System
JyJLGI I I I I I~lf\GJ CA
a lrvi i i w n v iv iuv
dance with the signal from the front oxygen sensor so that the stoichiometric ratio is maintained,
thus ensuring most effective exhaust gas purification by the three-way catalyst . Different basic fuel
injection durations are preset for various engine speeds and loads, as well as the amount of intake
air.
" This system also has a "learning" control function which stores the corrected data in relation to
the basic fuel injection in the memory map . This allows an appropriate air-fuel ratio correction to
be added automatically in quick response to any situation that requires such an effect. Thus, the
air-fuel ratio is optimally maintained under various conditions while purifying exhaust gases most
effectively, improving driving performance and compensating for changes in sensors' perfor-
mance over time .
EC-8
6. Ignition Control System

" The ignition system is controlled by the ECM .
timing .
ing control with excellent transient characteristics, i .e ., highly responsive ignition timing control .
(3)
(4)
(11)
B2H3970A
(1) ECM (9) Throttle position sensor

(2) #1 Ignition coil (10) #6 Ignition coil
(5) Camshaft position sensor (13) Engine coolant temperature sensor
(6) Pressure sensor (14) Knock sensor LH
(7) Intake air temperature sensor (15) Knock sensor RH
(8) Crankshaft position sensor
EC-9
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
7. Exhaust Gas Recirculation (EGR) System

A: GENERAL
" The EGR system aims at reduction of NOx by lowering the combustion temperature through re-
circulation of a part of exhaust gas into cylinders via the intake manifold .
" The EGR valve is controlled by the ECM according to the engine operating condition .
(3)
B2H3971A
(1) EGR valve (4) Exhaust port

(2) ECM (5) LH cylinder head
(3) Intake manifold
EC-10
Emission Control (Aux. Emission Control Devic es)
8 . Evaporative Emission Control System

A: GENERAL
" The evaporative emission control system prevents fuel vapors from escaping into atmosphere .
This system includes a canister, purge control solenoid valve, fuel cut valve, and the lines connect-
ing them .
" Fuel vapors in the fuel tank is introduced into the canister through the evaporation line, and are
absorbed by activated carbon in it. The fuel cut valve is also incorporated in the fuel tank line .
" The purge control solenoid valve is controlled optimally by the ECM according to the engine
condition .
" The pressure control solenoid valve incorporated in the fuel tank evaporation line regulates the
pressure/vacuum in the fuel tank under the control of the ECM which uses the signal from the fuel
tank pressure sensor.
(1
(13)
B2H3972A
(1) Fuel gauge (7) Pressure control solenoid valve (13) Fuel tank
(2) Intake manifold (8) Drain valve (14) Fuel cut valve
(3) Throttle body (9) Drain filter (15) Fuel tank pressure sensor
(4) Purge control solenoid valve (10) Shut-off valve (16) Vent valve
(5) Engine control module (ECM) (11) Fuel temperature sensor
(6) Canister (12) Fuel level sensor
EC-11
B: FUEL CUT VALVE

The fuel cut valve is built onto the evaporation pipe of the fuel tank cap . The rising level of the fuel
in the fuel tank causes the float to move up and close the cap hole so that no fuel can enter the
evaporation line .
To car
Valve open I Valve closed
1321-1334213
C: FUEL TANK CAP

The fuel tank cap has a relief valve which prevents development of vacuum in the fuel tank in the
event of a problem with the fuel vapor line .
When there is no problem with the fuel vapor line, the filler pipe is sealed at the portion (A) and
by the seal pressed against the filler pipe end . If vacuum develops in the fuel tank, the atmospheric
pressure forces the spring down to open the valve ; consequently outside air flows into the fuel tank,
thus controlling the inside pressure .
eal
ring
B2H0395A
EC-12
D: CANISTER
The charcoal filled in the canister temporarily stores fuel vapors . When the purge control solenoid
valve is opened by a signal from the ECM, the external fresh air entering the canister carries the
fuel vapors into the collector chamber.
(girl Filter _.
filter
To purge control solenoid
From fuel te
Spring
B2H4141 A
E : PURGE CONTROL SOLENOID VALVE

The purge control solenoid valve is on the evaporation line between the canister and throttle body.
It is installed at the underside of intake manifold .
To throttle body To canister
1 1
B2H4155A
EC-13
F : PRESSURE CONTROL SOLENOID VALVE

The fuel tank pressure control solenoid valve is located in the evaporation line between the shut-off
valve on fuel filler pipe and the fuel tank. It adjusts the fuel tank inside pressure under the control
of the ECM .
When the tank inside pressure becomes higher than the atmospheric pressure, the valve is
opened allowing fuel vapors to be introduced into the canister.
On the other hand, when the tank inside pressure becomes lower than the atmospheric pressure,
external air is taken from the drain valve into the canister.
The pressure control solenoid valve can also be electrically closed for the system diagnosis pur-
poses .
Spring
Atmospheric
pressure
;onnector
erminal
From shut-off valve L=> To fuel tank
Pin hole
B2H1719D
G : DRAIN FILTER
The drain filter is installed at the air inlet port of the vent control solenoid valve . It cleans the air taken
in the canister through the vent control solenoid valve .
To drain valve To atmosphere
lement
Case
S2H0874
EC-14
H : VENT VALVE
The vent valve is located on the fuel tank. During filling the fuel tank, fuel vapors are introduced
into the canister through the vent valve .
When the fuel vapor pressure becomes higher than the atmospheric pressure and overcomes the
spring force which is applied to the back side of the diaphragm, the port toward the canister is
opened . The vent valve also has a float which blocks the fuel vapor passage when the tank is filled
up . Increasing fuel level raises the float to close the port toward the canister.
Spring
m
To filler
To canister ~ to cover
B2H3424A
I : SHUTOFF VALVE
The shut-off valve is located at the top of the fuel filler pipe . When a filler gun is inserted into the
filler pipe, the shut-off valve closes the evaporation line .
Valve
Spring
B2H3423A
EC-15
J : DRAIN VALVE
The drain valve !S located on the line connecting the drain filter and canister, Just below the drain
filter. The drain valve is forcibly closed by a signal from the ECM while the evaporation system diag-
nosis is being conducted .
.
V^4
seat
B2H1770
EC-16
9 . On-board Refueling Vapor Recovery (ORVR) System

A : GENERAL
The on-board refueling vapor recovery system allows the fuel vapors in the fuel tank to be
introduced directly into the canister through the vent valve when the fuel tank inside pressure in-
creases as a result of refueling .
The diagnosis of the system is performed by monitoring the fuel tank inside pressure data from
the fuel tank pressure sensor while forcibly closing the drain valve.
B : OPERATION
" While driving
Since the back side of the diaphragm in the pressure control solenoid valve is open to the atmo-
sphere, the diaphragm is held pressed by the atmospheric pressure in the position where only the
external air is introduced into the canister. When the fuel vapor pressure acting on the other side
of the diaphragm increases and overcomes the atmospheric pressure, it pushes the diaphragm
and opens the port through which the fuel vapors make their way to the canister.
B2H3973A
(1) Canister (4) Intake manifold

(2) Pressure control solenoid valve (5) Shut-off valve: opened
EC-17
" While refueling

As the fuel enters the fuel tank, the tank inside pressure increases . When the inside pressure be-
comes higher than the atmospheric pressure, the port or` the vent naive opens, allowing ii~e fuel
vapors to be introduced into the canister through the vent line . The fuel vapors are absorbed by
charcoal in the canister, so the air discharged from the drain valve contains no fuel . When a filler
gun is inserted, the shut-off valve closes the evaporation line .
B2H3974A
(1) Canister (4) Shut-off valve: closed

(2) Pressure control solenoid valve (5) Filler gun
(3) Vent valve
EC-18
VACUUM CONNECTIONS
10. Vacuum Connections

The hose and pipe connections of the intake manifold, throttle body and other related parts are
as shown in the illustration .
(4f
B2H3975A
(1) Throttle body (5) Check valve

(2) Pressure regulator (6) Induction valve control solenoid
(3) Induction valve (a): Hose
(4) Purge control solenoid valve (b): Pipe
(c) : To fuel tank
EC-19
INSTRUMENT PANEL
1 . Instrument Panel
" A cup holder is peovided on the dashboard .
" The glove compartment has a lockable lid .
" A coin tray is provided .
" The vent grills are barrel type .
" The dashboard lower cover is fitted with a knee cover.
" The steering support beam connecting the left and right pillars is located behind the instrument
panel . The instrument panel is mounted on the support beam .
A
(2)
(D0000
0 70
(3)
(4)
(6)
Section A - A
B5H0822B
(1) Barrel type vent grill (4) Glove compartment
(2) Cup holder (5) Steering support beam
(3) Coin tray (6) Knee pad
EI-2
TRAILER LIGHTS CONNECTOR
2. Trailer Lights Connector

A: DESCRIPTION
The lights of a trailer (e .g ., camping car) can be supplied with power through this connector.
I F1
(2) (3)
(4) (5) (6)
B6H1305A
(1) Battery +B (4) Turn signal LH

(2) Turn signal RH (5) Taillight
(3) Stop light (6) Ground
EI-3
AUDIO SYSTEM
Entertainment System
1 . Audio System
A . 1'1C~fy+M1pT1AA1
M. L/ W Rlr 1 IV114
Employed as the 2001 Legacy's audio system is a MclntoshT"' system which consists of a head
unit, a speaker amplifier, two tweeters, four mid-range speakers, and a woofer. The speaker ampli-
fier is located below the front passenger's seat and the woofer at the right rear quarter trim .
The output power handled by each of the four channels is 24W and that handled by the woofer
is 60W. The total harmonic distortion of the system is as low as 0 .05% which is comparable to that
of high-class home-use audio systems .
The front panel with the traditional MclntoshT"^ logo distinguishes the new system from the conven-
tional systems .
_----
DISC IN
FM-~
ON-OFF ~~ AM Ip p7~ ~ ; ; " "";$TDISC !I DISC Il TAPE
D `-'' Iii F'i
..
F I F'I
.. ...
,
....~
°""1 L"". SCAN I.q
. . ..' 7.... . ...: RPTCH :..
~ ~.
OFADOVOLUME pull BAL -- OTUNEOSCAN /TRACK
~_ Dllll~UU~I~Q~lltl FB ff
IIIII IIII'~ O WEATHER BAND RECEIVER DSO II e I I IIII)

TUNED FOR LEGACY
I) CI
G O O O -
BASS ` TREBLE ~ O O pPT W.8 II I~
4 5 6~
i ~ ~ ~~ l ~~~ Ii
B NR PROD
3 REW PLAY FF ~
~
B6H1516
Speaker amplifier
B6H1517A B6H1518A
Speakers
Type Diameter Number
Front tweeter 20 mm (0 .8 in) ~ 2
Front mid-range speaker 160 mm (6 .3 in) 2

Rear mid-range speaker 160 mm (6 .3 in) 2
Woofer (oval shaped) 152 mm (6 in) x 229 mm (9 in) 1
McIntosh : McIntosh is the registered trademark of McIntosh Laboratory, Inc.
ET-2
GENERAL
Exhaust
1 . General
The exhaust system consists of front exhaust pipes, catalytic converters, a center exhaust pipe,
a rear exhaust pipe and a muffler. The front catalytic converter is located immediately behind the
front exhaust pipe, and the rear catalytic converter is incorporated in the center exhaust pipe .
The exhaust system features an improved sound suppression design ; the two branches of the
front exhaust pipe join at a point almost equal in distance from the engine's exhaust ports and the
rear exhaust pipe has resonance chambers in addition to a large capacity muffler.
.ral ~
(5) (6) (7)
(10)
B2H3426A
(1) Front exhaust pipe RH (6) Rear catalytic convener
(2) Front exhaust pipe LH (7) Resonance chamber
(3) Front catalytic converter (8) Rear exhaust pipe
(4) Front oxygen (A/F) sensor (9) Muffler
(5) Center exhaust pipe (10) Rear oxygen sensor
EX-2
GENERAL
Exhaust
1 . General
" The exhaust system consists of a front exhaust pipe assembly, a rear exhaust pipe with two reso-
nance chambers, and a variable-flow muffler. The front exhaust pipe assembly consists of right
and left exhaust pipes each incorporating a front catalytic converter, and a rear catalytic converter
that is located at the joint of the two pipes .
. . ,r.
(10)
(6)
B2H3903A
(1) Front oxygen (A/F) sensor RH (7) Rear catalytic converter
(2) Front oxygen (A/F) sensor LH (8) Rear oxygen sensor
(3) Front exhaust pipe RH (9) Resonance chamber
(4) Front exhaust pipe LH (10) Rear exhaust pipe
(5) Front catalytic converter RH (11) Muffler
(6) Front catalytic converter LH
" The variable-flow muffler has a valve which opens when the exhaust pressure increases . This
helps realize low exhaust noise and high engine output simultaneously.
-1~
11,oo A
B2H4425A
(1) Low engine speed

(2) High engine speed
EX-2
FRONT SUSPENSION
Front Suspension
1 . Front Suspension
A' OUTLINE
The front suspension is a strut-type independent suspension, with cylindrical double-acting, oil-
filled dampers and coil springs. The top of each strut assembly is attached to the body through
a rubber cushion . Used in combination with other rubber cushions, this rubber cushion effectively
insulate vibration and shock and thus improves ride comfort . This type also maintains a wide dis-
tance between the upper and lower supporting points and makes adjustment of the caster unnec-
essary.
The transverse link is an "L" shaped arm design to increase steering stability and reduce road
noise. The transverse link has a maintenance-free ball joint fitted by a castle nut at its outer end .
The front of the link's inner end is fitted to the front crossmember through a rubber cushion and
the rear of the inner end is bolted to the vehicle body through a fluid-filled bushing .
The front crossmember is bolted to the vehicle body.
The stabilizer is attached to the front crossmember through rubber cushions and its right and left
ends are connected to the stabilizer links through rubber bushings .
The lower end of the stabilizer link is connected to the transverse link through rubber bushings .
A camber angle adjustment mechanism, which uses eccentric bolts, is provided at the joint of the
damper strut and axle housing .
FS-2
FRONT SUSPENSION
Front Suspension
H4H1040B
(1) Strut mount (4) Stabilizer link

(2) Strut (5) Stabilizer
(3) Transverse link (6) Front crossmember
FS-3
GENERAL
Fuel Injection (Fuel System)
1 . General
" The 2001 Legacy's Multipoint Fuel Injection (MFI) system supplies optimum air-fuel mixture un-
der every engine operating condition through the use of the latest electronic control technology .
This system pressurizes the fuel to a constant pressure and injects it into each intake air port in
the cylinder head . The injection quantity of fuel is controlled by an intermittent injection system
where an electro-magnetic injection valve or injector opens for a short period that is precisely con-
trolled depending on the quantity of air appropriate for each condition of operation . In actual con-
trol, an optimum fuel injection quantity is achieved by varying the duration of an electric pulse ap-
plied to the injector. This way of control enables simple, yet highly precise metering of the fuel .
" The engine control module (ECM) that controls the fuel injection system corrects the fuel injec-
tion amount depending on the vehicle speed, throttle opening, coolant temperature and other ve-
hicle-operation-related information . The ECM receives the information in the form of electric sig-
nals from the corresponding sensors and switches .
The MFI system also has the following features :
" Reduced exhaust emissions
" Reduced fuel consumption
" Increased engine output
" Quick response to accelerator and brake pedal operation
" Superior startability and warm-up performance in cold weather due to corrective controls made
according to coolant and intake air temperatures
FU-2
AIR LINE (MT VEHICLES)
2 . Air Line (MT Vehicles)

A: GENERAL
The air filtered by the air cleaner enters the throttle body where it is regulated in the volume by the
throttle valve and then enters the intake manifold . It is then distributed to each cylinder where the
air is mixed with fuel injected by the injector. During idling operation, air flows into the cylinder
through the idle air control solenoid valve, bypassing the throttle valve . This enables controlling
the engine idling speed properly .
B : INTAKE MANIFOLD PRESSURE SENSOR

" The intake manifold pressure sensor is attached to the top of the throttle body, and continuously
sends to the engine control module (ECM) voltage signals that are proportional to intake manifold
absolute pressures . The ECM controls the fuel injection and ignition timing based on the intake
manifold absolute pressure signals in addition to other signals from many sensors and other con-
trol modules .
O~ Connector
Terminal
o m
o. o Absolute pressure
B2H1966A
C: THROTTLE BODY
In response to operation of the accelerator pedal, the throttle valve in the throttle body opens/
closes to regulate the volume of the air drawn into the combustion chamber.
During idling, the throttle valve is almost fully closed and the volume of air passing through the
throttle body is less than that passing through the idle air control solenoid valve .
More than half of the air necessary for idling is supplied to the intake manifold via the idle air control
solenoid valve which controls properly the engine idling speed, so the idling speed needs not be
adjusted .
FU-3
D : THROTTLE POSITION SENSOR

" The throttle position sensor is mounted in the throttle bodv and linked to the throttle valve .
" The throttle position sensor sends the ECM voltage signal corresponding to the opening of the
throttle valve . When the sensor's output voltage exceeds a predetermined level, the ECM inter-
prets it as complete closure of the throttle valve . When the output voltage is at another predeter-
mined level, the ECM recognizes that the throttle valve is at a wide open position . Since the output
characteristics of the sensor change over years, the ECM is provided with a learning function to
be able to interpret signals into throttle valve angles always correctly.
Wave washer
connector
Return spring
Terminal
Terminal
B2H1967A
E : IDLE AIR CONTROL SOLENOID VALVE

" The idle air control solenoid valve is located in the throttle body and regulates the amount of in-
take air that flows bypassing the throttle valve into the intake manifold during engine idling . It is
activated by a signal from the ECM in order to maintain the engine idling speed at a target speed .
" The idle air control solenoid valve is a solenoid-actuated rotary valve consisting of a coil, rotary
valve, spring and housing . The housing is an integral part of the throttle body and provided with
a bypass air port whose opening area is changed by the rotary valve .
r4
Connector
Air outlet pipe Terminal
Air outlet port
B2H1968B
FU-4
F : INTAKE AIR TEMPERATURE SENSOR

" The intake air temperature sensor is located in the air cleaner case and detects the temperature
or` the intake air introduced through the air intake duct. The ECM uses the resistance signal from
the sensor to correct the fuel injection amount.
C
U
C
N
.N
Intake air temperature (°C)
B2H1428
FU-5
AIR LINE (AT VEHICLES)
3 . Air Line (AT Vehicles)

__
A .-GENERAL
air is mixed with fuel injected by the injector. During idling operation, air flows into the cylinder
the engine idling speed properly.
B : INTAKE MANIFOLD PRESSURE AND AIR TEMPERATURE SENSORS

" The intake manifold pressure sensor and the intake air temperature sensor are integrated into
a single unit. The unit is mounted on the intake manifold and measures the absolute air pressure
in the intake manifold as well as the temperature of the intake air.
The measured pressure and temperature are converted into electrical signals and sent to the
ECM . The ECM uses these signals to control injection and ignition timing as well as the fuel injec-
tion amount.
H2H2825A
FU-6
C : ATMOSPHERIC PRESSURE SENSOR

The atmospheric pressure sensor converts pressure values into electric signals, and sends the
signals to the ECIVI .
H2H1869B
(1) Sensor unit (6) Terminal

(2) O-ring (7) Inner lead
(3) Case (8) Resin
(4) Pipe (9) Metal lid
(5) Through capacity
D: THROTTLE BODY
In response to operation of the accelerator pedal, the throttle valve in the throttle body opens/
adjusted .
FU-7
E : THROTTLE POSITION SENSOR

" The throttle position sensor is mounted in the throttle body and linked to the throttle valve .
throttle valve . When the sensor's output voltage exceeds a predetermined level, the ECM inter-
prets it as complete closure of the throttle valve. When the output voltage is at another predeter-
Lever
Terminal
Lever
B2H2004A
FU-8
F : IDLE AIR CONTROL SOLENOID VALVE

" The idle air control solenoid valve is located in the throttle body and regulates the amount of in-
" The idle air control solenoid valve is a stepping motor type solenoid-actuated valve which con-
sists of coils, a shaft, a permanent magnet, a spring and a housing . The housing is an integral part
of the throttle body.
" The stepping motor consists of two paired coils, the coils of each pair being arranged face to
face with a shaft in between .
" The shaft has a screw at the end around which the permanent magnets are arranged .
" As current flows in the form of pulses through the paired coils sequentially while alternating the
polarity, the N and S poles of the permanent magnets around the shaft are repelled by the same
poles of the magnetism generated by the coils . This causes a nut externally fixed to the magnets
and internally engaging with the screw of the shaft to turn .
The shaft then goes upward or downward .
" This upward and downward motions of the shaft open or close the valve port, adjusting the
amount of bypass air.
Connector
oil
Permanent
magnet
ng
Shat
B2H2005A
FU-9
G : AIR ASSIST INJECTOR SOLENOID VALVE

The air assist injector solenoid valve is located in the piping between the throttle body and the in-
jector and secured to the intake manifold .
This solenoid valve is opened or closed by the signals from the ECM, adjusting the flow rate of air
supplied to the injector.
re
Sheet
;onnector
N~
To injector B2H3447C
FU-10
FUEL LINE
4. Fuel Line
A: GENERAL
" The fuel pressurized by the fuel tank inside pump is delivered to each fuel injector by way of the
fuel pipe and fuel filter. Fuel injection pressure is regulated to an optimum level by the pressure
regulator.
" Each injector injects fuel into the intake port of the corresponding cylinder where the fuel is
mixed with air. The mixture then enters the cylinder.
Fuel injection amount and timing are regulated by the ECM .
(5)
(3
B2H3444A
(1) Fuel gauge (10) Canister (19) Fuel tank

(2) Combination meter (11) ECM (20) Vent valve
(3) Fuel injector (12) Pressure control solenoid valve (21) Shut-off valve
(4) Pressure regulator (13) Fuel tank pressure sensor (22) Drain filter
(5) Throttle body (14) Fuel temperature sensor (23) Fuel sub level sensor
(6) Intake manifold (15) Fuel level sensor
(7) Fuel filter (16) Fuel pump (a) Fuel line
(8) Purge control solenoid valve (17) Jet pump (b) Evaporation line
(9) Drain valve (18) Fuel cut valve
FU-11
FUEL LINE
B : PRESSURE REGULATOR
The pressure regulator is installed at the injector end of the fuel supply line . It has a fuel chamber
and spring chamber separated by a diaphragm . Fuel chamber is connected to the fuel supply
line and the spring chamber is connected to the intake manifold . Fuel chamber also has a relief
valve connected to the fuel return line through which fuel returns to the fuel tank. When the intake
manifold vacuum increases, the diaphragm is pulled and the relief valve opens to decrease the
fuel supply line pressure (or fuel injection pressure) . When the intake manifold vacuum decreases,
the diaphragm is pushed by the spring to increase the fuel supply line pressure . Thus, the differ-
ence between the fuel injection pressure and the intake manifold vacuum is kept at a constant level
of 294 kPa (3 .00 kg/cm2, 43.0 psi) for MT vehicles or 299.1 kPa (3 .05 kg/cm2, 43.4 psi) for AT ve-
hicles to precisely control the amount of injected fuel .
To intake manifold
'-' Fuel IN
~ Fuel
-- ~'I OUT
Diaphragm S2H0623B
FU-12
FUEL LINE
C : FUEL INJECTORS
" The MFI system employs top feed type fuel injectors with an air assist feature.
" Each injector is installed in the fuel pipe in such a way that the injector is cooled by fuel .
" The features of this type of fuel injector are as follows :
1) High heat resistance
2) Low driving noise
3) Easy to service
4) Small size
" The injector injects fuel according to the valve open signal from the ECM . The needle valve is
lifted by the solenoid which is energized on arrival of the valve open signal.
" Since the injector's nozzle hole area, the lift of valve and the fuel pressure are kept constant, the
amount of fuel injected is controlled only by varying the duration of the valve open signal from the
ECM .
" Fuel atomization is enhanced using assist air supplied from the idle air control solenoid valve
passing through the passage formed in the intake manifold at the area in which each injector is
installed . This contributes not only to higher combustion efficiency and higher output but also to
cleaner exhaust emissions .
M- 0-ring
filter
C 9
Cor
anger
Seal
-ring
B2H3517A B2H3442A
FU-13
FUEL LINE
D: FUEL TANK
The fuel tank utilizes a two-compartment design to ensure sufficient capacity without interfering
with the rear differential . It is provided with a suction jet pump (included in the fuel pump and fuel
level sensor assembly) which transfers fuel from one compartment to the other. Each compartment
has an individual fuel level sensor.
Fuel cut valve

(Maincompartment)
aIve
Fuel pump and

fuel level sense
:onnector
Fuel level sensor

(Sub-compartment)
B2H3651B
The fuel tank is located under the rear seat and secured with hold-down bands .
Cushion
Band
B2H3652A
FU-14
FUEL LINE
E : FUEL PUMP AND FUEL LEVEL SENSOR ASSEMBLY

1 . FUEL PUMP
The fuel pump consists of a motor, impeller, pump casing, pump cover, check valve and filter. It
is located in the fuel tank and combined with the fuel level sensor into a single unit. The operation
of this impeller type pump is very quiet .
From engine
(Return line)
To engine
(Delivery Ii
Fuel level Check valve
Fuel pun
Pump cow
Impeller
Impeller
B2H3653B
" When the ignition switch is turned ON, fuel pump relay is activated . Then the motor operates
to rotate the impeller.
" As the impeller rotates, fuel in a vane groove of the impeller flows along the fuel passage into
the next vane groove by centrifugal force . When fuel flows from one groove to the next, a pressure
difference occurs due to friction . This creates a pumping effect.
" The fuel pushed up by rotation of the impeller then passes through the clearance between the
armature and the magnet of the motor and is discharged through the check valve .
" When the fuel discharge pressure reaches the specified level, the relief valve opens and excess
fuel is released into the fuel tank . In this manner, the relief valve prevents an abnormal increase
in fuel pressure .
" When the engine and the fuel pump stop, spring force acts on the check valve to close the dis-
charge port, so that the fuel pressure in the fuel delivery line is retained .
FU-15
FUEL LINE
2. JET PUMP
* The jet pump utilizes the velocity of fuel returning from the engine to produce negative pressure
in it.
" Using the pumping effect produced by the negative pressure, the jet pump transfers fuel from
the sub-compartment to the main compartment of the fuel tank .
" When the return line nozzle is clogged, the fuel sent back through the return line flows back into
the fuel tank via the relief valve .
From sub tank

compartment L L Return line
Relief valve
Silencer
Rip
pump
Nozzle
Limp
Filter
Filter
B2H3654B
FU-16
FUEL LINE
F : SUB-COMPARTMENT FUEL LEVEL SENSOR

This sensor detects the level of the fuel in the sub-compartment (the compartment in which the
fuel pumN. .S ^~^.~ located j and acts as part (?f tl-~o f, 1-1 transfer line when
h,g,n, the
~P t N~;mrn, is in, nrng,r?tin,n,
to maintain the fuel in both compartments at the same level .
To jet pump
pat
B2H2912A
G : FUEL FILTER
The fuel filter located in the engine compartment is a pressure-withstanding, cartridge type . It has
a filter element in a metal case . The fuel entering the filter flows from the perimeter of the element
to the center of the filter and goes out from there .
OUT
IN
G2H0059
FU-17
SENSORS AND SWITCHES
5 . Sensors and Switches

A : FRONT OXYGEN (A/F) SENSOR
" The front oxygen sensor uses zirconium oxide (Zr02) which is a solid electrolyte, at portions ex-
posed to exhaust gas .
" The zirconium oxide has the property of generating electromotive force when its both sides are
exposed to oxygen ions of different concentration and the magnitude of this electromotive force
depends on how much the difference is .
" The front oxygen sensor detects the amount of oxygen in exhaust gases by making use of this
property of the zirconium oxide material .
" The zirconium oxide material is formed into a closed end tube and its external surface is ex-
posed to exhaust gases with smaller oxygen ion concentration, whereas its internal surface is ex-
posed to atmospheric air. The external surface has a porous platinum coating . The sensor housing
is grounded to the exhaust pipe and the inside is connected to the ECM through the harness to
be able to use the current output from the sensor.
" The sensor incorporates a ceramic heater to improve its performance at low temperatures
MT VEHICLES
Gasket Ceramic heater
.7C118U1 1 IUU81f I(,]

Protection tube
AT VEHICLES
Sensor element Sensor housing
Protection tube
Gasket
B2H3443A
FU-18
" When rich air-fuel mixture is burnt in the cylinder, the oxygen in the exhaust gases is almost com-
pletely used in the catalytic reaction by the platinum coating on the external surface of the zirconia
tube . This results in a very large difference ;n the oxygen ion concentration between the inside and
outside of the tube, and the electromotive force generated is large.
" When a lean air-fuel mixture is burnt in the cylinder, relatively large amount of oxygen remains
in the exhaust gases even after the catalytic action, and this results in a small difference in the oxy-
gen ion concentration between the tube's internal and external surfaces . The electromotive force
in this case is very small .
" The difference in oxygen concentration changes drastically in the vicinity of the stoichiometric
air-fuel ratio, and hence the change in the electromotive force is also large. By using this informa-
tion, the ECM can determine the air-fuel ratio of the supplied mixture easily. The front oxygen sen-
sor does not generate much electromotive force when the temperature is low. The output charac-
teristics of the sensor stabilize at a temperature of approximately 700°C (1,292°F) .
ZrO2
Atmospheric air
. "." V V f Q
E
c
.2-
0
J
Exhaust Exhaust
gases gases
_ ~'
Lean f Air-fuel ratio "- Rich
Ceramic heater
B2H2006B
FU-19
B: REAR OXYGEN SENSOR

" The rear oxygen sensor is used to sense oxygen concentration in the exhaust gas . If the air-fuel
ratio is leaner than the stoichiometric ratio in the mixture (i .e ., excessive amount of air), the exhaust
gas contains more oxygen. To the contrary, if the fuel ratio is richer than the stoichiometric ratio,
the exhaust gas contains almost no oxygen.
" Detecting the oxygen concentration in exhaust gas using the oxygen sensor makes it possible
to determine whether the air-fuel ratio is leaner or richer than the stoichiometry.
" The rear oxygen sensor has a zirconia tube (ceramic) which generates voltage if there is a differ-
ence in oxygen ion concentration between the inside and outside of the tube. Platinum is coated
on the inside and outside of the zirconia tube as a catalysis and electrode material . The sensor
housing is grounded to the exhaust pipe and the inside is connected to the ECM through the har-
ness.
" A ceramic heater is employed to improve performance at low temperatures.
MT VEHICLES
B2H1993B
AT VEHICLES
Protection tube
uasKet Harness
Sensor housing
B2H3810A
FU-20
tube. This results in a very large difference in the oxvqen ion concentration between the inside and
outside of the tube, and the electromotive force generated is large .
in this case is very small .
air-fuel ratio, and hence the change in the electromotive force is also large . By using this informa-
tion, the ECM can determine the air-fuel ratio of the supplied mixture easily. The rear oxygen sensor
does not generate much electromotive force when the temperature is low. The output characteris-
tics of the sensor stabilize at a temperature of approximately 300 to 400°C (572 to 752°F) .
Large I S~toic~ etric mixture ratio

Electromotive i
force (Rich signal) ' To be judged
v~ as rich
o a
o } Comparison
~ I voltage
- - -
o ~ ~
U m fC
W oo To be judged
Exhaust Exhaust as lean
gases i (Lean signal)
gases
Small ',
Lean'-- Air-fuel ratio- Rich
G2H0038B
FU-21
C : ENGINE COOLANT TEMPERATURE SENSOR

" The engine coolant temperature sensor is located on the engine coolant pipe . The sensor uses
a inermistor whose resistance changes inversely with temperature . Resistance signals as engine
coolant temperature information are transmitted to the ECM to make fuel injection, ignition timing,
purge control solenoid valve and other controls .
Retainer
0
2.5 35 kS2
Temp .°C (°F)

-20 0 20 40 60 80
(-4) (32) (68)(104)(140)(176)
174JRCl
Connector
B2H3452A
FU-22
D: CRANKSHAFT POSITION SENSOR

1 . MT VEHICLES
" The crankshaft position sensor is installed on the oil pump which is located in the front center
portion of the cylinder block. The sensor generates a pulse when one of the teeth on the perimeter
of the crankshaft sprocket (rotating together with the crankshaft) passes in front of it. The ECM de-
termines the crankshaft angular position by counting the number of pulses.
" The crankshaft position sensor is a molded type which consists of a magnet, core, coil, terminals
and other components as illustrated below.
1321-1040713
(1) Terminal (4) Coil

(2) Yoke core (5) Core
(3) Magnet (6) Cover
" As the crankshaft rotates, each tooth aligns with the crankshaft position sensor. At that time, the
magnetic flux in the sensor's coil changes since the air gap between the sensor pickup and the
sprocket changes . This change in magnetic flux induces a voltage pulse in the sensor and the
pulse is transmitted to the ECM .
Crankshaft
position
sensor
4~1
/O NDO\
\O O/
Crankshaft half rotation
Crankshaft sprocket
1321-13811A
FU-23
2. AT VEHICLES
. T .h.P c .ra_.nks .haft position sensor is installed on the oil pump which is located in the front center
portion of the cylinder block . The sensor generates a pulse when one of the teeth on the perimeter
of the crankshaft sprocket (rotating together with the crankshaft) passes in front of it. The ECM de-
termines the crankshaft angular position by counting the number of pulses.
" The crankshaft position sensor is-a molded type which consists of a magnet, core, coil, terminals
and other components as illustrated below.
(1)
(3)
(4)
(5) (6)
B2H0407B
(1) Terminal (4) Coil

(2) Yoke core (5) Core
(3) Magnet (6) Cover
" As the crankshaft rotates, each tooth aligns with the crankshaft position sensor. At that time, the
magnetic flux in the sensor's coil changes since the air gap between the sensor pickup and the
sprocket changes . This change in magnetic flux induces a voltage pulse in the sensor and the
pulse is transmitted to the ECM .
Crankshaft
position
sensor
/O O\
\O D/
sprocket
B2H1995A
FU-24
E: CAMSHAFT POSITION SENSOR

1 . MT VEHICLES
" The camshaft position sensor is located on the left-hand camshaft support . It detects the com-
bustion cylinder at any given moment .
" The sensor generates a pulse when one of the bosses on the back of the left-hand camshaft
drive sprocket passes in front of the sensor. The ECM determines the camshaft angular position
by counting the number of pulses.
Internal construction and the basic operating principle of the camshaft position sensor are similar
to those of the crankshaft position sensor. Two bosses are provided on the sprocket as shown be-
low.
Camshaft
Boss Air gap position . Cylinder identification signal
00 Bos
sensor
0 -~
Camshaft one rotation
(Crankshaft two rotations)
Camshaft sprocket
B2H1996B
2. AT VEHICLES
" The camshaft position sensor is located on the left-hand camshaft support . It detects the com-
bustion cylinder at any given moment .
" The sensor generates a pulse when one of the bosses on the back of the left-hand camshaft
drive sprocket passes in front of the sensor. The ECM determines the camshaft angular position
by counting the number of pulses .
Internal construction and the basic operating principle of the camshaft position sensor are similar
to those of the crankshaft position sensor. A total of seven bosses are arranged at equally spaced
four locations (one each at two locations, two at one location, and three at one location) of the
sprocket as shown below.
Boss
Camshaft
position " Cylinder identification signal
sensor

Camshaft sprocket
B2H3812B
FU-25
F: KNOCK SENSOR
" The knock sensor is installed on the cylinder block, and senses knocking that occurs in the en-
gine .
" The sensor is a piezo-electric type which converts vibration resulting from knocking into electric
signals.
" In addition to a piezo-electric element . the sensor has a weight and case as its components .
If knocking occurs in the engine, the weight in the case moves causing the piezo-electric element
to generate a voltage .
" The knock sensor harness is connected to the bulkhead harness .
To knock sensor
harness
V
B2H1998C
FU-26
G : VEHICLE SPEED SENSOR

1 . MT VEHICLES
" The vehicle speed sensor is mounted on the transmission .
" The vehicle speed sensor generates a 4-pulse signal for every rotation of the front differential
and send it to the ECM and the combination meter.
Combination meter
I 1 OI 101 1 II00IVI I B2H2458B
FU-27
2. AT VEHICLES
and send it to the transmission control module (TCM) . The signal sent to the TCM is converted
there into a 4-pulse signal, and then sent to the ECM and the combination meter.
Combination meter
B2H2459C
FU-28
CONTROL SYSTEM
Fuel Inject ion (Fuel System)
6 . Control System
A : GENERAL
The ECM receives signals from various sensors, switches, and other control modules. Using these
signals, it determines the engine operating conditions and if necessary, emits signals to one or
more systems to control them for optimum operation .
Major control items of the ECM are as follow :
" Fuel injection control
" Ignition system control
" Idle air control
" Canister purge control*
" Radiator fan control
" Fuel pump control
" Air conditioner cut control
" On-board diagnosis function
* : Canister purge control is described under "EC (H4) - Emission Control (Aux . Emission Control
Devices) Evaporative Emission Control System" .
FU-29
CONTROL SYSTEM
B: INPUT AND OUTPUT SIGNALS

1 . MT VEHICLES
Signal Unit Function
Intake manifold pressure sensor Detects the amount of intake air (Measures the absolute pressure).
Intake air temperature sensor Detects the temperature of intake air.
Throttle position sensor Detects the throttle valve position .
Detects the density of oxygen in exhaust gases at the upstream of
Front oxygen (A/F) sensor
the front catalytic converter.
Detects the density of oxygen in exhaust gases at the downstream
Rear oxygen sensor
of the front catalytic converter.
Crankshaft position sensor Detects the crankshaft angular position .
Camshaft position sensor Detects the combustion cylinder .
Engine coolant temperature sensor I Detects the engine coolant temperature .
Vehicle speed sensor I Detects the vehicle speed.
Input signals Ignition switch Detects operation of the ignition switch .
Starter switch Detects the condition of engine cranking .
Neutral position switch (MT) Detects that the gear is in neutral .
Heater circuit of front and rear oxy- Detects the abnormality in heater circuit of front and rear oxygen
gen sensor sensor .
A/C switch Detects ON-OFF operation of the A/C switch .
Fuel temperature sensor Detects the temperature of the fuel in the fuel tank.
Fuel level sensor Detects the level of the fuel in the fuel tank .
Fuel tank pressure sensor Detects the evaporation gas pressure in the fuel tank .
Small light switch Detects ON-OFF operation of the small light switch .
Blower fan switch Detects ON-OFF operation of the blower fan switch .
Rear defogger switch Detects ON-OFF operation of the rear defogger switch .
Fuel Injector Activates an injector.
Ignition signal Turns the primary ignition current ON or OFF.
Fuel pump relay Turns the fuel pump relay ON or OFF.
A/C control relay Turns the A/C control relay ON or OFF.
Radiator fan control relay Turns the radiator fan control relay ON or OFF.
Adjusts the amount of air flowing through the bypass line in the
Idle air control solenoid valve throttle body.
Output signals
Malfunction indicator lamp I Indicates existence of abnormality .
Purge control solenoid valve I Controls purge of evaporative gas absorbed by the canister.
Power supply Controls ON/OFF of the main power supply relay.
Pressure control solenoid valve I Controls evaporation gas pressure in the fuel tank .
Closes the evaporation line between the fuel tank and canister to
Drain valve detect leakage of evaporation gases .
FU-30
CONTROL SYSTEM
2. AT VEHICLES
Signal Unit I Function
Intake air temperature and pressure Detects the temperature of intake and amount of intake air (Mea-
sensor I sures the absolute pressure) .
Atmospheric pressure sensor I Detects the amount of intake air (Measure the atmospheric pres-
sure).
Front oxygen (A/F) sensor Detects the density of oxygen in exhaust gases at the upstream of
Rear oxygen sensor Detects the density of oxygen in exhaust gases at the downstream
of the front catalytic converter.
Camshaft position sensor Detects the combustion cylinder.
Engine coolant temperature sensor Detects the engine coolant temperature .
Vehicle speed sensor Detects the vehicle speed.
Park/Neutral position switch Detects shift positions.
Torque control signal Controls engine torque .
Heater circuit of front and rear oxy- Detects abnormality in the heater circuit of the front and rear oxygen
gen sensor I sensors.
Diagnostics of AT-ECU Detects the self-diagnostics of the AT-ECU .
A/C switch I Detects ON-OFF operation of the A/C switch .
Fuel temperature sensor I Detects the temperature of the fuel in fuel tank .
Fuel level sensor Detects the level of the fuel in fuel tank .
Fuel tank pressure sensor I Detects the evaporation gas pressure in fuel tank .
Small light switch I Detects ON-OFF operation of the small light switch .
Fuel Injector Activates an injector .
Idle air control solenoid valve Adjusts the amount of air flowing through the bypass line in the
Output signals throttle body .
Malfunction indicator lamp Indicates existence of abnormality .
Purge control solenoid valve I Controls purge of evaporative gas absorbed by the canister .
Power supply Control ON/OFF of the main power supply relay.
Pressure control solenoid valve Controls evaporation gas pressure in the fuel tank .
[Drain valve Closes the evaporation line between the fuel tank and canister to
detect leakage of evaporation gases.
FU-31
CONTROL SYSTEM
C : FUEL INJECTION CONTROL

-a T,h,g FrnA ,rPrPi~iP~ ~i~ .n.al.~f .rn.m. va .rinti, sensors and based on them ; it determines the amount
of fuel injected and the fuel injection timing . It performs the sequential fuel injection control over
the entire engine operating range except during start-up of the engine .
" The amount of fuel injected depends upon the length of time the injector stays open . The fuel
injection duration is determined according to varying operating condition of the engine . For the
purpose of achieving highly responsive and accurate fuel injection duration control, the ECM per-
forms a new feedback control that incorporates a learning feature as detailed later.
" The sequential fuel injection control is performed such that fuel is injected accurately at the time
when the maximum air intake efficiency can be achieved for each cylinder (i .e ., fuel injection is
completed just before the intake valve begins to open) .
1 . FUEL INJECTION DURATION

Fuel injection duration is basically determined as indicated below :
" During engine start-up :
The duration defined below is used .
" Duration of fuel injection during engine start-up . . . . . Determined according to the engine cool-
ant temperature detected by the engine coolant temperature sensor.
" During normal operation :
The duration is determined as follows :
Basic duration of fuel injection x Correction factors + Voltage correction time
" Basic duration of fuel injection . . . . . The basic length of time fuel is injected . This is determined
by two factors - the amount of intake air detected by the manifold pressure sensor and the en-
gine speed monitored by the crankshaft position sensor.
" Correction factors . . . . . See the next section .
" Voltage correction time . . . . . This is added to compensate for the time lag before operation of
injector that results from variation in the battery voltage .
FU-32
CONTROL SYSTEM
2. CORRECTION FACTORS
The following factors are used to correct the basic duration of fuel injection in order to make the
air-fuel ratio meet the requirements of varying engine operating conditions :
" Air-fuel ratio feedback factor :
This factor is used to correct the basic duration of fuel injection in relation to the actual engine
speed . (See the next section for more detail .)
" Start increment factor:
This factor is used to increase the fuel injection duration only while the engine is being cranked
to improve its startability.
" Coolant-temperature-dependent increment factor:
This factor is used to increase the fuel injection duration depending on engine coolant temperature
signals to facilitate cold starting . The lower the coolant temperature, the greater the increment.
" After-start increment factor :
" This factor is used to increase the fuel injection duration for a certain period immediately after
start of the engine to stabilize engine operation .
" The increment depends on the coolant temperature at the start of the engine .
" Wide-open-throttle increment factor:
This factor is used to increase the fuel injection duration depending on the relationship between
the throttle position sensor signal and manifold pressure sensor signal .
" Acceleration increment factor :
This factor is used to increase the fuel injection duration to compensate for a time lag between air
flow measurement and fuel injection control for better engine response to driver's pedal operation
during acceleration .
FU-33
CONTROL SYSTEM
3. AIR-FUEL RATIO FEEDBACK FACTOR

The ECM creates this factor utilizing the front oxygen sensor signal . When the signal voltage is low,
the air-fuel ratio is richer than the stoichiometric ratio . The ECM then makes the fuel injection dura-
tion shorter by modifying the factor. When the voltage is high showing that the mixture is lean, the
ECM modifies the factor to make the injection duration longer. In this way, the air-fuel ratio is main-
tained at a level close to the stoichiometric ratio at which the three-way catalyst acts most effective-
ly.
Injection duration increment signal

---~ Injection duration decrement signal
(4) (5) (2)

--------
N
ECM Inj
ect duration increases I
Injection duration decreases .- ECM 1
-F
` (4)
i ~ ~ i~ ~ ~~J -a a.
I p (5)
(3) ~, r I
i Lean signal ' T o. o
(3) ~ -
Rich signal (2)~\ i
B2H0989C
(1) Front catalyst (4) Fuel injector

(2) Exhaust gas (5) Combustion chamber
(3) Front oxygen (A/F) sensor
4. LEARNING FEATURE
The 2001 Legacy's air-fuel ratio feedback control includes a learning feature which contributes to
more accurate and responsive control .
" In the air-fuel ratio feedback control, the ECM calculates the necessary amount of correction
based on data from the oxygen sensor and adds the result to the basic duration (which is stored
in the ECM's memory for each condition defined by the engine speed and various loads .)
" Without a learning feature, the ECM carries out the above-mentioned process every time . This
means that if the amount of necessary correction is large, the air-fuel ratio feedback control be-
comes less responsive and less accurate .
" The learning feature enables the ECM to store the amount of correction into memory and add
it to the basic fuel injection duration to create a new reference fuel injection duration . Using the
reference duration as the basic duration for the injection a few times later, the ECM can reduce
the amount of correction and thus make its feedback control more accurate and responsive to
changes in the air-fuel ratio due to difference in driving condition and sensor/actuator characteris-
tics that may result from unit-to-unit variation or aging over time .
FU-34
CONTROL SYSTEM
D : IGNITION SYSTEM CONTROL

1 . MT VEHICLES
" The ECM determines operating condition of the engine based on signals from the pressure sen-
sor, engine coolant temperature sensor, intake air temperature sensor, crankshaft position sensor
and other sources . It then selects the ignition timing most appropriate for the condition thus deter-
mined from those stored in its memory and outputs at that timing a primary current OFF signal to
the ignitor to initiate ignition.
" This control uses a quick-to-response learning feature by which the data stored in the ECM
memory is processed in comparison with information from various sensors and switches .
" Thus, the ECM can always perform optimum ignition timing taking into account the output, fuel
consumption, exhaust gas, and other factors for every engine operating condition .
" Ignition control during start-up
Engine speed fluctuates during start of the engine, so the ECM cannot control the ignition timing .
During that period, the ignition timing is fixed at 10° BTDC by using the 10° signal from the crank-
shaft position sensor.
I _ I Spark
Crankshaft position sensor ~--~I I
i ~~ plug #1
Camshaft position sensor
Engine coolant temperature sensor

Spark
plug #2
Intake manifold pressure sensor
ECM Ignition coil and

Intake air temperature sensor E--~I ignitorassembly
Knock sensor f--~I Spark

-~ r--~ plug #3
Throttle position sensor
Neutral position switch ~-

I
Spark
A/C switch plug #4
B2H3448C
FU-35
CONTROL SYSTEM
" The ECM identifies cylinders at TDC and determines ignition timing as follows :
" Within the range (A), the crank angle signal is input every 10° rotation of the crankshaft .
" The ECM discriminates a TDC cylinder group from the other by detecting the ranges (B) and
(C) where no signals are input.
" The ECM judges that the No. 1 and No. 2 cylinders are at TDC when it detects the range (B),
and that the No . 3 and No. 4 cylinders are at TDC when it detects the range (C) .
#4 #1 #3 #2 #4
Cylinder number I 1 1 1 1
(TDC)
I (A) (B) ~ (?) (C) ~ (?) (B) ~ (A) (C)
Crank angle pulse
1,2 3,4 2,1 4, 3

Ignition timing
at starting
> > 2 l~I 3, 4 4, 3

Ignition timing / I l I l I
at normal condition
Burning cylinder I #4 #1 #3 #2
B2H2007A
FU-36
CONTROL SYSTEM
2. AT VEHICLES
sor, enyinfz-~ Coolant temperature sensor, Intake air temperature sensor, crankshaft position sensor
the ignitor to initiate ignition .
Crankshaft position sensor Spark

plug #1
Engine coolant temperature

sensor
Spark
Atmospheric pressure sensor plug #2
Ignition
Intake air temperature and coil
ECM and
pressure sensor
ignitor
assembly
Knock sensor
Spark
plug #3
*Neutral position switch (MT)

-Park/Neutral position switch (AT)
Spark
A/C switch plug #4
B2H3449C
FU-37
CONTROL SYSTEM
" Ignition control after start of engine

Between the 97° and 65° crank angle signal, the ECM measures the engine speed, and by using
Lf 115 UcllCl :it decides the dwell set timing and IIJ, g to
IILIVI I 111 I III Ilk, dlCVlUII Ilk lU LI It-, Gi ~J.iriG ion uiliGii .
#4 #1 #3 #2 #4
Cylinder number -I- I I I I
97° 65° 10° 97° 65° 10° 97° 65° 10° 97° 65° 10°
Crank angle
pulse (BTDC)
27 .5°
20° 5° 1 r 50o 20° 201501 20°
Cam angle
pulse (ATDC)
(1),2 j (3),4 (2),1 (4), 3

Ignition timing
at starting
(1),2(1 ; (3), 4 ~j (2), 1 ,~ (4), 3

Ignition timing at r i r i
normal condition
Dwell set
Ignite
1
Burning cylinder #4 #1 #3 #2
B2H0410A
FU-38
CONTROL SYSTEM
E: IDLE AIR CONTROL

" The ECM activates the idle air control solenoid valve to control the bypass air flowing through
al., .. 1., . L I,. .. aL .~ .-.++I ,. L. .. .J . .J ,- . .- ..J~ !,I" Fv +h .~ r,linhnf+ r,i,ni+ii,r nnric~r~r
if IC [J~/FJcl55 passage III LI IC U IIUILIC lJVUy UCf.JCI IUIIIl~~ . VII Jll~j
. ICiIJ II VI I LI IC; ViCu inJi iai~ ~.JVJILIVI I OK-'I IJVi~
engine coolant temperature sensor, pressure sensor and A/C switch so that the proper idle speed
for each engine load is achieved .
" The idle air control solenoid valve uses a duty-ratio-controlled solenoid which can continuously
vary the opening area of the rotary valve . As the ECM increases the duty ratio, opening of the rotary
valve increases so that the bypass airflow increases, and the engine idling speed becomes higher
as a result .
e The bypass air control is necessary for :
" Increasing idling speed when the air conditioning system and/or electrical loads are turned
on .
" Increasing idling speed during early stage of warm up period .
" Obtaining dashpot function when the throttle valve is quickly closed .
" Prevention of engine speed variation during idling .
-intake mainfold pressure sensor (MT)

-intake air temperature and
pressure sensor (AT)
ECM
Vehicle speed sensor
Ignition switch
Idle air control solenoid valve

I A/C switch I
" Neutral position switch (MT)

" Park/Neutral position switch (AT)
B2H3450B
F : CANISTER PURGE CONTROL

" The ECM receives signals from the engine coolant temperature sensor, vehicle speed sensor
and crankshaft position sensor to control the purge control solenoid .
Purge of fuel from the canister takes place during operation of the vehicle except under certain
conditions such as during idling operation .
e The purge line is connected to the throttle chamber so that fuel gas from the canister is purged
according to flow of intake air.
FU-39
ON-BOARD DIAGNOSIS SYSTEM
7. On-board Diagnosis System

A: GENERAL
" The on-board diagnosis system detects and indicates a fault by generating a code correspond-
ing to each fault location . The malfunction indicator lamp (CHECK ENGINE light) on the combina-
tion meter indicates occurrence of a fault or abnormality.
" When the malfunction indicator lamp comes on as a result of detection of a fault by the ECM,
the corresponding diagnostic trouble code (DTC) and freeze frame engine condition are stored
in the ECM .
" On the OBD-II conformable car, it is necessary to connect the Subaru Select Monitor (SSM) or
General Scan Tool (GST) to the data link connector in order to check the DTC .
" The SSM and GST can read and erase DTCs . They can also read freeze frame data in addition
to other pieces of engine data .
" If there is a failure involving sensors which may affect drive control of the vehicle, the fail-safe
function ensures minimum level of driveability .
B : FAIL-SAFE FUNCTION
For a sensor or switch which has been judged faulty in the on-board diagnosis, the ECM, if ap-
propriate, generates an associated pseudo signal to keep the vehicle operational . (The control
becomes degraded .)
FU-40
GENERAL
1 . General
" The 2001 Legacy's Multipoint Fuel Injection (MFI) system supplies optimum air-fuel mixture un-
der every engine operating condition through the use of the latest electronic control technology.
This system pressurizes the fuel to a constant pressure and injects it into each intake air port in
the cylinder head . The injection quantity of fuel is controlled by an intermittent injection system
where an electro-magnetic injection valve or injector opens for a short period that is precisely con-
trolled depending on the quantity of air appropriate for each condition of operation . In actual con-
trol, an optimum fuel injection quantity is achieved by varying the duration of an electric pulse ap-
plied to the injector. This way of control enables simple, yet highly precise metering of the fuel .
" The engine control module (ECM) that controls the fuel injection system corrects the fuel injec-
tion amount depending on the vehicle speed, throttle opening, coolant temperature and other ve-
hicle-operation-related information . The ECM receives the information in the form of electric sig-
nals from the corresponding sensors and switches .
The MFI system also has the following features :
" Reduced exhaust emissions
" Reduced fuel consumption
" Increased engine output
" Quick response to accelerator and brake pedal operation
" Superior startability and warm-up performance in cold weather due to corrective controls made
according to coolant and intake air temperatures
FU-2
AIR LINE
2. Air Line
A: GENERAL
air is mixed with fuel injected by the injector . During idling operation, air flows into the cylinder
the engine idling speed properly .
B : INTAKE MANIFOLD PRESSURE SENSOR

" The intake manifold pressure sensor is attached to the top of the throttle body, and continuously
sends to the engine control module (ECM) voltage signals that are proportional to intake manifold
absolute pressures . The ECM controls the fuel injection and ignition timing based on the intake
manifold absolute pressure signals in addition to other signals from many sensors and other con-
trol modules.
0
a
0
Absolute pressure
B2H3905A
C : THROTTLE BODY
fn response to operation of the accelerator pedal, the throttle valve in the throttle body opens/
adjusted .
FU-3
AIR LINE
Full Injection (Fuel System)
D : THROTTLE POSITION SENSOR

The throttle position sensor is mounted in the throttle body and linked to the throttle salve .
throttle valve. When the sensor's output voltage exceeds a predetermined level, the ECM inter-
prets it as complete closure of the throttle valve . When the output voltage is at another predeter-
0
a
O
Throttle opening
B2H3906A
E: IDLE AIR CONTROL SOLENOID VALVE

The idle air control solenoid valve is located in the throttle body and regulates the amount of in-
" The idle air control solenoid valve is a solenoid-actuated rotary valve consisting of a coil, rotary
valve, spring and housing . The housing is an integral part of the throttle body and provided with
a bypass air port whose opening area is changed by the rotary valve .
B2H3907
FU-4
AIR LINE
F : INTAKE AIR TEMPERATURE SENSOR

" The intake air temperature sensor is located in the air cleaner case and detects the temperature
of the intake air introduced through the air intake duct . The ECM uses the resistance signal from
the sensor to correct the fuel injection amount.
C
U
C
(d
.N
N
Gonneetor
Intake air temperature (°C)
B2H1428
G : INDUCTION CONTROL SYSTEM

There is a butterfly valve on the partition between the intake manifold's right bank and left bank
chambers . This valve is operated by the induction valve actuator installed on the intake manifold .
During operation of the engine, pressure waves are generated in the intake manifold . The pressure
waves have an effect of improving air intake efficiency. To make the most of this effect, the direction
of the pressure wave is changed by opening and closing the induction valve in accordance with
the engine speed so that increased engine output torque is obtained in all speed ranges .
Mid-speed range Low and high speed ranges

From air cleaner From air cleaner
i
,,-- , .
C ~ . C
Induction valve (closed) Induction valve (open)

B2H3908A
FU-5
FUEL LINE
3 . Fuel Line
e~ r1=N1=Rei
" The fuel pressurized by the fuel tank inside pump is delivered to each fuel injector by way of the
fuel pipe and fuel filter. Fuel injection pressure is regulated to an optimum level by the pressure
regulator.
" Each injector injects fuel into the intake port of the corresponding cylinder where the fuel is
mixed with air. The mixture then enters the cylinder .
Fuel injection amount and timing are regulated by the ECM .
FU-6
FUEL LINE
(2
B2H3909A
(1) Fuel gauge (10) Canister (19) Fuel tank

(2) Combination meter (11) ECM (20) Vent valve
(3) Fuel injector (12) Pressure control solenoid valve (21) Shut-off valve
(4) Pressure regulator (13) Fuel tank pressure sensor (22) Drain filter
(5) Throttle body (14) Fuel temperature sensor (23) Fuel sub level sensor
(6) Intake manifold (15) Fuel level sensor (24) Pressure damper
(7) Fuel filter (16) Fuel pump

(8) Purge control solenoid valve (17) Jet pump (a) Fuel line
(9) Drain valve (18) Fuel cut valve (b) Evaporation line
FU-7
FUEL LINE
Fuel Injection (FUel Systo?ni)
B : PRESSURE REGULATOR
The pressure regulator is installed at the iniector end of the fuel supply line . It has a fuel chamber
and spring chamber separated by a diaphragm . Fuel chamber is connected to the fuel supply
line and the spring chamber is connected to the intake manifold . Fuel chamber also has a relief
valve connected to the fuel return line through which fuel returns to the fuel tank. When the intake
manifold vacuum increases, the diaphragm is pulled and the relief valve opens to decrease the
fuel supply line pressure (or fuel injection pressure) . When the intake manifold vacuum decreases,
the diaphragm is pushed by the spring to increase the fuel supply line pressure . Thus, the differ-
ence between the fuel injection pressure and the intake manifold vacuum is kept at a constant level
of 294 kPa (3 .00 kg/cm2, 43 .0 psi) for MT vehicles or 299.1 kPa (3 .05 kg/cm2, 43 .4 psi) for AT ve-
hicles to precisely control the amount of injected fuel .
To intake manifold
'-' Fuel IN
,~ Fuel
-- ~/ OUT
Diaphragm S2H0623B
FU-8
FUEL LINE
C : FUEL INJECTORS'
" The MFI system employs top feed type fuel injectors with an air assist feature .
" Each injector is installed in the fuel pipe in such a way that the injector is cooled by fuel .
" The features of this type of fuel injector are as follows:
1) High heat resistance
2) Low driving noise
3) Easy to service
4) Small size
" The injector injects fuel according to the valve open signal from the ECM . The needle valve is
lifted by the solenoid which is energized on arrival of the valve open signal .
" Since the injector's nozzle hole area, the lift of valve and the fuel pressure are kept constant, the
amount of fuel injected is controlled only by varying the duration of the valve open signal from the
ECM .
" Fuel atomization is enhanced using assist air supplied from the idle air control solenoid valve
passing through the passage formed in the intake manifold at the area in which each injector is
installed . This contributes not only to higher combustion efficiency and higher output but also to
cleaner exhaust emissions.
Filter
~r
al
B2H3517C
FU-9
FUEL LINE
D : FUEL TANK
The fuel tank utilizes a two-compartment design to ensure sufficient capacity without interfering
with the rear differential . It is provided with a suction jet pump (included in the fuel pump and fuel
level sensor assembly) which transfers fuel from one compartment to the other. Each compartment
has an individual fuel level sensor.
Fuel cut valve

- -- -- -- (Main compartment)
ilve
Fuel pump and

fuel level sense
onnector
Fuel level sensor

(Sub-compartment)
B2H3651 B
The fuel tank is located under the rear seat and secured with hold-down bands .
Band
B2H3652A
FU-10
FUEL LINE
E: FUEL PUMP AND FUEL LEVEL SENSOR ASSEMBLY

1 . FUEL PUMP
The fuel pump consists of a motor, impeller, pump casing, pump cover, check valve and filter. It
is located in the fuel tank and combined with the fuel level sensor into a single unit. The operation
of this impeller type pump is very quiet .
From engine
(Return line)
To engine
(Delivery Iii
Fuel level Check valve

Fuel pun
Pump cow
Impeller
Impeller
B2H3653B
" When the ignition switch is turned ON, fuel pump relay is activated . Then the motor operates
to rotate the impeller.
" As the impeller rotates, fuel in a vane groove of the impeller flows along the fuel passage into
the next vane groove by centrifugal force . When fuel flows from one groove to the next, a pressure
difference occurs due to friction . This creates a pumping effect .
" The fuel pushed up by rotation of the impeller then passes through the clearance between the
armature and the magnet of the motor and is discharged through the check valve .
" When the fuel discharge pressure reaches the specified level, the relief valve opens and excess
fuel is released into the fuel tank . In this manner, the relief valve prevents an abnormal increase
in fuel pressure .
" When the engine and the fuel pump stop, spring force acts on the check valve to close the dis-
charge port, so that the fuel pressure in the fuel delivery line is retained .
FU-11
FUEL LINE
2. JET PUMP
" The jet pump utilizes the velocity of fuel returning from the engine to produce negative pressure
in it .
" Using the pumping effect produced by the negative pressure, the jet pump transfers fuel from
the sub-compartment to the main compartment of the fuel tank .
" When the return line nozzle is clogged, the fuel sent back through the return line flows back into
the fuel tank via the relief valve .
From sub tank

compartment Return line
Relief valve
Silencer
Rig
ump
Nozzle
imp
Filter
Filter
B2H3654B
FU-12
FUEL LINE
Fuel Inject io n (Fu e l Sys te m)
F: SUB-COMPARTMENT FUEL LEVEL SENSOR

this sensor detects the level of the fuel in the sub-compartment (the compartment in which the
duel pump is not located) and acts as part of the fuel transfer line when the jet pump is in operation
to maintain the fuel in both compartments at the same level .
To jet pump
B2H2912A
G : FUEL FILTER
The fuel filter located in the engine compartment is a pressure-withstanding, cartridge type. It has
a filter dement in a metal case . The fuel entering the filter flows from the perimeter of the dement
to the center of the filter and goes out from there .
OUT
IN
G2H0059
FU-13
4. Sensors and Switches

~~ FRC)NT OXYGEN (A/F1 SENSOR
" The front oxygen sensor uses zirconium oxide (Zr02) which is a solid electrolyte, at portions ex-
posed to exhaust gas .
" The zirconium oxide has the property of generating electromotive force when its both sides are
exposed to oxygen ions of different concentration and the magnitude of this electromotive force
depends on how much the difference is.
" The front oxygen sensor detects the amount of oxygen in exhaust gases by making use of this
property of the zirconium oxide material .
* The zirconium oxide material is formed into a closed end tube and its external surface is ex-
posed to exhaust gases with smaller oxygen ion concentration, whereas its internal surface is ex-
posed to atmospheric air. The external surface has a porous platinum coating . The sensor housing
is grounded to the exhaust pipe and the inside is connected to the ECM through the harness to
be able to use the current output from the sensor.
" The sensor incorporates a ceramic heater to improve its performance at low temperatures .
Gasket Ceramic heater
Protection tube vv~ ~VV ~ ~ ~V Yv

B2H3910A
FU-14
tube . This results in a very large difference in the oxygen ion concentration between the inside and
in this case is very small.
air-fuel ratio, and hence the change in the electromotive force is also large . By using this informa-
tion, the ECM can determine the air-fuel ratio of the supplied mixture easily. The front oxygen sen-
sor does not generate much electromotive force when the temperature is low. The output charac-
teristics of the sensor stabilize at a temperature of approximately 700°C (1,292°F) .
ZrO2
Atmospheric air
" " V V f"

. . E
. . . .
"r p_
V ~ O
Exhaust Exhaust
gases . gases
==> L .* <=
Lean --o- Air-fuel ratio - Rich
Ceramic heater
1321-1200613
FU-15
B : REAR OXYGEN SENSOR

" The rear oxygen sensor is used to sense oxygen concentration in the exhaust gas . If the air-fuel
ratio is leaner than the stoichiometric ratio in the mixture (i .e., excessive amount of air), the exhaust
gas contains more oxygen. To the contrary, if the fuel ratio is richer than the stoichiometric ratio,
the exhaust gas contains almost no oxygen .
" Detecting the oxygen concentration in exhaust gas using the oxygen sensor makes it possible
to determine whether the air-fuel ratio is leaner or richer than the stoichiometry.
" The rear oxygen sensor has a zirconia tube (ceramic) which generates voltage if there is a differ-
ence in oxygen ion concentration between the inside and outside of the tube . Platinum is coated
on the inside and outside of the zirconia tube as a catalysis and electrode material . The sensor
housing is grounded to the exhaust pipe and the inside is connected to the ECM through the har-
ness .
* A ceramic heater is employed to improve performance at low temperatures .
Gasket
Sensor housing
B2H4156A
FU-16
* When rich air-fuel mixture is burnt in the cylinder, the oxygen in the exhaust gases is almost com-
fiihP This rP.-,i ilt .q in a vPrv IarnP diffPrPncP in the oxvnen inn concentration between the inside and
. . . . ... ... . . . . . ... .~ ., ... . . . .. .w . .l- J__. . . . . ._ . .__ . . ._ . .__ .J~l- _
.__
. .

in this case is very small.
air-fuel ratio, and hence the change in the electromotive force is also large. By using this informa-
tion, the ECM can determine the air-fuel ratio of the supplied mixture easily. The rear oxygen sensor
does not generate much electromotive force when the temperature is low. The output characteris-
tics of the sensor stabilize at a temperature of approximately 300 to 400°C (572 to 752°F) .
Large Stoichiometric mixture ratio

Electromotive ~ Atmosphere
force u ~ (Rich signal) ~ To be judged
a
v~ as rich
o 0
(D 0 Comparison
., c I voltage
oC ~
V 07 ~6
°D x o Tobejudged
Exhaust st W ° ' as lean
i (Lean signal)
gases
Small
it Lean- Air-fuel ratio- Rich
G2H0038B
C: ENGINE COOLANT TEMPERATURE SENSOR

" The engine coolant temperature sensor is located on the engine coolant pipe . The sensor uses
a thermistor whose resistance changes inversely with temperature . Resistance signals as engine
coolant temperature information are transmitted to the ECM to make fuel injection, ignition timing,
purge control solenoid valve and other controls .
Connector
vc 2 .5 S2
a>
1 Temp. °V (°F)
-20 0 20 40 60 80
(-4) (32) (68) (104) (140) (176)
~rmistor element
S2H1113A
FU-17
D: CRANKSHAFT POSITION SENSOR

" The crankshaft position sensor is installed on the rear end of the cylinder block. The sensor gen-
erates a pulse when one of the teeth on the perimeter of the crankshaft plate (rotating together with
the crankshaft) passes in front of it. The ECM determines the crankshaft angular position by count-
ing the number of pulses.
" As the crankshaft rotates, each tooth of the crankshaft plate aligns with the crankshaft position
sensor so that the magnetic flux in the sensor's coil changes since the air gap between the sensor
pickup and the crankshaft plate changes . This change in magnetic flux induces a voltage pulse
in the sensor and the pulse is transmitted to the ECM .
%000\`
000
OO
\O O/,
Crankshaft plate
B2H3912A
FU-18
E : CAMSHAFT POSITION SENSOR

" The camshaft position sensor is located on the right-hand cylinder head . It detects the combus-
tion cylinder at any given moment .
" The sensor generates a pulse when one of the slots on the back of the right-hand camshaft plate
passes in front of the sensor. The ECM detects the camshaft position by measuring the pulse .
Three slots are provided on the plate as shown below.
Slot
" Cylinder identification signal

" During idling
I
Detection point

Camshaft plate
B2H3913A
FU-19
F : KNOCK SENSOR
* The knock sensor is installed on the cylinder block, and senses knocking that occurs in the en-
gine .
" The sensor is a piezo-electric type which converts vibration resulting from knocking into electric
signals .
" In addition to a piezo-electric element, the sensor has a weight and case as its components .
If knocking occurs in the engine, the weight in the case moves causing the piezo-electric element
to generate a voltage .
" The knock sensor harness is connected to the bulkhead harness .
Nut Weight
Housing
Piezo-electric element 1321-14157A
FU-20
G : VEHICLE SPEED SENSOR

and send it to the transmission control module (TCM). The signal sent to the TCM is converted
there into a 4-pulse signal, and then sent to the ECM and the combination meter .
Combination meter -
B2H2459C
FU-21
CONTROL SYSTEM
5. Control System
D " f,FNFRAI
The ECM receives signals from various sensors, switches, and other control modules . Using these
signals, it determines the engine operating conditions and if necessary, emits signals to one or
more systems to control them for optimum operation .
Major control items of the ECM are as follow:
" Fuel injection control
e Ignition system control
" Idle air control
" Canister purge control*
" Radiator fan control
" Fuel pump control
" Air conditioner cut control
" On-board diagnosis function
* : Canister purge control is described under "EC (H6) - Emission Control (Aux . Emission Control
Devices) Evaporative Emission Control System" .
FU-22
CONTROL SYSTEM
B : INPUT AND OUTPUT SIGNALS

Signal Unit Function
Intake manifold pressure sensor Detects the amount of intake air (Measures the absolute pressure).
Intake air temperature sensor Detects the temperature of intake air.
Detects the density of oxygen in exhaust gases at the upstream of
Front oxygen (A/F) sensor
Detects the density of oxygen in exhaust gases at the downstream
Rear oxygen sensor
of the rear catalytic converter.
Camshaft position sensor Detects the combustion cylinder .
Engine coolant temperature sensor Detects the engine coolant temperature .
Front vehicle speed sensor Detects the vehicle speed.

Park/Neutral position switch Detects shift positions.
Diagnostic of AT Detects the self-diagnostics of AT
Heater circuit of front and rear oxy- Detects the abnormality in heater circuit of front and rear oxygen
gen sensor sensor.
A/C switch Detects ON-OFF operation of the A/C switch .
Fuel temperature sensor Detects the temperature of the fuel in the fuel tank .
Fuel level sensor Detects the level of the fuel in the fuel tank .
Fuel tank pressure sensor Detects the evaporation gas pressure in the fuel tank.
Small light switch Detects ON-OFF operation of the small light switch .
Fuel Injector Activates an injector.
Adjusts the amount of air flowing through the bypass line in the
Idle air control solenoid valve
throttle body.
Output signals Induction control solenoid valve Controls induction control valve .
EGR solenoid valve Controls EGR valve.
Malfunction indicator lamp Indicates existence of abnormality.
Purge control solenoid valve Controls purge of evaporative gas absorbed by the canister.
Power supply Controls ON/OFF of the main power supply relay.
Pressure control solenoid valve Controls evaporation gas pressure in the fuel tank .
Drain valve Closes the evaporation line between the fuel tank and canister to
detect leakage of evaporation gases.
FU-23
CONTROL SYSTEM
C : FUEL INJECTION CONTROL

" The ECM receives signals from various sensors and based on them, it determines the amount
of fuel injected and the fuel injection timing . It performs the sequential fuel injection control over
the entire engine operating range except during start-up of the engine.
" The amount of fuel injected depends upon the length of time the injector stays open . The fuel
injection duration is determined according to varying operating condition of the engine . For the
purpose of achieving highly responsive and accurate fuel injection duration control, the ECM per-
forms a new feedback control that incorporates a learning feature as detailed later.
" The sequential fuel injection control is performed such that fuel is injected accurately at the time
when the maximum air intake efficiency can be achieved for each cylinder (i .e ., fuel injection is
completed just before the intake valve begins to open) .
1 . FUEL INJECTION DURATION

Fuel injection duration is basically determined as indicated below :
" During engine start-up :
The duration defined below is used .
" Duration of fuel injection during engine start-up . . . . . Determined according to the engine cool-
ant temperature detected by the engine coolant temperature sensor.
" During normal operation :
The duration is determined as follows :
Basic duration of fuel injection x Correction factors + Voltage correction time
" Basic duration of fuel injection . . . . . The basic length of time fuel is injected . This is determined
by two factors - the amount of intake air detected by the manifold pressure sensor and the en-
gine speed monitored by the crankshaft position sensor.
" Correction factors . . . . . See the next section .
" Voltage correction time . . . . . This is added to compensate for the time lag before operation of
injector that results from variation in the battery voltage .
FU-24
CONTROL SYSTEM
2. CORRECTION FACTORS
The following factors are used to correct the basic duration fuel injJecti in order to make the
r. ._~ ~ .__ ~ t . ._ . . . .,__. ~of~_ _. :~o_n
:_ _
dig-iu~i ~dii~ ~rieei ins ~ec~ui~eiriei5 ui vdryinc~ eiiUiiie UPe~d ~iliy (~UfIUIUUf 15 :
" Air-fuel ratio feedback factor:
This factor is used to correct the basic duration of fuel injection in relation to the actual engine
speed . (See the next section for more detail .)
" Start increment factor :
This factor is used to increase the fuel injection duration only while the engine is being cranked
to improve its startability.
" Coolant-temperature-dependent increment factor :
This factor is used to increase the fuel injection duration depending on engine coolant temperature
signals to facilitate cold starting . The lower the coolant temperature, the greater the increment .
" After-start increment factor :
" This factor is used to increase the fuel injection duration for a certain period immediately after
start of the engine to stabilize engine operation .
" The increment depends on the coolant temperature at the start of the engine .
" Wide-open-throttle increment factor :
This factor is used to increase the fuel injection duration depending on the relationship between
the throttle position sensor signal and manifold pressure sensor signal .
" Acceleration increment factor :
This factor is used to increase the fuel injection duration to compensate for a time lag between air
flow measurement and fuel injection control for better engine response to driver's pedal operation
during acceleration .
FU-25
CONTROL SYSTEM
3. AIR-FUEL RATIO FEEDBACK FACTOR

The ECM creates this factor utilizing the front oxygen sensor signal . When the signal voltage is low,
the air-fuel ratio is richer than the stoichiometric ratio. The ECM then makes the fuel injection dura-
tion shorter by modifying the factor . When the voltage is high showing that the mixture is lean, the
ECM modifies the factor to make the injection duration longer. In this way, the air-fuel ratio is main-
tained at a level close to the stoichiometric ratio at which the three-way catalyst acts most effective-
ly.
Injection duration increment signal

---~ Injection duration decrement signal
(5) (2) --------

ECM Injectionduration increases ' ' I
Injection duration decreases ECM J

.. . ..... _ (4)
~.J
() ,-
Lean signal
--------9------ 3
Rich signal
(1)
B2H0989C
(1) Front catalyst (4) Fuel injector

(2) Exhaust gas (5) Combustion chamber
(3) Front oxygen (A/F) sensor
4. LEARNING FEATURE
The 2001 Legacy's air-fuel ratio feedback control includes a learning feature which contributes to
more accurate and responsive control .
" In the air-fuel ratio feedback control, the ECM calculates the necessary amount of correction
based on data from the oxygen sensor and adds the result to the basic duration (which is stored
in the ECM's memory for each condition defined by the engine speed and various loads .)
" Without a learning feature, the ECM carries out the above-mentioned process every time . This
means that if the amount of necessary correction is large, the air-fuel ratio feedback control be-
comes less responsive and less accurate .
" The learning feature enables the ECM to store the amount of correction into memory and add
it to the basic fuel injection duration to create a new reference fuel injection duration . Using the
reference duration as the basic duration for the injection a few times later, the ECM can reduce
the amount of correction and thus make its feedback control more accurate and responsive to
changes in the air-fuel ratio due to difference in driving condition and sensor/actuator characteris-
tics that may result from unit-to-unit variation or aging over time .
FU-26
CONTROL SYSTEM
D : IGNITION SYSTEM CONTROL

sor, engine coolant temperature sensor, intake air temperature sensor, crankshaft position sensor
the ignitor to initiate ignition .
I Crankshaft position sensor No .

Spark
plug #1

Spark
plug #2
Intake manifold pressure sensor Spark

plug #3
Ignition coil and
Intake air temperature sensor f-BPI ECM ignitorassembly
Spark
I Knock sensor I plug #4
..
position sensor
Spark
I Throttle
plug #5
Park/Neutral position switch
Spark
I A/C switch I plug #6
B2H4153A
FU-27
CONTROL SYSTEM
" The ECM receives two types of crank angle signal pulse ; one is generated every 10° of crank-
shaft rotation and the other, every 30° of crankshaft rotation . Using these two types of signal pulse,
_ rr-~ n n _i _r _ _ i_ _ r_i i _
fl~ position UI edCfl piston d5 TO IIO WS :
lfi_le CI~ IVI U _ele(flllfle5 the
The ECM interprets the pulses of range (A) shown below as the No . 1 and No. 2 cylinder pistons
being at TDC, the pulses of range (B) as the No . 5 and No . 6 cylinder pistons being at TDC, and
the pulses of range (C) as the No. 3 and No . 4 cylinder pistons being at TDC .
" The ECM outputs an ignition signal for the No . 1, No . 3 or No. 5 cylinder when it receives a cam-
shaft angle pulse before a TDC signal and for the No . 2, No. 4 or No. 6 cylinder when it receives
no camshaft angle pulse before a TDC signal .
Cylindernumber #5,6 #4,3 #1,2 #6,5 #3,4 #2,1 #5,6 #4,3 #1,2 #6,5 #3,4 #2,1
(TDC)
Crank angle pulse II II I IIIIIIIIIIIII

1W.LJ.LLLIW.L_L11W1llLLLL11llLJ.LLLIW .L_L11W11.LW1 IIIII IIIIIIIIII I I IIIIIIIIIIIIIIIII IIIIII
. .
. .
Cam angle pulse
.
#1
#6 /~
Ignition
#3 . . . . . . . ~ fL
timing
#2 ~ ~-
#5 I I I I I I I I I I I I
I I I I I I I I I I I I
#4
B2H3914A
FU-28
CONTROL SYSTEM
E : IDLE AIR CONTROL

" The ECM activates the idle air control solenoid valve to control the bypass air flowing through
the bypass passage in the throttle body depending on signals from the crankshaft position sensor,
engine coolant temperature sensor, pressure sensor and A/C switch so that the proper idle speed
for each engine load is achieved .
" The idle air control solenoid valve uses a duty-ratio-controlled solenoid which can continuously
vary the opening area of the rotary valve. As the ECM increases the duty ratio, opening of the rotary
valve increases so that the bypass air flow increases, and the engine idling speed becomes higher
as a result .
" The bypass air control is necessary for :
" Increasing idling speed when the air conditioning system and/or electrical loads are turned
on .
" Increasing idling speed during early stage of warm up period .
" Obtaining dashpot function when the throttle valve is quickly closed .
" Prevention of engine speed variation during idling .
Intake manifold pressure sensor
Intake air temperature sensor
Engine coolant temperature sensor ~--~- I ECM
Front vehicle speed sensor
Ignition switch r Idle air control solenoid valve
I A/C switch I
Park/Neutral position switch
B2H3915A
F : CANISTER PURGE CONTROL

" The ECM receives signals from the engine coolant temperature sensor, front vehicle speed sen-
sor and crankshaft position sensor to control the purge control solenoid .
Purge of fuel from the canister takes place during operation of the vehicle except under certain
conditions such as during idling operation .
" The purge line is connected to the throttle chamber so that fuel gas from the canister is purged
according to flow of intake air.
FU-29
ON-BOARD DIAGNOSIS SYSTEM
6 . On-board Diagnosis System

nrFNFRni
" The on-board diagnosis system detects and indicates a fault by generating a code correspond-
ing to each fault location . The malfunction indicator lamp (CHECK ENGINE light) on the combina-
tion meter indicates occurrence of a fault or abnormality.
" When the malfunction indicator lamp comes on as a result of detection of a fault by the ECM,
the corresponding diagnostic trouble code (DTC) and freeze frame engine condition are stored
in the ECM .
" On the OBD-II conformable car, it is necessary to connect the Subaru Select Monitor (SSM) or
General Scan Tool (GST) to the data link connector in order to check the DTC .
" The SSM and GST can read and erase DTCs . They can also read freeze frame data in addition
to other pieces of engine data .
" If there is a failure involving sensors which may affect drive control of the vehicle, the fail-safe
function ensures minimum level of driveability.
B : FAIL-SAFE FUNCTION
For a sensor or switch which has been judged faulty in the on-board diagnosis, the ECM, if ap-
propriate, generates an associated pseudo signal to keep the vehicle operational . (The control
becomes degraded .)
FU-30
POWER WINDOW
1 . Power Window
n~ r_nN-QTRi ir_-ronN
r-vv~v " vvv~
" The power window system consists of regulator motors and switches for individual doors, relays
and a circuit breaker unit .
" Each door window opens/closes by pushing down/pulling up the switch .
" Only the driver's door window switch has a 2-stage mechanism :
" When the switch is pushed lightly and held in the pushed position, the window continues to
lower until the switch is released .
" When the switch is pushed down fully, the window lowers to the end position automatically.
NOTE:
For the sake of safety, the power window system is designed to operate only when the ignition
switch is in the ON position .
B : CIRCUIT DIAGRAM
i LP1*
i
---------------------------------------------------------------------------
B6H1306A
G W-2
COMBINATION METER
1 . Combination Meter
A o WAkIl"11,4111AU mllu
SAIA r'%IkllklP% A KIM
%in L.1%A1 I I %_0
lklr%l&'% A'rf%M I If%-U'rC
(3)
(4)
BRAKE 4~ 0t, ~ (6)
AT OIL
AIR BAG TEMP
0
FWD 1
lJ
'&,,o O O
(7)
B6H1295A
(1) ABS warning light

This light illuminates when a fault occurs in any electrical component of the ABS (Anti-lock Brake System) .
(2) AIR BAG system warning light
This light illuminates when a fault occurs in the airbag system .
(3) Brake fluid level warning / parking brake indicator light
This light illuminates when thefluid level in the brake reservoirtank lowers below the specified level and/orwhen the parking
brake is applied.
(4) CHECK ENGINE warning light
This light illuminates when a fault occurs in the MFI (Multiple point Fuel Injection) system .
(5) Oil pressure warning light
This light illuminates when the engine oil pressure decreases below 14 .7 kPa (0 .15 kg/cm2, 2.1 psi) .
(6) AT oil temperature warning light
This light illuminates when the ATF temperature exceeds 150°C (302°F) .
(7) Charge indicator light
This light illuminates when a fault occurs in the charging system while the engine is running .
1D1-2
COMBINATION METER
' Instrumentation/Driver Info
If everything is normal, the warning and indicator lights should be ON or OFF as shown below ac-
cording to ignition switch positions .
Warning/Indicator tight Ignition switch position
LOCK/ACC ON ST While engine is running
(1) ABS OFF `3 ON OFF
(2) AIR BAG OFF "2 ON '2
(3) Brake fluid level / parking brake OFF ON ON '4
(4) CHECK ENGINE OFF '1 ON OFF
(5) Oil pressure OFF ON ON OFF
(6) AT oil temperature OFF ON ON OFF
(7) Charge OFF ON ON OFF
*1 :This light comes ON before engine starts, and stays OFF after engine has started .
"2 :This light comes ON for about 7 seconds, and then goes out.
`3:This light comes ON for about 2 seconds, and then goes out.
*4 :This light comes ON when the parking brake is applied.
I DI-3
COMBINATION METER
B : TELLTALE (GRAPHIC MONITOR)
(2) (2) (4)

(3)
CHECK
~(3C
AIR BAG A1BJP

1B
ABS FWO
°
C O /
(7) (s)
B6H1295B
(1) Seat belt warning light

This light stays illuminated for about 6 seconds after the ignition switch has been turned ON if the driver's seat belt is not
fastened .
(2) Turn signal indicator light
This light blinks in unison with the corresponding turn signal lights when the turn signal switch is operated .
(3) Door open warning light
This light illuminates when one or more doors, rear gate and/or trunk lid are not completely closed .
(4) Headlight beam indicator light
This light illuminates when the headlights are in the high-beam position .
(5) FWD indicator light
This light illuminates when the center differential locks (with the fuse installed in the center differential locking circuit) .
(6) AT selector lever position indicator
The light corresponding to the present AT select lever position illuminates when the ignition switch is in any position other
than ACC and LOCK .
(7) Security indicator light
This light illuminates when the security system is armed.
(8) Low fuel warning light
This light illuminates when the quantity of the fuel remaining in the tank has decreased to 10 liters (2 .6 US gal, 2.2 Imp gal)
or smaller.
1D1-4
COMBINATION METER
If everything is normal, the telltales should be ON, OFF or in other states as shown below according
to ignition switch positions .
Telltale light Ignition switch position
LOCK/ACC ON I ST While engine is
running
(1) Seat belt OFF '2 <2 "2
(2) Turn signal OFF Blink Blink Blink
(3) Door, rear gate or 9 Open ON ON ON ON
trun k lid open , Shut OFF OFF OFF OFF
(4) Headlight beam * High beam OFF ON ON ON
Low beam OFF OFF OFF OFF
(5) FWD * FWD OFF ON ON ON
* AWD OFF OFF OFF OFF
!
(6) AT selector lever position I OFF ON ON ON
(7) Security I '`3 I OFF I OFF I OFF
(8) Low fuel I OFF I *1 I *1 I '1
'1 :This light illuminates when quantity of the fuel remaining in the tank has decreased to 10 liters (2 .6 US gal, 2 .2 Imp gal) or smaller.
'2 :This light illuminated for about 6 seconds after the ignition switch has been turned ON if the driver's seat belt is NOT fastened .
"3:This light blinks when the security system is armed.
I DI-5
COMBINATION METER
C : SPEEDOMETER
1 . DESCRIPTION
" The speedometer system is an electrical type that uses electric signals from the speed sensor
in the MT model or the transmission control module (TCM) in the AT model .
" The vehicle speed sensor is installed on the manual transmission .
" Since the system does not use mechanical components such as rotating cable, there are no
opportunities of occurring such problems as meter needle vibration and cable disconnection .
Also, it does not constitute any means of mechanical noise transmission .
" The odometer and tripmeter readings appear on a liquid crystal display (LCD).
2. OPERATION
MT model : The vehicle speed sensor sends vehicle speed signals (4 pulses per rotation of speed
sensor's driven shaft) to the speedometer drive circuit and odometer/tripmeter drive circuit in the
speedometer .
AT model : The TCM sends vehicle speed signals (4 pulses per rotation of output shaft) to the
speedometer drive circuit and odometer/tripmeter drive circuit in the speedometer.
NOTE :
Signals from the speed sensor or TCM are also used by the engine control module, automatic
transmission control module, etc .
3. SPECIFICATION
Speedometer Type Electric pulse type .

Indication Needle points to 60 km/h (37 .3 miles) when 2,548 pulses are input per minute .
Odometer Type Pulse count type .
Display LCD/6 digits ; 0 to 999,999 km (mile) .
Counts up 1 km per 2,548 pulses (1 mile per 4,104 pulses). (Count down is impos-
Indication
sible.)
Tripmeter Type Pulse count type .
Display LCD/4 digits ; 0 to 999.9 km (mile) .
Counts up 1 km per 2,548 pulses (1 mile per 4,104 pulses). (Push knob is adopted
Indication
to return the tripmeter to zero indication .)
IDI-6
COMBINATION METER
4. SYSTEM DIAGRAM
MT medal
(12)
B6H1167B
(1) Odometer/tripmeterdrive circuit (7) Front wheel

(2) Speedometer movement (8) Speed sensor
(3) Speedometer (9) TCM
(4) Odometer/tripmeter (10) Electromagnetic pick-up
(5) Speedometer drive circuit (11) Gear for the speed sensor
(6) Combination meter (12) Differential
IDI-7
COMBINATION METER
D : VEHICLE SPEED SENSOR

The ~iohir~lo
vlri i~v~v criAArl
v~.rvv~n cAncnr
w~. ... iicac a ,H,al,l, I.(
1
-ick-~~n to generate speed signals. (MT model)
r .J -
This sensor is installed on the transmission case and detects rotating speed of the transmission
output gear.
The sensor generates 4 pulses per rotation of the speed sensor driven shaft and send them to the
speedometer.
1 . CONSTRUCTION
The speed sensor mainly consists of a Hall IC, magnet ring, driven shaft and spring .
kYl
B6H0911 B
(1) Upper case (4) Driven key (7) Rivet

(2) O-ring (5) Lower case (8) Hall IC
(3) Magnet ring (6) Driven shaft
I DI-8
COMBINATION METER
2 . OPERATION
As the driven key rotates, the magnet turns causing the magnetic field of the Hall IC to change.
The Hall IC generates a signal that corresponds to a change in the magnetic field.
One turn of the driven key in the speed sensor sends 4 pulses to the combination meter, engine
control module and cruise control module .
Signal (4 pulses
per revolution)
Low speed
Combination meter
High speed
Revolution of Speedometer
transmission drive circuit
output gear
Vehicle speed ~ IG
sendor Odometerand
L tripmeterdrive
circuit
Engine control module

Cruise control module
B6H0912D
E : TACHOMETER
The tachometer drive circuit is connected to the engine speed sensing circuit in the engine control
module .
When the engine speed increases or decreases, the voltage of the circuit also increases or de-
creases, changing the magnetic force of the tachometer drive coil .
The tachometer needle then moves in accordance with change in the engine speed .
Combination meter
H6H0419
IDI-9
COMBINATION METER
F: WATER TEMPERATURE GAUGE

" The water temperature gauge is a cross-coil type .
" The water temperature signal is sent from the thermo gauge located on the engine .
" The resistance of the thermo gauge changes according to the engine coolant temperature .
Therefore, the current sent to the water temperature gauge also changes according to the engine
coolant temperature . As the change in current causes the magnetic force of the coil to change,
the gauge's needle moves according to the engine coolant temperature .
" When the coolant is at a normal operating temperature of approx . 70 to 100 °C (158 to 212 °F),
the gauge's needle stays in the middle of the indication range as shown below.
50 65 100 120
Temperature
Combination meter
'hereto gauge
H6H0420
IDI-10
COMBINATION METER
G : FUEL GAUGE
1 . GENERAL
" The fuel gauge unit consists of a float and a potentiometer whose resistance varies depending
on movement of the float. It is located inside the fuel tank and forms an integral part of the fuel
pump . The fuel gauge indicates the fuel level in the tank even when the ignition switch is in the
LOCK position .
" All models are equipped with two fuel level sensors . These sensors are installed in the fuel tank,
one on the right side and the other on the left side. Two sensors are necessary because the fuel
tank is divided into main and sub tank compartments .
9 The low fuel warning light switch is incorporated in the main fuel level sensor.
(3)
Sy ,"
J
(3)
.
B6H1296A
(1) Main fuel level sensor

(2) Sub fuel level sensor
(3) Float
IDI-11
COMBINATION METER
Main fuel level sensor Sub fuel level sensor

(2) (7)
(4)
B6H1297A
(1) To engine (5) Float

(2) From engine (6) Jet pump
(3) From sub tank compartment (7) To jet pump
(4) Level sensor (8) Gas sensor
IDI-12
<rVIY1d11VAI IVIV IVIC 1 GR
2. OPERATION
The low fuel warning light operates as follows :
The ECM continually monitors the resistance signal from the fuel level sensor. It turns on the low
fuel warning light in the combination meter if a resistance value corresponding to the critical fuel
level (approx . 76 Q) is detected successively for about 10 minutes or the period spent for driving
a distance of 10 km .
This monitoring time has been decided to avoid false operation of the warning light which may
happen when a large part of remaining fuel is collected temporarily in the sub tank compartment .
Sub fuel
Main fuel
IP\/PI cancnr level sensor
B6H0026B
3. SPECIFICATIONS
Fuel amount Resistance
Main fuel level I FULL 0.5-2 .50

sensor 1/2 18 .5-22 .50
EMPTY I 52 .5-54.5 S2
Sub fuel level FULL 0.5-2 .50
sensor 1/2 - 23 .6-27.6 S2
EMPTY 39 .5-41 .50
IDI-13
COMBINATION METER
4. CIRCUIT DIAGRAM
input
interface
ECM
Fuel
" IG
SW Low fuel
warning
DC12V light
driver
Low fuel
warning light
Sub tank Main tank

co mpartment ~_ comp artment
Sub fuel level sensor Main fuel level sensor
B6H1281 B
IDI-14
OUTSIDE AIR TEMPERATURE DISPLAY
2. Outside Air Temperature Display

A: CONSTRUCTION
The outside air temperature display system consists of an ambient sensor (a), the CUSTOM CPU
and a liquid crystal display installed in the combination meter. The ambient sensor detects the out-
side air temperature using the built-in thermistor which varies its resistance according to change
in ambient temperature, and sends signals to the CUSTOM CPU .
As soon as the ignition switch is turned ON, the CUSTOM CPU compares the temperature data
sent from the ambient sensor with the one that was stored in its memory when the ignition switch
was turned OFF last time and it causes the lower of the temperatures to be displayed . However,
if 60 minutes or more time has passed between the last turning OFF and the next turning ON of
the ignition switch, the temperature that is displayed is a sensor-provided temperature .
When the vehicle is running slowly, the heat released from the engine compartment raises the tem-
perature of the air around the ambient sensor and this affects the temperature data the sensor
sends to the CUSTOM CPU . The CPU then makes a special control using the vehicle speed data,
i .e ., when the vehicle is running at a speed slower than 10 km/h, the CPU uses the temperature
that was detected during the most recent vehicle's movement at a speed exceeding 10 km/h rather
than a temperature currently being provided by the ambient sensor .
To have the outside air temperature displayed on the liquid crystal display, press the odometer/
tripmeter selection knob (b) several times, and it will be displayed on the odometer/tripmeter dis-
play (c).
B6H1432A
IDI-15
OUTSIDE AIR TEMPERATURE DISPLAY
B : CIRCUIT DIAGRAM
Outside air
temperature
Ambient display
sensor
CUSTOM
CPU
7-
I
Thermistor Combination meter
Vehicle Transmission
speed control
sensor I I module
M/T A/T
B6H1515A
IDI-16
IGNITION COIL
Ignition
1 . Ignition Coil
ThP PnninP usPS a clirPCt innition system with one innition coil mounted for each cylinder (or stark
. . . . . . . J . . . . .. . . . __ _. . . _ _ _ . J . . . _. _ . . _ J - _ _ . . . _ . . _. . _ J _ _ . _.
plug) .
The secondary terminal of the ignition coil is in contact with the spark plug terminal nut.
Since no spark plug cable is used, secondary voltage drop, leaks, or other problems that are in-
herent in a system using spark plug cables do not occur. The result is high performance and high
reliability .
Ignition coil
Connector
B2H3978A
IG-2
SPARK PLUG
Ignition
2. Spark Plug
The spark plug has a platinum tipped electrode . The thread diameter is 14 mm (0 .551 in) and the
gap is controlled to a value between 1 .0 and 1 .1 mm (0 .039 and 0 .043 in) .
Gap : 1 .0 - 1 .1 mm (0 .039 - 0 .043 in)
Platinum tipped electrode
B2H3979A
IG-3
IGNITION COIL
Ignition
1 . Ignition Coil
innitinn rnil.q are marP intPnral with an innitnr
. . ._ .~ . . . . . . . w .w .. . . . ._ . J . .. . . . ._ . . ._ . . .J . . .__ . .
The ignition system is of a dual-ignition-coil design, each coil causing two plugs to generate
sparks simultaneously. In response to the signal from the ECM, the ignitor supplies current to an
ignition coil and the ignition coil supplies high-voltage current to a pair of spark plugs (#1 and #2
or #3 and #4) simultaneously.
B6H1294A
(1) Ignition coil and ignitor assembly
(6)
B6H0806C
(1) ECM (5) Spark plug #2

(2) Ignitor (6) Spark plug #3
(3) Ignition coil (7) Spark plug #4
(4) Spark plug #1 (8) Ignition switch
IG-2
SPARK PLUG
Ignition
2. Spark Plug
The spark plug's thread diameter is 14 mm (0 .551 in) and the gap is controlled to a value between
1 .0 and 1 .1 mm (U.U3y and 0 .043 in) .
Gap : 1 .0-1 .1 mm (0 .039-0 .043 in)
dMj'DHD3o
B2H4152A
IG-3
GENERAL
Intake (Induction)
1 . General
The intake system consists of an air intake duct, a resonator chamber, and an air cleaner housed
in its case . The resonator, located upstream of the air cleaner, effectively reduces the intake noise
level .
(3)
(4)
(a)
B2H3977A
(1) Air intake duct (a) Fresh air

(2) Resonator chamber (b) To throttle body
(3) Air cleaner case
(4) Air cleaner
IN-2
GENERAL
Intake (Induction)
1 . General
The intake qvstPm cnn~ists nf an air intake clod . two rPSnnatnr chamhers . an air cleaner. and a
duct . The resonator chambers (one is located upstream of the air cleaner and the other down-
stream of the air cleaner) effectively reduce the intake noise level .
(2)
(a)
B2H3904A
(1) Air intake duct (a) Fresh air

(2) Resonator chamber (b) To throttle body
(3) Air cleaner case
(4) Air cleaner element
(5) Duct
IN-2
GENERAL
Lubrication
1 . General
" The lubrication system force-circulates engine oil throughout the engine using an oil pump . The
oil pressure is regulated by the relief valve built into the oil pump . v
" The oil pump is a thin, large-diameter trochoid rotor type which can accommodate the engine's
high output. The pump is directly driven by the crankshaft .
" The engine oil is cleaned by a full-flow, paper element type oil filter. The filter has a bypass valve
which allows the engine oil to flow bypassing the filter if it is clogged .
" The inside of the oil pan is fitted with a baffle plate which reduces changes in the oil level due
to movement of the vehicle, thus ensuring uninterrupted suction of oil .
" The engine oil discharged from the oil pump is delivered to the journal bearings, connecting rod
bearings, and other parts requiring lubrication and cooling via the vertical passage in the right
bank of the cylinder block, the oil filter, and the oil galleries in the right and left banks of the cylinder
block .
" The engine oil is also distributed to each cylinder head valve mechanism at a proper flow rate
achieved by metering by the orifice provided in each oil gallery.
LU-2
GENERAL
Lubrication
(3)
(5)
(6)
B2H1964A
(1) Oil filter (5) Roller

(2) Oil pump (6) Rocker arm
(3) Oil strainer (7) Rocker shaft
(4) Camshaft
(a) Bypass valve opening pressure :
157 kPa (1 .6 kg/cm2, 23 psi)
(b) Relief valve opening pressure :
490 kPa (5 .0 kg/cm2, 71 psi)
LU-3
ENGINE OIL FLOW
Lubrication
2. Engine Oil Flow
Intake cam Exhaust cam Exhaust cam Intake cam

and roller and roller and roller and roller
Intake valve Intake valve

seem end stem end
Intake Exhaust Exhaust Intake

Camshaft Camshaft rocker arm
rocker arm rocker arm journal
rocker arm
journal journal journal journal journal
Intake Exhaust Exhaust Intake

Camshaft Camshaft rocker shaft rocker shaft
rocker shaft rocker shaft
Camshaft cap I I Camshaft cap
#1&#3 #2&#4
cylinder head cylinder head
(R . H .) (L.H .)
#1 #4 #2&#3
connecting connecting connecting
rod bearing rod bearing rod bearing
# 1 journal # 4 journal # 5 journal # 2 journal # 3 journal

bearing bearing bearing bearing bearing
(Front) (Center) (Rear) (Center) (Center)
Oil pressure switch
Cylinder block Cylinder block

main gallery R.H . main gallery L.H .
Oil filter ; Oil filter element Bypass valve
i
i
---------------------
Oil pump ~ Oil pump rotor Relief valve

- ,
i - T i
Oil strainer
Oil pan
B2H1965B
LU-4
OIL PUMP
Lubrication
3. Oil Pump
" The oil pump is a trochoid rotor type consisting of an inner rotor and outer rotor assembled with
each other in a pump body. When the inner rotor is driven by the crankshaft, the outer rotor is ro-
tated, changing the space between it and the inner rotor. The change in the space occurs because
of the difference in the number of teeth between the rotors .
" Engine oil is drawn into the large space created near the inlet of the pump . It is then carried to
the discharge port. As the pump rotates, the space carrying the oil becomes smaller, thus the oil
is pressurized and discharged from the outlet port . Oil pressure is regulated by the relief valve built
into the pump. Excess oil is directly returned to the inlet port.
c1> (4) (1)

o
0
0
0
v
(3)
($) (7)
S2H0851A
(1) Inner rotor (6) Plug

(2) Outer rotor (7) Gasket
(3) Oil seal (8) Relief valve spring
(4) Oil pump case (9) Relief valve
(5) Oil pump cover
LU-5
OIL FILTER
Lubrication
4. Oil Filter
The ail filter is a fell-flow filtering ; cartridge type that utilizes a paper element. It also has a built-in
bypass valve . The filter element has a special pleat design to increase the effective filtering area .
Oil seal Pleatedelement
Filter
Bypass valve S2H0249C
LU-6
OIL PAN AND OIL STRAINER
Lubrication
5 . Oil Pan and Oil Strainer

" The oil pan is attached to the cylinder block using liquid gasket for sealing . The oil strainer is
a metal net type and removes large foreign particles from the engine oil . It is located in the middle
of the oil pan . The pipe from the strainer is connected to the suction port of the oil pump in the left
bank of the cylinder block .
" There is a baffle plate in the oil pan, near the bottom of the cylinder block . It stabilizes the oil level
and reinforces the oil pan .
Oil strainer Oil level gauge
Level gauge guide
FULL level
(Engine HOT condition)
FULL level
(Engine COLD condition)
LOW level
Baffle plate
S2H0852A
LU-7
OIL PRESSURE SWITCH
Lubrication
6. Oil Pressure Switch

The oil pressure switch is located in the front upper portion of the right cylinder block bank. The
purpose of this switch is to monitor the operation of the oil pump as well as the lubricating oil pres-
sure when the engine is running .
B2H1023
(1) Contact point (4) Molded portion

(2) Diaphragm (5) Terminal
(3) Spring
1) When oil pressure does not build up (immediately after ignition switch is turned ON) :
The diaphragm is pushed toward the cylinder block by the spring force (a force equivalent to the
specified oil pressure) . This closes the contact points, causing the oil pressure warning light in the
combination meter to illuminate .
2) When oil pressure reaches the specified value (after engine starts) :
After reaching the specified value of 14.7 kPa (0 .15 kg/cm2, 2.1 psi), the oil pressure pushes the
diaphragm overcoming the spring force . This opens the contact points and the oil pressure warn-
ing light goes out.
LU-8
GENERAL
Lubrication
1 . General
" The lubrication system force-circulates engine oil throughout
., the engine
.., using.., an oil bumb . The
oil pressure is regulated by the relief valve .
" The oil pump is a thin, large-diameter trochoid rotor type which can accommodate the engine's
high output. The pump is directly driven by the crankshaft .
" The engine oil is cleaned by a full-flow, paper element type oil filter. The filter has a bypass valve
which allows the engine oil to flow bypassing the filter if it is clogged .
" The engine oil discharged from the oil pump is delivered to the journal bearings, connecting rod
bearings, and other parts requiring lubrication and cooling via an oil passage, oil filter, and oil gal-
leries .
" The engine oil is also distributed to each cylinder head valve mechanism at a proper flow rate
achieved by metering by the orifice provided in each oil gallery.
LU-2
GENERAL
Lubrication
($
l~1
(1)
B2H3887A
(1) Oil strainer (7) Oil pressure switch

(2) Oil pump (8) Camshaft
(3) Relief valve case (9) Crankshaft
(4) Chain tension adjuster RH (10) Lower idler sprocket
(5) Oil cooler (11) Upper idler sprocket
(6) Oil filter (12) Chain tension adjuster LH
LU-3
ENGINE OIL FLOW
Lubrication
2 . Engine Oil Flow
Camshaft Camshaft Camshaft Camshaft

journal journal journal journal
Intake camshaft Exhaust camshaft Exhaust camshaft Intake camshaft

gallery gallery gallery gallery
Orifice Orifice
Cylinder Cylinder
head RH head LH
Connecting
rod bearing Chain tension
adjuster LH
Crankshaft
bearing Upper idler
sprocket
Cylinder block
main gallery
Oil pressure Lower idler

switch sprocket
Chain tension
adjuster RH
Oil filter
Oil filter ~ Bypass valve
element
--- ----------- ---------

--------- -----
Oil cooler
Relief valve
Oil pump
Oil strainer
Oil pan
B2H3888A
LU-4
OIL PUMP AND RELIEF VALVE
Lubrication
3 . Oil Pump and Relief Valve

" The oil pump is a thin, large-diameter trochoid roller pump directly driven by the crankshaft . Its
outer rotor and inner rotor are assembled with each other inside the rotor housing which is formed
in the rear chain cover. The rotor housing is closed by the oil pump cover. The outer rotor, inner
rotor and the oil pump cover are made of sintered metal .
" When the pump discharge pressure exceeds a certain level, the relief valve located at the outlet
port of the oil pump opens and allows excess oil to return to the inlet of the pump . The relief valve
is a single-spool type and housed in an aluminum die-cast case. It is mounted on the rear chain
cover with a metal gasket.
c2>
B2H3889A
(1) Inner rotor (5) Plug

(2) Outer rotor (6) Gasket
(3) Oil pump cover (7) Relief valve spring
(4) Relief valve case (8) Relief valve
LU-5
OIL FILTER
Lubrication
4. Oil Filter
The oil filter is a full-flow filtering, cartridge type that utilizes a paper element. It also has a built-in
bypass valve . The filter element has a special pleat design to increase the effective filtering area.
Oil seal Pleatedelement
Filter I
Bypass valve S2H0249C
LU-6
OIL PAN AND OIL STRAINER
Lubrication
5. Oil Pan and Oil Strainer

" The oil pan consists of an upper oil pan (aluminum die-casting) and a lower oil pan (formed steel
plate) . The upper oil pan has a baffle plate molded in it to improve stability of the oil level .
" The oil strainer has a stay whose end is attached to the upper oil pan. The strainer's pipe is con-
nected to the oil pump using an O-ring . The strainer is located close to the bottom at the center
of the oil pan where the oil level changes the least .
B2H3890A
(1) Upper oil pan (4) O-ring

(2) Strainer (5) Magnet
(3) Lower oil pan
LU-7
OIL PRESSURE SWITCH
Lubrication
6 . Oil Pressure Switch

The nil, nraccire cWitr,h, is located at the ,rir7h,t of the i inner nil an,
.., . T,,g ni irnncP of t,h,iSc~niitc,, i~
to monitor the operation of the oil pump as well as the lubricating oil pressure when the engine is
running .
B2H1023
(1) Contact point (4) Molded portion

(2) Diaphragm (5) Terminal
(3) Spring
1) When oil pressure does not build up (immediately after ignition switch is turned ON) :
The diaphragm is pushed toward the cylinder block by the spring force (a force equivalent to the
specified oil pressure) . This closes the contact points, causing the oil pressure warning light in the
combination meter to illuminate .
2) When oil pressure reaches the specified value (after engine starts) :
After reaching the specified value of 14 .7 kPa (0 .15 kg/cm2, 2.1 psi), the oil pressure pushes the
diaphragm overcoming the spring force . This opens the contact points and the oil pressure warn-
ing light goes out.
LU-8
GENERAL
Mechanical
1 . General
The H4 engine is of a horizontally opposed, four-cylinder design . This four-stroke-cycle, water-
cooled, SOHC engine uses a total of 16 valves and its main components are made of aluminum
alloy. It is fueled by a multiple fuel injection system .
The engine's major structural and functional features are as follows :
" The cylinder head forms pentroof combustion chambers, each having a spark plug located at
its center and two each of intake and exhaust valves (four valves per cylinder) . The intake and ex-
haust ports are located in a cross-flow arrangement .
" There are a screw and nut at the valve end of each rocker arm . They are used for adjusting the
valve clearance.
" A single timing belt drives two camshafts on the left and right banks and the engine coolant
pump on the left bank. Belt tension is automatically adjusted by a belt tension adjuster, eliminating
need for a manual adjustment .
" The crankshaft is supported by five bearings with high rigidity and strength .
" The cylinder block is an aluminum die casting fitted with iron die-cast cylinder liners .
IntaH
rock.
arm
Intake
rocker
shaft
Exhaust
rocker
shaft
Exh
rock salve
arm ocker
over
B2H1983A
ME-2
TIMING BELT
Mechanical
2 . Timing Belt
" A single timing belt drives two camshafts (one in the left bank and one in the right bank) . The
belt also drives the water pump by its non-toothed side .
" The timing belt teeth have a specially designed round profile which contributes to quiet opera-
tion . The timing belt is made of strong and inflexible core cords, wear-resistant canvas and heat-re-
sistant rubber material .
" A hydraulic automatic belt tension adjuster always keeps the belt taut to the specified tension .
Any manual belt tension adjustment is unnecessary.
Timing indicator (For timing mark of crankshaft pulley) `Piston position mark
r Belt tension pulley
Alignment
mark Automatic belt tension adjuster
0 i-( ? \ / : !I 1 / :J
Alignment
"Piston mark
position mark
mark
U `*Piston
position
mark
_°. . r'
C~ I(
Camshaft sprocket LH
Camshaft
sprocket RH lC7 Water pump pulley
`-Timing belt
Crankshaft sprocket
Idler Idler No. 2
B2H3410B
NOTE:
*: The #1 piston is at TDC when the piston position mark on the crankshaft sprocket is aligned with
the timing mark on the cylinder block.
** : The #1 piston is at TDC on the compression stroke when the piston position mark on the cam-
shaft sprocket is aligned with the timing mark on the belt cover.
ME-3
AUTOMATIC BELT TENSION ADJUSTER
Mechanical
3 . Automatic Belt Tension Adjuster

The automatic belt tension adjuster consists of a tensioner unit and a bracket . It maintains the tim-
ing belt tension automatically at a specified level to enable the belt to transmit power correctly,
reduce operating noise and increase the life of the belt.
The cylinder of the tensioner unit incorporates an adjuster rod, wear ring, plunger spring, return
spring, check ball and silicone oil .
The automatic belt tension adjuster gives tension to the belt by a levering action which is produced
by the push force of the tensioner unit's adjuster rod . It operates in the process detailed below .
o
o ~ --- _---
Oil seal `--`
Tensioner bracket
Wear ring
Belt tension pulley
Oil reservoir chamber
Return spring
Adjuster rod
Cylinder
Plunger
Oil pressure chamber
`Pb~~ Plunger spring

Timing belt ( 1
Check ball
B2H1694C
Tb
" Timing belt tensioning action

When the belt becomes slack, the adjuster rod is pushed upward by the return spring . The oil in
the reservoir chamber, which is pressurized by the plunger spring to a certain level, pushes open
the check ball and flows into the oil pressure chamber to keep the pressure constant .
The thrust force F resulting from extension of the adjuster rod applies a counterclockwise torque
to the tensioner bracket, which causes the belt tension pulley at its end to turn in the same direc-
tion. This applies tensioning pressure Pb to the timing belt.
" Timing belt tension balancing action
When the belt tension pulley is pushed against the timing belt with pressure Pb, reaction force Tb
of the timing belt generates the reaction force P at the point on which the adjustor rod force is act-
ing .
This force P pushes the adjuster rod until it balances with the sum of the thrust force F and the
pressure of the oil in the oil pressure chamber. Therefore, the timing belt tension is kept constant .
" Overtension correction action
If the tension of the timing belt increases excessively, the force P becomes larger than the thrust
force F and silicone oil is returned from the oil pressure chamber to the reservoir chamber little by
little until the force P balances again with the thrust force F. Thus the timing belt tension is main-
tained at the specified level at all times .
ME-4
BELT COVER
Mechanical
4. Belt Cover
" The belt cover is made of lightweight, heat resistant synthetic resin molding . It constitutes a total-
ly enclosed housing with its cylinder block mating edges sealed with rubber gaskets . This effec-
tively protects the inside components from dust and liquid .
" Rubber seals used between the cylinder block and the belt cover effectively reduces transmis-
sion of noise and vibration .
" The front belt cover has a line mark for ignition-timing checking .
B2H1985A
(1) Front belt cover

(2) Belt cover No . 2 (RN)
(3) Belt cover No . 2 (LH)
(4) Belt cover (LH)
ME-5
Mechanical
5 . Valve Rocker Assembly

* The intake valve rocker arms and the exhaust valve rocker arms are installed on their own rocker
shafts both of which are retained by the camshaft caps.
" The valve end of each rocker arm is provided with valve rocker adjusting screw and nut . Turning
of this screw adjusts the valve clearance .
" The exhaust valve rocker arms are Y-shaped, and each arm operates two exhaust valves simul-
taneously.
" Each rocker shaft has an oil passage in it.
(3) (3)
B2H1986A
(1) Valve rocker adjusting screw and nut (4) Camshaft cap
(2) Intake valve rocker arm (5) Supporter
(3) Wave washer (6) Exhaust valve rocker arm
ME-6
CAMSHAFT
Mechanical
6 . Camshaft
" The right-hand camshaft is supported inside the cylinder head at three journals while the left-
hand camshaft is supported at four journals .
" The two flanges on each camshaft supports thrust forces to limit the end play of the camshaft
within the tolerance .
" Each camshaft has an oil passage in it .
(1) (2) (1) (3)
(1) (3) 1-
B2H1987A
(1) Journal
(2) Oil passage
(3) Shaft flange
ME-7
CYLINDER HEAD
Mechanical
7. Cylinder Head
" The cylinder head is made of aluminium die casting .
" Each combustion chamber in the cylinder head is a compact, pentroof design. The spark plug
is located at the center of the combustion chamber, which contributes to creation of a wide "squish
area" for increased combustion efficiency.
" The two intake and two exhaust valves are arranged on opposite sides for a cross-flow feature .
" The cylinder head gasket is a metallic gasket consisting of three layers of the stainless steel
sheets . It is highly resistant to heat and maintains high level of sealing performance for a long peri-
od .
(2) (3)
o ~ ~ ~o
boo°o o°
° ~ 00~
(7)
(6) (5)
B2H3341A
(1) Intake valve (5) Exhaust port

(2) Intake port (6) Exhaust valve
(3) Squish area (7) Spark plug
(4) Combustion chamber
ME-8
CYLINDER BLOCK
Mechanical
8 . Cylinder Block
" The cylinder block is made of aluminum die casting . Its open-deck design provides it with such
advantageous features as relatively small weight, high rigidity and excellent cooling efficiency.
" The cylinder liners are made of cast iron . They are dry type which means their outer surfaces
are entirely in contact with the cylinder block.
" The cylinder block supports the crankshaft at its five journals . The journal supporting portions
are designed such that sufficient stiffness and quiet operation are ensured .
" The oil pump is located in the front center of the cylinder block and the engine coolant pump
is located at the front of the right-cylinder bank. At the rear of the right-cylinder bank is an oil sepa-
rator which removes oil mist contained in blow-by gas .
ME-9
CRANKSHAFT
Mechanical
9 . Crankshaft
The crankshaft is supported in the cylinder block by five bearings . Each corner formed by a journal
or pin and a web is finished by fillet-rolling method which increases strength of that area. The five
crankshaft bearings are made of aluminum alloy and the No. 5 bearing is provided with a flanged
metal to support thrust forces .
#5
#3
B2H1978A
ME-1 0
PISTON
Mechanical
10 . Piston
" The pistons are of a slipper skirt design for reduced weight and friction . The oil control ring
groove utilizes a thermal design .
" The piston pin is offset either downward (Nos. 1 and 3 pistons) or upward (Nos. 2 and 4 pistons) .
" The piston head has recesses to prevent interference with the intake and exhaust valves . It also
has engraved marks to identify the piston size and the direction of installation . All the pistons are
common in their design .
" Three piston rings are used for each piston - two compression rings and one oil control ring .
The top piston ring has inner bevels and the second piston ring has a cut on the bottom outside
to reduce oil consumption .
Location mark (Engine front side)

Identification mark (Piston size) (Inner-bevel)
Top ring
Second ring
(Cut)
Upper rail
Oil ring Spacer
Lower rail
Engine capacity (2500 cc)
B2H3411 C
ME-11
ENGINE MOUNTING
Mechanical
11 . Engine Mounting
A : STANDARD TYPE (BRIGHTON AND L AT VEHICLES)
Cushion rubber
B2H3142B
ME-12
ENGINE MOUNTING
Mechanical
B : LIQUID-FILLED TYPE (EXCEPT BRIGHTON AND L AT VEHICLES)
B2H3143A
ME-13
GENERAL
Mechanical
1 . General
The H6 engine is of a horizontally opposed, six-cylinder design . This four-stroke-cycle, water-
cooled, DOHC engine uses a total of 24 valves and its main components are made of aluminum
alloy. It is fueled by a multiple fuel injection system .
The engine's major structural and functional features are as follows :
" A maintenance-free, chain-and-sprocket type camshaft drive mechanism is used which also
contributes to reduction in the size of the engine .
" The cylinder block is an aluminum die casting fitted with iron die-cast cylinder liners .
" Lightweight and compact design
The cylinder bore pitch is 98 .4 mm (3 .9 in), which is much shorter than 113 mm (4 .4 in) of the H4
engine .
The cylinder bore and piston stroke dimensions have been selected optimally for sufficient output
and reduced size of the engine ; they are 96.9 mm (3 .8 in) and 75 mm (3 .1 in) in contrast to 89.2
mm (35 .1 in) and 80 mm (3 .1 in) of the H4 engine .
The cylinder block is of a "triple siamese cylinder" design with the three cylinders of each bank
cast without coolant passages between cylinders, while ensuring adequate cooling by employing
an open-deck design .
The right bank camshafts and the left bank camshafts are driven by different timing chains, where-
as the accessories are driven through their own pulleys by a single serpentine belt (two belts were
used in the previous model's engine) .
" Quiet operation
Unlike V6 engines, horizontally opposed six-cylinder engines do not generate secondary vibration
(which is caused by primary operational vibration in a V6 engine and has a frequency twice as
large as that of the primary vibration) although V6 engines have space saving merit . In addition
to this inherent quietness provided by complete dynamic balance, the H6 engine incorporates the
following quietly operating considerations :
The crankshaft is supported by seven bearings and has a diameter of 62 mm (2 .4 in), which is 2
mm (0.08 in) larger than with the previous model's engine.
The chains driving the camshafts are provided with hydraulic tension adjusters and covered by
a chain cover at the front of the engine.
An aluminum die-cast upper oil pan reinforces the joint of the right and left cylinder block banks,
while giving additional rigidity to the crankshaft bearing areas .
The engine is connected to the transmission more rigidity than with the previous model by using
11 bolts (eight bolts in the previous model).
" Clean exhaust gas and high power
The H6 engine has enabled the 2000 Legacy to comply with the US LEV standard without sacrific-
ing output power by adopting, among others, tumble flow generating intake ports and a variable
length intake manifold that creates a resonance ramcharging effect.
ME-2
TIMING CHAINS
Mechanical
2. Timing Chains
" Two timing chains are used to drive the camshafts, one each for driving the two camshafts on
each bank . Every camshaft is fitted with a sprocket through which it is driven by the corresponding
timing chain . The left bank timing chain transmits the power from the crankshaft sprocket directly
to the left bank camshaft sprockets, whereas the right bank timing chain transmits the crankshaft
power via the lower idler sprocket which is driven by the left bank timing chain . (The lower idler
gear has two tooth rows ; the left bank timing chain engages with the inner row teeth and the right
bank chain engages with the outer row teeth .) By this way, the right and left bank camshafts rotate
in synchronization with each other.
The left bank timing chain also drives the water pump .
" The hydromechanical automatic chain tension adjuster provided for each chain constantly
maintains the specified chain tension necessary to properly drive the camshafts, as well as to pro-
vide this chain and sprocket camshaft drive mechanism with a "maintenance-free" feature .
(1)
(2)
(10)
(i1
B2H3895A
(1) Intake camshaft sprocket RH (7) Water pump sprocket (13) Tension adjuster LH
(2) Chain guide RH No .1 (8) Chain guide LH No .2 ('4) Upper idler sprocket
(3) Exhaust camshaft sprocket RH (9) Exhaust camshaft sprocket LH (15) Crankshaft sprocket
(4) Chain tension adjuster RH (10) Chain guide LH No .1 (16) Center chain guide
(5) Chain tension adjuster lever RH (11) Intake camshaft sprocket LH (17) Chain guide RH No .2
(6) Lower idler sprocket (12) Tension adjuster lever LH
ME-3
AUTOMATIC CHAIN TENSION ADJUSTER
Mechanical
3 . Automatic Chain Tension Adjuster

The rinht and IPft hank timinn rhain .-, are nrnviciPcl with their nwn tPnsinners . The tensioners are
. . . . . . ~ . . _ ~ . . .. . . . _ .. w. .. , _. . . . .. . J . . . .. . . . . ._ . . I. . . . . .. . .. . . . _. . _. . . . . . . . . . _ . . . - . . _ _
of a hydromechanical type that utilizes the engine oil pressure and can automatically keep the ten-
sion of the chains at a proper level without need for manual adjustments .
The tensioner case has an oil port that aligns with the oil port in the cylinder block when it is installed
in position . The inside of the tensioner case is a high-pressure hydraulic chamber with a check
ball . The pressure of the oil in the camber is adjusted by the relief valve . Since the tensioner has
a plunger with external screw threads and springs with adequate tension ratings inside, it can
keep the plunger extended even when the engine oil pressure drops following a stop of the engine .
(6)
---n
(3)~
of I \
(1) o
B2H3896A
(1) Tensioner case (4) Spring

(2) Spring (5) Adjuster rod
(3) Plunger (6) Plunger case
ME-4
TIMING CHAIN CASE
Mechanical
4. Timing Chain Case

" The timing chain case is formed by the front chain cover and rear chain cover, both made of
aluminum die casting . This two-piece chain case design helps reduce noise.
" Sealing materials used between the engine block and rear chain cover are an O-ring, metal gas-
ket, and liquid gasket . Between the front and rear chain covers, liquid gasket is used to prevent
ingress of foreign matter.
" A fluorocarbon resin oil seal is used at the crankshaft opening in the front chain cover
B2H3897A
(1) Front chain cover

(2) Rear chain cover
ME-5
CAMSHAFT
Mechanical
5 . Camshaft
cir~taro~ ctoAl fnr ~um In{hAC unl~ carbon
The Camshafts are vfa uvi~irnrvSii° i~iiai°rial type iaSlnn
steel for pipe part (first in Subaru) .
The sintered steel cams are very high in the resistance to wear, which enables the cam lift to be
increased . In addition, use of the sintered steel cams contributes to reduction in weight.
* Each camshaft is supported at its four journals by the corresponding bearings . The front-most
bearing has flanges on its both ends to receive thrust loads that are generated during movement
of the camshaft.
" The bearings are lubricated by the oil that enters the passage in each camshaft from the port
at the front-end journal and flows out through the hole in each journal .
" The right intake camshaft has at its rear end a flange which is used as an angle sensing wheel
by the camshaft position sensor.
lil (11 lil (1)
-~1) (1) (3) (1)

(b)
(2) (3)
~1) ~1) ~1)
(3)
C1)
0
V
(3)
B2H3898A
(1) Journal (a) RH intake camshaft

(2) Oil passage (b) RH exhaust camshaft
(3) Shaft flange (c) LH intake camshaft
(4) Camshaft position sensor flange (d) LH exhaust camshaft
ME-6
CYLINDER HEAD
Mechanical
6 . Cylinder Head
" The cylinder heads are made of aluminum alloy which features light weight and high cooling
efficiency.
" Each cylinder head incorporates a DOHC mechanism which is adapted to the "four valves per
cylinder" arrangement . The two intake ports are designed to create tumble flow in the cylinder,
whereas the two exhaust ports join each other in the cylinder head to form a single oval port . These
design features contribute together to cleaner exhaust emissions and higher output.
" The combustion chamber is of a compact pentroof design with the spark plug located at its top
center. In combination with the tumble promoting intake ports, a squish area formed between the
piston top surface and combustion chamber helps improve mixing of air and fuel and thus com-
bustion efficiency.
" Coolant flows from the rear to the front of the cylinder head of each bank . This serial-flow coolant
line arrangement ensures highly efficient cooling of the engine .
" A metal gasket is used between the cylinder head and cylinder block . Tightening the cylinder
head bolts by the angle-tightening method ensures invariable sealing performance of this gasket .
(5)
B2H3899A
(1) Intake port (4) Exhaust port

(2) Intake valve (5) Combustion chamber
(3) Exhaust valve
ME-7
CYLINDER BLOCK
Mechanical
7. Cylinder Block
" The cylinder block of this horizontally-opposed-cylinder engine is made of aluminum die cast-
ing . It is split into right and left halves at its center where the crankshaft is supported . The cylinder
liners are made of cast iron and are embedded as integral part of the cylinder block body during
the casting process .
" The coolant passages of the right and left banks are independent of each other (parallel-flow
type) . The water jackets around the cylinder liners are open at the cylinder head side end of each
bank (open-deck design) .
" The cylinder block supports the crankshaft's journals through seven main bearings rigidly and
quietly . The #7 bearing is a flanged thrust bearing which controls the crankshaft's end play.
" Rigid engine-to-transmission connection is ensured by 11 bolts (three more bolts than with the
four-cylinder engine) .
" The aluminum die-cast upper oil pan located below the cylinder block reinforces connection
between the cylinder block banks and its special form provides a buff1e effect to suppress large
fluctuation of oil level . In addition, the upper oil pan constitutes part of the oil and cooling circuits
as well as the water pump volute chamber and thermostat chamber.
ME-8
CRANKSHAFT
Mechanical
8. Crankshaft
The crankshaft is supported in the cylinder block by seven bearings . Each corner formed by a
journal or pin and a web is finished by fillet-rolling method which increases strength of that area .
The seven crankshaft bearings are made of aluminum alloy and the No . 7 bearing is provided with
a flanged metal to support thrust forces.
B2H3900A
ME-9
PISTON
Mechanical
9 . Piston
" The pistons are of a slipper skirt design for reduced weight and friction . The oil control ring
groove utilizes a thermal design .
" The piston pin is offset either downward (Nos . 1, 3 and 5 pistons) or upward (Nos. 2, 4 and 6
pistons) .
" The piston crown is spherically concaved and has no recesses for valve head clearance . All the
right and left bank pistons are the same in shape. Each piston has a location mark (mark indicating
the front of engine) on its top .
" Three piston rings are used for each piston - two compression rings and one oil control ring .
The top piston ring has inner bevels and the second piston ring has a cut on the bottom outside
to reduce oil consumption .
Location mark (Engine front side)
(Inner-bevel)
Top ring
Second ring
M~_ (Cut)
Upper rail
Spacer
Oil ring
Lower rail
B2H3901A
ME-10
ENGINE MOUNTS
Mechanical
10. Engine Mounts

The H6 engine is supported by liquid-filled elastic mounts specially developed for use with it . Each
mount is rigidly attached to the engine at three points . The mount can effectively reduce vibration
and noise thanks to presence of a membrane between the two liquid chambers . The membrane
has a function of reducing the spring constant of the mount .
a.-
(1)
R '
-- --
--
B2H3976A
(1) Diaphragm (4) Orifice

(2) Air chamber (5) Membrane
(3) Liquid chamber (6) Rubber piece
ME-11
GENERAL
Manual Transmission and Differential
1 . General
The 2001 Legacy's manual transmission is of a full-time all-wheel-drive design integrating a trans-
mission assembly, front differential, and transfer gear assembly with center differential into a single
unit. The transmission creates five forward speeds and one reverse using the corresponding
gears all provided with inertia lock-key type synchronizers .
The transmission and front differential are housed in an aluminum case which is split into right and
left halves and constitutes also a clutch housing . Located at the rear and joined each other are
the transfer case and extension case which house the transfer gears and center differential as well
as part of the transmission assembly.
The major features of the transmission are as follows :
" The clutch shaft forms an integral part of the mainshaft .
" The driven shaft arranged coaxially with the drive pinion shaft functions as a countershaft .
" The front differential uses a hypoid gear pair that allows the centers of its component gears to
offset each other to form a compact powertrain .
" The forward speed gears are helical gears featuring high tooth face strength, large tooth contact
areas, and quiet operation .
" Reversing rotation is achieved by making a slidable reverse idler gear engage with both the re-
verse drive gear on the mainshaft and the reverse driven gear integral with the 1 st-2nd synchroniz-
er hub on the drive pinion shaft.
" The 1st driven gear on the drive pinion shaft has a subgear which helps reduce noise during
engagement .
The center differential compensates for the difference in front and rear axle speeds . It consists of
a bevel gear set and a viscous coupling located at its rear end which are housed in a single case.
The center differential, together with a pair of transfer gears, transmits the power from the transmis-
sion to the drive pinion shaft (front wheel drive shaft) and the rear drive shaft . The viscous coupling
functions as a differential-action-control element .
MT-2
GENERAL
(2) (3) (4) (5) (6) (7)
(15) (14) (13) (12) (11) (10) (9) ($) B3H1853A
(1) Mainshaft (7) Extension case (13) 1st driven gear
(2) 3rd drive gear (8) Transfer drive gear (14) Drive pinion shaft
(3) 4th drive gear (9) Viscous coupling (15) Front differential assembly
(4) 5th drive gear (10) Center differential assembly
(5) Transfer case (11) Driven shaft (countershaft)
(6) Transfer driven gear (12) 2nd driven gear
MT-3
REVERSE CHECK MECHANISM
2 . Reverse Check Mechanism

Located in the transfer case, the reverse check mechanism prevents a direct 5th-to-reverse shift
by using a selector arm and cam combination which allows the gear to be shifted into the reverse
only after it has been returned once into the neutral .
A: CONSTRUCTION
The construction of the reverse check mechanism is as shown in the drawing on the opposing
page .
The reverse check sleeve is bolted to the transfer case and houses the mechanism's main compo-
nents .
The reverse accent shaft is slidable inside the reverse check sleeve and its smaller-diameter end
is fitted with the reverse check cam . The cam is rotatable and axially movable on the shaft but its
leftward movement is restricted by a step formed on the sleeve's inner wall .
The reverse accent shaft has hollows in both ends. In the left end hollow are the 1 st return spring
and its cap and in the right end hollow is the reverse return spring which pushes the shaft leftward .
Around the check cam is the reverse check spring whose left end applies simultaneous leftward
and rotational forces to the cam .
Both the reverse check spring and reverse return spring are retained at their right ends by the re-
verse check plate which is held in place by the snap ring .
The reverse accent shaft has a V-groove in which the detent ball is pressed by the reverse accent
spring fitted through the hole in the reverse check sleeve .
The reverse check sleeve and reverse accent shaft have a slot and a notch at their bottoms, re-
spectively, and the selector arm is inserted in the notch through the slot.
MT-4
(3)
0)
B3H1007A
(1) Select adjust shim (6) Reverse check cam (11) Selector arm
(2) Detent ball (7) Reverse return spring (12) Spring cap
(3) Reverse accent spring (8) Reverse check spring (13) 1st return spring
(4) Reverse check sleeve (9) Snap ring (14) O-ring
(5) Reverse accent shaft (10) Reverse check plate
MT-5
B : OPERATION
The drawing below shows the state of the reverse check mechanism when the selector arm is in
the neutral position . The 1st and 2nd gears will be selected if the selector arm is moved leftward
from this point to a stop and then turned in either way. A rightward movement of the arm to a stop
will enable selection of the 5th and reverse gears. In the neutral position, the selector arm receives
a rightward force (force toward the 5th and reverse gear side) from the 1 st return spring and a left-
ward force (force toward the 1st and 2nd gear side) from the reverse return spring to stay in that
position .
The following explanation describes how the selector arm and reverse check mechanism operate
when the driver selects the 5th gear and then selects the reverse gear.
(6) (4) B3H1007B
(1) 1st return spring (3) Reverse accent shaft (5) 5th and reverse gear side
(2) Reverse check sleeve (4) Reverse return spring (6) 1 st and 2nd gear side
MT-6
1 . WHEN SELECTOR ARM IS MOVED TOWARD 5TH AND REVERSE GEAR SIDE
The selector arm moves rightward while pushing both the reverse accent shaft and reverse check
ram cirri iltanoni icl~i
vui ~ i -~ i -i-i ivv-y .
(3) (2)
~(4) A-A (5) B3H1008B
(1) Reverse check sleeve (3) Reverse check cam (5) Neutral position
(2) Reverse accent shaft (4) Selector arm
2. WHEN SHIFT IS MADE TO 5TH GEAR

The selector arm is turned toward the 5th gear selection direction . When the arm clears the edge
of the reverse check cam as it turns, the cam becomes free of the selector arm's pressure and re-
turns to its original position by the force of the reverse check spring .
(1) (2) (3)
\A -A
(4)
B3H1009A
(1) Reverse check sleeve (3) Reverse check cam (5) Reverse check spring
MT-7
3 . WHEN A SHIFT FROM 5TH TO REVERSE IS ATTEMPTED

The selector arm turns toward the reverse gear while pushing the reverse accent shaft rightward
and the reverse check cam counterclockwise has viewed in the direction or` arrows Hj .
The reverse check cam, however, stops to rotate at a point where its stopper hits against the re-
verse check plate (this point corresponds to the neutral position in terms of the angle) and prevents
the selector arm from moving toward the reverse gear selection direction . The selector arm is then
axially pushed to the neutral position by the reverse accent shaft which is given a leftward force
by the reverse return spring .
(1) (2) (3)(4) (5)

3ition at
i --> Neutral position"
(6)
A-A
5th ---> Neutral position
B3H2118A
(1) Reverse check sleeve (5) Reverse check plate

(2) Reverse accent shaft (6) Snap ring
(3) Reverse check cam (7) Selector arm
(4) Reverse return spring
MT-8
M a n ua l Transmission and Differential
4. WHEN A SHIFT TO REVERSE IS MADE AFTER RETURN OF SELECTOR ARM TO NEU-

TRAL
As the ends of the reverse accent shaft and the reverse check cam are on the same place, the
selector arm now can turn toward the reverse gear selection direction after pushing leftward both
the shaft and cam simultaneously.
(2) (3)
A-A
\(4) (4)
B3H1011A
(1) Reverse check sleeve (3) Reverse check cam

MT-9
CENTER DIFFERENTIAL
3 . Center Differential
A: CONSTRUCTION
The center differential consists of a set of bevel gears and a viscous coupling .
The center differential has the following two functions : distributing the engine torque to the front
and rear wheel drive shafts and absorbing the difference in rotating speed between the front and
rear wheels .
The engine torque enters the center differential case from the transmission's driven shaft . The
torque is then distributed through the bevel gear set directly to the drive pinion shaft and via the
transfer drive and driven gears to the rear drive shaft.
The viscous coupling limits the bevel gear set's differential action when either front or rear wheels
spin so that adequate torques are transmitted to the front and rear wheels and proper traction is
obtained .
(1)
(6) (5) (4) (3) (2)

B3H1854A
(1) Transfer driven gear (4) Center differential with viscous coupling
(2) Transfer drive gear (5) Drive pinion shaft
(3) Viscous coupling (6) Driven shaft
MT-1 0
CENTER DIFFERENTIAL
B : MECHANISM OF VISCOUS COUPLING

The viscous coupling consists of a number of alternately arranged inner and outer plates and air-
and-silicone oil mixture filled into a sealed space that is formed ay the center differential case and
the rear side gear of the differential gear set. The inner plates have their inner perimeters splined
to the side gear and the outer plates have their outer perimeters splined to the center differential
case . The outer plates are held apart by spacer rings . There are no spacer rings between the inner
rings, so the inner rings are movable slightly in axial directions. X-section rings are used to prevent
leakage of silicone oil which would otherwise occur if the oil is pressurized due to large difference
in front and rear axle speeds .
(1) (2) (3) (4)
1331-1100213
(1) X-section ring (5) Inner plate

(2) O-ring (6) X-section ring
(3) Spacer ring (7) Side gear (rear)
(4) Outer plate
MT11
CENTER DIFFERENTIAL
1 . TORQUE CHARACTERISTICS
When a speed difference occurs between the center differential case and the rear side gear, a
shear force is generated in the silicone oil placed between the outer and inner plates . The torque
is then transmitted by the silicone oil between the center differential case and the rear side gear.
The greater the speed difference, the greater the shear force generated in the silicone oil . The rela-
tionship between the torque transmission and the speed difference is shown in the figure below.
As can be seen from the figure, the smaller the speed difference, the smaller the torque transmis-
sion and the differential action .
0
0
Speed difference
B3H1723B
2 . HUMP PHENOMENON
Silicone oil is heated and expanded as differential action continues . This causes the pressure of
air inside the viscous coupling to increase and the pressure of oil between plates to decrease. As
a result, the inner and outer plates are pushed together. This direct plate-to-plate contact causes
a non-viscous operation to occur, and this phenomenon is called "hump" .
The hump eliminates the rotating speed difference between the center differential case and the
rear side gear (or locks the differential), so soon after it has occurred, the internal pressure and
temperature drop . The viscous coupling then returns to the normal shear torque transmitting op-
eration . (The hump phenomenon does not occur under normal operating conditions .)
MT 12
CENTER DIFFERENTIAL
C: FUNCTION
When there is no speed difference between the front and rear wheels, the center differential deliv-
ers the engine torque icy the front and rear wheels at a ratio of 5U0 :50.
When a rotating speed difference occurs between the front and rear wheels, the center differential
operates to absorb it in a controlled way by the function of the viscous coupling .
1 . DURING NORMAL DRIVING

During straight-line driving on a flat road at a constant speed, all the four wheels rotate at the same
speed . The center differential delivers engine torque evenly to the front and rear drive axles . The
viscous coupling does not generate shear torque because there is no relative movements be-
tween the inner and outer plates .
cB>
(A)
1331-1100313
(1) Engine torque (A) To front differential (B) To rear differential
2 . DURING TURNS AT LOW SPEEDS

During turns at low speeds, rotating speed difference occurs between the front and rear wheels,
as well as between the left and right wheels . More particularly, the front wheels rotate faster than
the rear wheels . The center differential then acts to absorb the speed difference to enable smooth
driving .
Although the speed difference is small under this condition, operation of the viscous coupling
causes more torque to be transmitted to the rear than to the front.
B3H1004
MT-1 3
CENTER DIFFERENTIAL
3. DRIVING ON ROUGH OR SLIPPERY ROADS

" When front wheels are on a slippery surface . .r .
When the front wheels begin to spin, the resulting speed difference between in e front anU_ rear
drive shafts causes the viscous coupling to generate significant amount of shear torque. As a re-
sult, the torque distributed to the rear wheels becomes much larger than that distributed to the
spinning front wheels . The traction and driving stability are thus ensured on a rough or slippery
road .
B3H1006
" When rear wheels are on a slippery surface

When the vehicle is accelerated quickly from a standing start with the rear wheels on a slippery
surface, the distribution of the vehicle weight on the front and rear wheels changes and the rear
wheels start spinning . Due to the resulting speed difference between the front and rear drive
shafts, the viscous coupling generates a significant amount of shear torque, now in the direction
opposite to that generated when the front wheels are on a slippery surface . As a result, the torque
distributed to the front wheels becomes much larger than that distributed to the rear wheels .
B3H1005
MT14
TRANSMISSION MOUNTING
4 . Transmission Mounting
The bolt hole in the transmission end of the resin pitching stopper is a slot so that the bolt position
can be adjusted in it.
B2H3144B
(1) Resin pitching stopper (2) Cushion rubber (3) Cross member
MT-1 5
PARKING BRAKE (REAR DISC BRAKES)
Parking Brake
1 . Parking Brake (Rear Disc Brakes)

ThP
. . .~ narkinn
i.. .. . . . . . . . y hraka
. ., . .... .~ i...~~~
i-qP-, a... rlri
v. . ,..im
. . . hni
. .~ ...i--,Prl
.._,. .. in
. . . the
_. ., ., rli-,r.
... . ._._ .rntnr
_ .... . of
. .. . Par.h
.., .... ... . rear
. .., .... (Ii-,r,.
.. .. .,.., . hrakP
.. .. . H. __ . ThP
. . ._ -,hnP.q arP
_ . .___ w. _
mechanically controlled through linkage and cables .
1
f
I
B4H1939
P B-2
Parking Brake
A: OPERATION
1 . SETTING
When the parking brake lever is pulled, the shoe actuating lever to which the end of the parking
brake cable is connected turns the strut in direction "F" around point "P" .
The strut then presses the brake shoes A and B against the drum . These brake shoes utilize a float-
ing design and are movably supported by hold-down pins. The force applied to brake shoe A and
the reaction force "F" applied to the brake shoe B via point "P" press them against the brake drum .
(6)
B4H1940B
(1) Parking brake cable (5) Brake shoe B

(2) Lever (6) Shoe return spring
(3) Strut (7) Shoe hold down pin
(4) Brake shoe A (8) Point "P"
PB-3
Parking Brake
2 . RELEASING
When the parking brake lever is returned to the release position and the parking brake cables are
slackened, the brake shoes A and B are moved back to their original positions by the tension of
return springs, so that the parking brake is released .
(s)
(7)
B4H1941B
(1) Parking brake cable (5) Brake shoe B

(2) Lever (6) Shoe return spring
(3) Strut (7) Shoe hold down pin
(4) Brake shoe A (8) Point "P"
P B-4
PARKING BRAKE (REAR DRUM BRAKES)
Parking Brake
2 . Parking Brake (Rear Drum Brakes)

When the parking brake lever is moved up, the parking lever in each rear drum brake moves
around point "A" so that the trailing shoe expands . The leading shoe also expands by way of the
adjuster assembly. The shoes are thus pressed against the drum to generate a wheel locking
force .
(1)
3)
(4)
i)
(A)
(2)
1341-1163213
(1) Wheel cylinder (7) Lower shoe return spring

(2) Upper shoe return spring (8) Adjuster assembly
(3) Point "A" (9) Parking lever
(4) Adjuster lever
(5) Trailing shoe (A) Automatic brake lining clearance adjustment mechanism
(6) Leading shoe (B) Parking brake mechanism
PB-5
TILT STEERING COLUMN
Power Assisted System (Power Steering)
1 . Tilt Steering Column

A: TILT MECHANISM
" The steering wheel vertical position can be adjusted within a 35 mm (1 .38 in) range by using
the tilt lever to unlock the steering column and lock it again at the desired position .
20 mm (0 .79 in)
~~' 15 mm (0 .59 in)
B4H1716B
(1) Tilt steering column

(2) Tilt lever
PS-2
B : ENERGY-ABSORBING MECHANISM
" To absorb the backward movement energy generated in the engine in the event of a frontal colli-
5iuii, cllI CIIIf..JUC,dI I IIUI I~j. Lype 5~e~i iii~ column pipe has ueen c1UUf.JLCU. VVf ICf I clfI IIfI(Jcil:l IUc1U CX-
ceeding a certain level is applied to the steering column, the elliptical fittings crash and their ends
come in contact with each other. The column bending load is supported by the fittings .
" Another measure to alleviate impact on the driver in the event of a collision is the ripping plate
which is located between the steering column and the tilt bracket attached to the steering support
beam. When a large impact load is applied to the steering column, the ripping plate is deformed
and torn progressively. The impact energy is absorbed during this process .
(B)
(3) (4)
B4H1717B
(A) Before absorption of impact energy (1) Ripping plate

(B) After absorption of impact energy (2) Elliptical fitting
(C) Ripping plate (3) Before ripping
(4) After ripping
PS-3
C : STEERING SUPPORT BEAM

The steering column is held in position by a support beam which is installed crosswise in the ve-
hicle body at a level close to the steering wheel to reduce the overhang distance of the steering
wheel from the supporting point of the column . The steering shaft upper bearing is also located
close to the steering wheel to increase supporting efficiency as well as to minimize vibration of the
steering wheel .
B4H1718B
(1) Steering support beam
PS-4
POWER STEERING SYSTEM
2. Power Steering System

A: HYDRAULIC SYSTEM
" The fluid pump is directly driven by the engine through a belt .
" When the steering wheel is not being turned, the pressure-sensitive valve in the pump opens
to drain the fluid into the fluid reservoir tank .
" The fluid pressure is maintained almost constant regardless of change in the engine speed by
the function of the flow control valve . The pressure-regulated fluid is delivered to the control valve
via hose A.
" When the steering wheel is turned, the rotary control valve connected to the pinion shaft opens
the hydraulic circuit corresponding to the direction in which the steering wheel is turned . The fluid
then flows into chamber A or B via pipe A or B .
" The fluid pressure in chamber A or B acts on the rack piston in the same direction as that in which
the rack shaft is moved by rotation of the steering wheel . This helps reduce the effort required of
the driver to operate the steering wheel .
" Movement of the rack piston causes the fluid in the other chamber to return to the reservoir tank
via pipe A or B, control valve, and hose B .
" As the steering shaft is connected to the pinion shaft mechanically via the rotary control valve,
the steering system can operate as a manual system even if the hydraulic system becomes in-
operative .
" To control the maximum fluid pressure, a relief valve is built into the fluid pump to prevent build-
up of an excessive fluid pressure .
PS-5
2.5f MODEL
n~ l31
B4H1719B
(1) Power cylinder (8) Steering shaft (15) Flow control valve
(2) Rack piston (9) Steering wheel (16) Engine
(3) Rack shaft (10) Pressure-sensitive valve (17) Fluid pump
(4) Piston shaft (11) Tank (18) Hose A
(5) Pipe A (12) Vane pump (19) Chamber A
(6) Pipe B (13) Relief valve (20) Chamber B
(7) Rotary control valve (14) Hose B
PS-6
3.0f MODEL
(9)
(10)
1)
S4H0023B
(1) Power cylinder (11) Steering wheel

(2) Rack piston (12) Tank
(3) Rack shaft (13) Vane pump
(4) Pinion shaft (14) Relief valve
(5) Chamber A (15) Hose A
(6) Chamber B (16) Hose B
(7) Pipe A (17) Pump control valve
(8) Pipe B (18) Fluid pump
(9) Control valve (19) Engine
(10) Steering shaft
PS-7
B : GEARBOX ASSEMBLY
1 . POWER CYLINDER
The gearbox integrates the control valve and power cylinder into a single unit. The rack shaft
serves as a power cylinder piston . The rotary control valve is located around the pinion shaft.
The rotary control valve and power cylinder are connected to each other by two pipes through
which hydraulic fluid flows .
(4)
S4H0024A
(1) Piston (4) Power cylinder

(2) Rack shaft (5) Pinion shaft
(3) Cylinder (6) Control valve
PS-8
2 . ROTARY CONTROL VALVE

The rotary control valve consists of a rotor (which rotates together with the steering shaft), a Pinion
(which is connected to the rotor and torsion bar), and a sleeve (which rotates together with the
pinion) . The rotor and sleeve have grooves C and D, respectively, which form fluid passages V1
through V4 .
The pinion is in mesh with the rotor with adequate clearance, which enable the rack to be moved
manually by rotating the steering shaft (fail-safe feature) .
B
(A)
4(7) *(104)(8)
~11~ (1f 8)
(6) (g)
(,2) __1__a/__111-1 aI ~r~

(13)
(15)
1
(14)
S4H0025C
PS-10
(1) Torsion bar (12) Torsion bar

(2) Sleeve (13) Rotor
(3) Rotor (14) Sleeve
(4) Pinion (15) Fluid return line (to reservoir tank)
(5) Pinion-to-rotor engagement (fail-safe feature) (16) Pinion
(6) Fluid passage Vi (17) Torsion bar
(7) Fluid passage V2 (18) Rotor
(8) Fluid passage V3

(9) Fluid passage V4 (A) Cross-sectional view A (fluid passage switching cir-
cuit)
(10) Groove C (B) Cross-sectional view B (pinion-to-rotor engagement)
(11) Groove D
PS-11
" Principle of operation

When the torsion bar is twisted by a rotational force applied to the steering wheel, the relative posi-
tion between the rotor and sleeve changes . This changes the cross-sectional area of fluid ~pas-
sages V1, V2, V3 and V4 . The fluid passages are thus switched and the fluid pressure is controlled
in accordance with the operation of the steering wheel .
" When no steering force is applied :
The rotor and sleeve are held at the neutral position . Fluid passages V1, V2 and V3, which are
formed by grooves C and D are open equally. Under this condition, the fluid from the pump re-
turns to the reservoir tank so that neither fluid pressure builds up nor the rack piston moves in
the power cylinder.
(1) (2)
001 14-
06 I I 4 "
(4) (5)
~0a
)'Qk" V"' V -Vr(8)
>'' (9)
\/ \/
~(7)
S4H0334A
(1) Chamber A (4) V2 (7) From fluid pump

(2) Chamber B (5) V3 (8) To A
(3) V1 (6) V4 (9) To B
PS-12
* When steering force is applied :

When the steering wheel is turned to the right, for example, fluid passages V1 and V3 are opened
while fluid ra .qqanPq V2 and V4 are nea rly closed .
At this point, the fluid pressure in chamber A of the power cylinder increases depending on the
degree of closure of fluid passages V2 and V4 so that the rack piston moves to the right . The
fluid in chamber B, on the other hand, is drained through fluid passage V3 into the reservoir tank.
(1> (2)
(4)
(3)
(7) ~ ~~)
**a
~7"
(9) b 0 (~~
b O G5
v
#0
(7 )
($) S4H0336A
(1) Chamber A (4) V2 (7) From fluid pump

(2) Chamber B Vs (8) To A
(3) Vi Va (9) From B
" Fail-safe feature

If fluid pressure fails to build up due to, for example, a broken fluid pump drive belt, the steering
wheel rotating torque is transmitted from the valve rotor to the pinion through mechanical engage-
ment between them .
PS-13
C: FLUID PUMP AND RESERVOIR TANK

1 . 2.5f MODEL
The fluid pump is a vane type driven by the engine via belt .
The reservoir tank is mounted on the vehicle body.
The fluid pump incorporates the flow control valve, pressure-sensitive valve, and relief valve, each
performing the following functions :
" The flow control valve regulates the flow rate of discharged fluid to a constant level irrespective
of the engine speed .
" The pressure-sensitive valve returns the fluid to the reservoir tank when there is no steering in-
put.
" The relief valve protects the system from an excessively high pressure which may occur, for ex-
ample, when the steering wheel is turned all the way.
B4H1720B
(1) Fluid pump

(2) Reservoir tank
PS-14
(6)
B4H1764B
(1) Reservoir tank (5) Flow control valve

(2) Relief valve (6) Fluid pump
(3) Pressure-sensitive valve (7) Steering gearbox
(4) Vane pump
PS-15
" VANE PUMP

The vane pump consists of a rotor, a cam ring, and ten vanes.
When the rotor rotates, the vane movably fitted in each slot of the rotor is radially moved out by
centrifugal force and pressed against the inside wall of the cam ring . Since the inside of the cam
ring is oval-shaped, the fluid from the suction port is confined and pressurized in the chamber
formed between two adjacent vanes as the rotor rotates and is delivered through the discharge
port. The pressurized fluid circulates through the hydraulic circuit .
(1)
-(3)
(3)-
(6) H4H1188C
(1) Discharge (5) Vane pump

(2) Rotor (6) Discharge
(3) Suction (7) Cam ring
(4) Vane
PS-16
" FLOW CONTROL VALVE

The flow control valve consists of a sub-spool which is pushed to the right when the fluid pressure
,r ;gAQ as the rrnrrin,P SYIPPd increases (and r(lt1,CP('fl IAnt!\/ the C111mp discharge rate becomes high-
er). When the sub-spool is shifted to the right, the variable orifice is narrowed, thus the discharge
rate is reduced .
(A) (2)
(1) 1J
\ (3)
--_T=
(---
y I
J
(1) LJ
(4)
=>
B4H1721B
(A) Engine speed low (1) Sub-spool

(B) Engine speed high (2) To steering gearbox
(3) Variable orifice
(4) From vane pump
PS-17
Powe r Assisted System (Power Steering)
" PRESSURE-SENSITIVE VALVE

The pressure-sensitive valve's left end is exposed to the fluid pump discharge-pressure and its
ri "t end to the flow control valve outlet p_,.,.,. . ._ ..
ICJJUIC (the pressure of the fluid being directed to the
steering gearbox) .
1341-1172213
(1) Pressure-sensitive valve (3) Flow control valve

(2) Fluid pump (4) To steering gearbox
PS-18
" When the steering wheel is not being turned, the fluid that has passed through the flow control
valve is directed to the steering gearbox but it is returned to the reservoir tank without entering the
rotary control valve's passages in the Gearbox . Therefore, the qressure acting on the valve's right
end does not increase . v v v
On the other hand, the pressure acting on the left end of valve is the fluid pump-discharge pres-
sure which is higher than the pressure acting on the right end . This causes the pressure-sensitive
valve's spool assembly to move to the right . As a result, the drain port which was closed by the
outer spool is now opened . The pump discharged fluid then flows to the reservoir tank and the
pressure inside the pump is reduced .
(3)
~ (4)
B4H1723B
(1) To reservoir tank (3) Pressure from vane pump (high)

(2) Drain port open (4) Fluid pressure after passing through flow control valve
(low)
PS-19
" When the steering wheel is turned in either direction, the pressure of the fluid that has passed
through the flow control valve and directed into the steering gearbox increases as it enters the
p'~
..
power -nn the raf-L, piston .
Cyllrlulo ru!l ~uCtSC
The inner spool of the pressure-sensitive valve is kept pressed to the right by the pump-discharge
pressure acting on its left end . On the other hand, the fluid pressure acting on the right end of the
valve is also high . So, the outer spool is moved to the left, closing the drain port. As a result, the
pump internal pressure increases so that the fluid with a high pressure necessary for power assis-
tance is supplied to the gearbox .
/2)
(3)
--~ (4)
(6)
B4H1724B
(1) To reservoir tank (4) Fluid pressure after passing through flow control valve
(increased)
(2) Drain port closed (5) Inner spool
(3) Pressure from vane pump (6) Outer spool
PS-20
" RELIEF VALVE

The relief valve consists of a check ball and a spring . The check ball is exposed to the fluid pres-
JUIG t1hat is regulated by% the I IVVV lVrILIVI VQI VG ~6hJl QIIlrliGl~d II VI I 11IG IIIIG LV 11IG JIGGIIIIy
. 1~,. GQIlhJVX) .
If the pressure acting on the check ball is increased abnormally due to, for example, rotation of
the steering wheel to a stop and overcomes the spring tension, the ball is pushed to the left, allow-
ing the fluid to be drained into the reservoir tank . Therefore, the pressure to the steering gearbox
is prevented from becoming excessively high .
._. ,.,
(1)a
(5)
(6)
B4H1778B
(A) Relief valve not in operation

(B) Relief valve in operation
(1) To reservoir tank (5) Fluid pressure after passing through flow control valve
(low)
(2) Spring (6) Valve open
(3) Check ball (7) Fluid pressure after passing through flow control valve
(higher than preset level)
(4) Valve closed
PS-21
2. 3.0f MODEL
" The reservoir tank is mounted on the vehicle body.
" The fluid pump is belt-driven by the engine . The fluid flow is controlled according to the engine
speed so that an adequate steering resistance is given during high-speed operation .
The fluid pump is a variable capacity type vane pump whose delivery rate per rotation decreases
as the engine speed increases . The pump is integral with a pump control valve and relief valve .
(5)
B4H2453A
Reservoir tank (4) Vane pump

Relief valve (5) Fluid pump assembly
(3) Pump control valve (6) Steering gearbox
PS-22
" The vane pump consists of a rotor, a cam ring, and eleven vanes.
When the rotor rotates, the vane in each slot of the rotor is radially moved out by centrifugal force
and pressed against the cam ring . The fluid from the suction port is confined in chambers formed
between two adjacent vanes and carried to the discharge port. Since the cam ring is movable in
relation to the rotor, the volume of each chamber is variable . This enables the delivery rate per rota-
tion of the pump to be changed .
(3)
(4)
(5)
B4H2478A
(1) Suction
(2) Vane
(3) Rotor
(4) Cam ring
(5) Discharge
PS-23
FLOW CONTROL
The variable capacity pump changes its delivery rate per rotation by changing the degree of ec-
centricity of the cam ring according to its rotating speed (engine speed) .
c
Delivery rate per unit time
3
0
``~ Delivery rate per rotation of pump

1
-------------------------------
Idling' ~ Pump speed

Low- Mid- High
A range range speeds
speeds speeds
S4H0028B
NOTE:
In the following description, pump speed ranges will be indicated using the speed points A
through D shown in the drawing above .
PS-24
Low-range-speed operation (A - B range)

In this speed range, as well as in all the other speed ranges, two different pump discharge pressur-
es are always applied to the control valve ; one is directly led from the discharge port to the left end
of the valve and the other is led through an orifice (variable orifice) to the right end of the valve .
Since the orifice has a pressure reducing effect, the latter pressure is lower than the former.
When the pump is operating at a low speed, its discharge pressure is also low, resulting in only
small difference between the two pressures . In this condition, the valve stays pushed leftward by
the spring, allowing the non-pressurized reservoir tank fluid to enter chamber A . To chamber B,
on the other hand, the orifice-reduced discharge pressure is applied, so the cam ring is pushed
leftward by the cam ring spring . This makes the eccentricity of the cam ring a maximum and, there-
fore, the delivery rate per rotation of the pump become a maximum .
(2)
B4H2479A
(1) Control valve (6) Variable orifice

(2) Reservoir tank fluid (7) Pressure chamber A
(3) Control valve spring (8) Pressure chamber B
(4) Gearbox (9) Cam ring
(5) Cam ring spring
PS-25
Mid-range-speed operation (B - D range)

Durina mid-ranae speed operation, the Dump increases its delivery rate. Since the Pressure be-
fore passing through the variable orifice increases, the control valve moves rightward, overcoming
the tension of the control valve spring . This movement of the control valve allows the pressure up-
stream of the variable orifice to be directed to chamber A after being adjusted to a necessary pres-
sure* by the port opening area created by the control valve . On the other hand, chamber B re-
ceives the reservoir pressure (suction pressure) . This means that the pressure in chamber A is
higher than that in chamber B . As a result, the cam ring moves rightward against the tension of
the cam spring . This causes the delivery rate per rotation of the pump to be reduced, so that the
flow rate of the fluid to the steering gear box decreases accordingly.
The above control is performed when the pump is operating at a speed in the B - D range .
* The "necessary pressure" for chamber A is a pressure required to move the cam ring to the posi-
tion corresponding to each predetermined flow rate (pump delivery rate) . The pressure is ob-
tained by changing the port opening area appropriately through displacement of the control valve.
The displacement of the control valve is determined by how much the pressure before the variable
orifice is different from that after the orifice .
(10)
B4H2480A
(1) Control valve (6) Variable orifice
(2) Reservoir tank fluid (7) Pressure chamber A
(3) Control valve spring (8) Pressure chamber B
(4) Gearbox (9) Cam ring
(5) Cam ring spring (10) Opening area
PS-26
Maximum pressure control

When the hydraulic circuit in the steering gear box is closed as a result of a steering action, the
pressure in the circuit increases to a very high level . The relief valve prevents the pressure from
exceeding a preset safe level in the following way :
If the fluid in the circuit is pressurized to the preset pressure, the fluid pushes the ball of the valve
overcoming the tension of the relief spring . Through the opened relief valve, the fluid makes its way
to the pump's suction side passage, thus maintaining the circuit pressure at a level lower than the
preset pressure .
/11
(4)
B4H2481A
(1) Reservoir tank fluid

(2) Relief valve
(3) Gear box
(4) Relief spring
PS-27
REAR SUSPENSION
Rear Suspension
1 . Rear Suspension
A : OUTLINE
The rear suspension is a multilink type . This type of suspension is characterized by small changes
in camber and toe-in against external input of vertical, longitudinal and lateral forces . This enables
full use of tire performance and ensures high kinetic performance and stability of the vehicle.
This suspension also features quiet operation because the front link, rear link, upper link and rear
differential are all attached to a subframe which in turn is installed to the vehicle body through
heavy-duty bushings .
(2)
9)
(6) B4H1933A
(1) Rear arm (4) Upper link (7) Rear link

(2) Shock absorber and coil spring (5) Subframe (8) Helper
(3) Front link (6) Stabilizer (9) Rear differential
Component Key feature Function

Rear arm Made of cast iron for sufficient rigidity. Supports longitudinal dynamic load .
Front link Made of sheet metal with U-shaped section for Supports lateral dynamic load .
sufficient rigidity.
Rear link Made of sheet metal with U-shaped section for Supports lateral dynamic load .
sufficient rigidity.
Upper link Made of cast iron for sufficient rigidity against im- Supports lateral dynamic load .
pact from helper when suspension is bumped .
Shock absorber and Overall length is optimally minimized to eliminate Supports and controls vertical dynamic load .
coil spring protrusion into the passenger compartment.
Stabilizer Ball joint type stabilizer link is used to minimize Controls body rolling.
transient rolling of the body.
Helper Attached to the body independently of shock ab- Combined with upper link to serve as vehicle
sorber to avoid its protrusion into the passenger bump stopper.
compartment.
Subframe Attached to the body through heavy duty bush- Supports front link, rear link, upper link and rear
ings for quiet operation . differential .
RS-2
SEAT BELT
Seat Belt System
1 . Seat Belt
AnUJ~U~~w r~ ~ r w w~/~uAP1
H: .71HCfLG SHOULDER BELT ANCHOR
Each front seat belt system has an adjustable shoulder belt anchor which allows the occupant to
select the most appropriate anchor height from among the five positions in a 129 mm (5 .08 in)
range .
Push
B5H0605A
SB-2
SEAT BELT
Seat Belt System
B : REAR CENTER THREE-POINT TYPE SEAT BELT (SEDAN)

A three-point type seat belt is available for the center seating position of the rear seat.
The retractor for the seat belt is installed on the luggage shelf behind the seating position .
B5H0792A
(1) Retractor
C : REAR CENTER THREE-POINT TYPE SEAT BELT (WAGON)

A three-point type seat belt is available for the center seating position of the rear seat.
The retractor for the seat belt is installed on the ceiling at the rear right of the cabin .
B5H0606A
(1) Retractor
(2) Bracket
SB-3
SEAT BELT
Seat Belt System
D: SEAT ANCHORED INNER BELT

The front inner belt (buckle stalk) is attached to the front seat rather than to the floor. This keeps
the position of the occupant relative to the front inner belt always constant even when the front seat
is moved for adjustment .
When an impact is applied to the occupant in a collision, the inner belt is pulled together with the
upper hook in the direction of the arrow to engage the upper hook with the lower hook. As a result,
the impact load is transmitted to the vehicle body and dispersed .
(1)
(3)
1
A
H5H0807
(1) Inner belt

(2) Upper hook
(3) Lower hook
E: AUTOMATIC RETRACTOR
When the front passenger's seat belt and the rear seat belts for the right and left seating positions
are drawn out completely, their retractors are placed in the automatic locking mode which is used
when installing a child restraint system . In this mode, the belt can be retracted but cannot be ex-
tended . When the belt is retracted to a certain length, this mode is cancelled and normal operation
is restored .
retrFully
acted I , Normal mode, Automatic locking mode
I extended
Belt can be Belt can be retracted but

extended and I cannot be extended .
retracted .
Automatic locking Normal mode to

mode to normal mode automatic locking
changeover I I modechangeove
B5H0328A
SB-4
SEAT BELT
Seat Belt System
F : PRETENSIONER
1 . CONSTRUCTION
The driver's and front passenger's seat belts are equipped with seat belt pretensioners .
The pretensioners use the front sub sensors and the airbag control module inside sensors to con-
trol their operation . If the sensors detect an impact exceeding the predetermined level during a
frontal or front-angled collision, the front seat belts are quickly rewound by the retractors to take
up slacks for maximum restraining of the seat occupants . If the load placed on a seat belt exceeds
the predetermined level, the torsion bar twists to allow the belt to be payed out, thus lessening the
load imposed on the belt wearer's chest . Once the seat belt pretensioner has been activated, the
seat belt retractor remains locked .
(5)
B5H0828A
(1) Webbing
(2) Retractor
(3) Rack
(4) Pinion gear
(5) Torsion bar
SB-5
SEAT BELT
Seat Belt System
2 . FUNCTION
Safty sensor and ~ ~- Airbag

electric sensor 1
Front sub sensor
Collision occurs .
Retractor with
pretensioner
Front sub sensor, electric

sensor and safety sensor
detect an impact exceeding
predetermined level .
ty e Pretensioneroperates .
410-
Completion .
B5H0630B
SB-6
SEAT BELT
Seat Belt System
3. CAUTION LABEL
41t iJ A L, Vii . i~`#TiE

co:
DO NOT REMOVE, IMPACT
OR DISASSEMBLE.
NE PAS ENLEVER, PROVOQUER DOr

DE CHOC OU DEMONTER .
47372
I
J
B5H0829
S B-7
STARTER
Starting/Charging
1 . Starter
The starter is of a reduction type . Its output is 1 .0 kW on the MT model and 1 .4 kW on the AT model .
Starter switch
Lion
B2H3980A
SC-2
GENERATOR
Starting/Charging
2. Generator
The aenerator has a built-in regulator which provides diagnostic functions in addition to a voltage
regulating function as follows :-
1) Voltage regulation
The on-off operation of transistor Tr1 connects and disconnects the field current circuit, providing
a constant level of output voltage .
2) Diagnosis warning
When any of the following problems occur, the charge lamp illuminates .
a . No voltage generation
Brush wear exceeds specified wear limits, field coil circuit is broken, etc .
b . Excessive output
Output voltage is greater than 16 volts (approx .)
c . Terminal B disconnection
Harness is disconnected from alternator terminal B .
d . Terminal S disconnection
Harness is disconnected from alternator terminal S . In this case, voltage is slightly greater than
specified regulated voltage ; however, voltage regulation is still controlled and the battery is
prevented from becoming overcharged .
Trio diode (3 pcs.)

Plus diode (3 pcs .) 1 .----------------------
Energizing
Additional diode (2 pcs .) circuit
Tr3 '
S OS
IG switch
I
Tri ~
Stator coil Constant
voltage . (al Charge
circuit light
T
Irz
Diagnostic
and warning
circuit
7777-
Field coil -----------------------
IC regulator
O : Alternator terminal
O : Regulator terminal
Minus diode (3 pcs .)
B2H3981 A
SC-3
BATTERY
Starting/Charging
3 . Battery
;All ,m, ,nriPlC aYP Pni iinnPrj ~~/~t{'~ mu~r~tonun~o_froo
~aii°iiQ~ .
SC-4
STARTER
Starting/Charging
1 . Starter
The starter is of a reduction type . Its output is 1 .4 kW.
Starter switch
lion
B2H3980A
SC-2
GENERATOR
Starting/Charging
2. Generator
The generator has a built-in regulator which provides diagnostic functions in addition to a voltage
regulating function as follows :
1) Voltage regulation
The on-off operation of transistor Tr1 connects and disconnects the field current circuit, providing
a constant level of output voltage .
2) Diagnosis warning
When any of the following problems occur, the charge lamp illuminates .
a . No voltage generation
Brush wear exceeds specified wear limits, field coil circuit is broken, etc .
b. Excessive output
Output voltage is greater than 16 volts (approx .)
c . Terminal B disconnection
Harness is disconnected from alternator terminal B .
d . Terminal S disconnection
Harness is disconnected from alternator terminal S . In this case, voltage is slightly greater than
specified regulated voltage ; however, voltage regulation is still controlled and the battery is
prevented from becoming overcharged .
Trio diode (3 pcs .)

Plus diode (3 pcs .) 1 .----------------------
Energizing
Additional diode (2 pcs .) circuit
Tr3
S SO
`r v IG switch
TO
Stator coil Constant
olt
vvoltage Charge
circuit § light T
I
I
Tr2
Diagnostic
and warning
circuit
Field coil
-----------------------
IC regulator
O : Alternator terminal
O : Regulator terminal
Minus diode (3 pcs.)
B2H3981A
SC-3
BATTERY
Starting/Charging
3 . Battery
All mnrlAlc arP orri iinnArl With maintonanro_froo hottorioe
. . . . . -- - v._1-~- vv iu III -i i- - ivv i i vv "uLLL,i iw .
SC-4
FRONT SEAT
Seats
1 . Front Seat
A: AUaJIJSI IVICIV 1
1 . STANDARD SEAT
" The height of each headrest is adjustable to any of the 4 positions available at 18 mm (0.71 in)
steps .
" The angle of each backrest is adjustable to any of the 32 positions available at 2° steps.
" The front seat can be slid back and forth to one of the 17 positions available at 13 .5 mm (0.53
in) steps .
33rd position
1 st position
i ou i Nwnwii
17x13 .5 mm (0 .53 in)
B5H0824C
SE-2
FRONT SEAT
Seats
2 . POWER SEAT (6-WAY)

e The driver's 6-way power seat has a function of automatically adjusting its fore-aft position, cush-
ion's front and rear portion h eights, 10ac k resIL an g le, and headrest hei g ht in. res p onse to op eration
of the corresponding switches .
* The height of the headrest is adjustable to any of the 4 positions available at 18 mm (0.71 in)
steps .
" The angle of the backrest is adjustable to any of the 32 positions available at 2° steps .
r The front seat can be slid back and forth steplessly within a 229 .5 mm (9 .04 in) range .
" The front portion height of the seat cushion can be adjusted steplessly within a 35 mm (1 .38 in)
range.
" The rear portion height of the seat cushion can be adjusted steplessly within a 25 mm (0 .98 in)
range .
33rd position
229 .5 mm (9 .04 in) B5H0825B
SE-3
FRONT SEAT
Seats
3. POWER SEAT (8-WAY)

" The driver's 8-way power seat has a function of automatically adjusting its fore-aft position, cush-
1 f lelyfll5, backrest forward and backward angles, and headrest height
IVI I J I I VI Il and rear portion
in response to operation of the corresponding switches .
" The height of the headrest is adjustable to any of the 4 positions available at 18 mm (0.71 in)
steps .
" The angle of the backrest is adjustable steplessly within a 18° range forward and a 58° range
backward .
" The front seat can be slid back and forth steplessly within a 229 .5 mm (9 .04 in) range
" The front portion height of the seat cushion can be adjusted steplessly within a 35 mm (1 .38 in)
range.
" The rear portion height of the seat cushion can be adjusted steplessly within a 25 mm (0 .98 in)
range .
18°
229 .5 mm (9.04 in)

B5H1093A
SE-4
FRONT SEAT
Seats
B : SEAT HEATER
The electric seat heater consists of wire heating elements embedded in the seat cushion and
backrest under the seat covering . Heating temperature can be selected between two settings :
high-temperature setting for quick warming and low-temperature setting for continuous warming .
Two thermostats are used to maintain a selected temperature and ensure safety.
G5H0503
C : LUMBAR SUPPORT
The position of the lumber support plate in the backrest changes as the lumbar support adjust-
ment lever is operated to adjust the force of support to the occupant's lower back .
bar
Lumbar sub
adjustment Lumber support plate ~ i:~
Torsion bar
I
I ly
I
I
~~ i Lumbar support plate
S5H0005A
SE-5
REAR SEAT
Seats
2. Rear Seat
A- OPERATION
SEDAN
A trunk-through hatch is provided behind the armrest. It is accessed by folding down the cen-
tral portion of backrest which also serves as an armrest in its down position .
WAGON
The rear seat is foldable by following the illustrated steps .
B5H0826B
SE-6
REAR SEAT
Seats
B : BUILT-IN CHILD RESTRAINT

The built-in child restraint is designed for use only with a child who is between 9 .05 kg (20 Ib .) and _.
18 .09 kg (4U ib .) in weight, 1100 mm (44 .~i in) or less in height, capable or` sitting upright ray ise~land
a shoulder lower than the shoulder belt slot .
ko) B5H0827A
(1) Lap-shoulder belt

(2) Chest clip
(3) Release button
(4) Crotch belt
(5) Warning label
(6) Child restraint cushion
(7) Belt buckle
(8) Tongue plate
(9) Maximum shoulder height indicator label
(10) Removable pad
SE-7
IGNITION SWITC1H
Security and Locks
1 . Ignition Switch
A: DESCRIPTION
" The ignition switch has a function of giving the driver warning by sound if he or she opens the
door with the key still in the "LOCK" or "ACC" position .
" The ignition switches on the MT models have a safety mechanism that prevents inadvertent lock-
ing of the steering wheel during driving . The driver cannot turn the ignition key from "ACC" to
"LOCK" unless the key is pushed inward at the "ACC" position (arrow 1 in the drawing below) .
S6H0483
" The ignition switches on the AT models have a key interlock mechanism to avoid locking of the
steering wheel during driving . The ignition key can be turned to the "LOCK" position only when
the select lever is in the P position .
NOTE :
Should the key be impossible to turn to "LOCK" when the select lever is in the P position due to
failure of the key interlock mechanism, the interlocking can be cancelled by operating the release
lever located on the underside of the steering column .
Ignition switch
Key interlock solenoid (AT)
S6H0484A
SL-2
POWER DOOR LOCK
Security and Locks
2. Power Door Lock

A : CONSTRUCTION
The power door lock system consists of driver's and front passenger's door lock switches, front
door lock actuators, rear door lock actuators, and a rear gate lock actuator (WAGON) .
B6H1298A
(1) Unlock
(2) Lock
B : CIRCUIT DIAGRAM
Door lock timer 1 2 3 4

51 61 71 81
O+ Batt Door lock timer
connector
Lock sw Lock output

2
T I Unlock Unlock
sw output
3
b b b b
Lock Unlock Lock Unlock M t M 1 l M 1 l M 1 km
Front Front Rear Rear Rear gate

LH RH LH RH lock actuator
Driver's Front
actuator actuator actuator actuator (Wagon)
door passenger's
lock sw door
lock sw
B6H0759B
SL-3
Security and Locks
3. Keyless Entry System

A: CONSTRUCTION
" The keyless entry system consists of a transmitter, keyless entry control module (with a built-in
antenna), door lock actuators, door switches, horn and interior light .
" The keyless entry system operates on a radio frequency, so its transmitter can be used in almost
all directions relative to the vehicle.
B : FUNCTION
1 . DOOR LOCKING
1) Push the transmitter's LOCK button once .
2) All doors are locked .
3) Check that the horn chirps once .
2 . DOOR UNLOCKING (DRIVER'S DOOR)

1) Push the transmitter's UNLOCK button once.
2) The driver's door is unlocked and the interior light turns ON (when the interior light switch is set
at the middle position) .
NOTE :
The interior light illuminates for 30 seconds and then goes out . (However, if the ignition switch is
turned ON or a door locking procedure is performed again during this period, the light will go out
immediately.)
3) Check that the horn chirps twice .
3 . DOOR UNLOCKING (ALL DOORS)

1) Push the transmitter's UNLOCK button twice .
2) All doors are unlocked .
3) No audible or visible sign is given even after all the doors are unlocked .
4. PANIC ALARM SETTING

1) Push the transmitter's LOCK button for more than 2 seconds .
2) The horn sounds continuously . To stop the horn, push any transmitter's button .
5. ANSWER BACK (HORN SIGNALING) ON/OFF SELECTION

1) Push the transmitter's LOCK and UNLOCK buttons simultaneously for more than 2 seconds to
activate the answer back function and push them again to deactivate it .
2) When the answer back function is activated, the horn will sound once . When it is deactivated,
the horn will sound twice.
6. DOOR OPEN WARNING FUNCTION

" The horn sounds three times if the transmitter's LOCK button is pressed with any door, rear gate
or trunk lid opened .
SL-4
SECURITY SYSTEM
Security and Locks
4. Security System
A: FEATURES
" The security system protects the vehicle from a theft action (unauthorized entry into the vehicle) .
Upon detection of such an action, it gives audible and visible alarms by causing the horn to sound
and the parking lights to flash . It also immobilizes the vehicle by disabling the starter circuit .
" Unauthorized entry is monitored through the switches on the doors, rear gate and trunk lid . If
one of the switches is turned ON, the system interprets it as an attempt of unauthorized entry and
gives alarms while disabling the starter circuit.
" Unauthorized entry is also monitored by the impact sensor. The system operates in the same
manner as mentioned above whenever the sensor senses an abnormal impact on the vehicle.
1 . ALARMS
" When activated, the security system causes the parking lights to flash and the horn to sound
intermittently . In addition, the security indicator light on combination meter flashes fast and the
starter motor circuit is disabled .
" The alarms automatically turn OFF after 30 seconds . However, they will be reactivated if the ve-
hicle is tampered with again .
" The alarms are activated when a door, rear gate or trunk lid is opened without using the keyless
entry transmitter . (When the system is armed, the alarms will be triggered even if a door is opened
by releasing the inside door handle or the trunk lid is opened by operating the trunk lid release
lever.)
" They are also activated when an impact on vehicle body is sensed .
2. HOW TO ARM THE SYSTEM

1) Remove the key from the ignition switch .
2) Make sure that the trunk lid is closed .
3) Close all the windows . Close and lock all the doors and rear gate .
4) Push the transmitter's LOCK button .
5) The horn will chirp once and the parking lights will flash once .
NOTE:
The system can be armed even if the windows are open .
6) Confirm that the security indicator light blinks slowly (once every two seconds) . If any of the
doors, rear gate or trunk lid is not properly closed, the system warns the driver of this by causing
the horn to chirp three times, the parking lights to flash three times, and the security indicator to
flash rapidly. When the door, rear gate or trunk lid is closed, it will be automatically locked and the
security system starts working . The indicator light blinks every two seconds when the system is
armed and continues to blink until the system is disarmed .
SL-5
SECURITY SYSTEM
Security and Locks
3 . HOW TO DISARM THE SYSTEM

1) Push keyless entry transmitter's UNLOCK button .
2) The horn will chirp twice and the parking lights flash twice.
3) The security indicator light turns OFF.
4) The interior light will illuminate for 30 seconds and then turns OFF. (However, if ignition switch
is turned ON or a system arming procedure is performed during this period, the interior light will
turn OFF.)
4. HOW TO STOP ALARMS

Push the transmitter's UNLOCK button or turn the ignition switch from "LOCK" to "ON" repeatedly
three times at an interval shorter than five seconds .
SL-6
GENERAL
Speed Control System
1 . General
The accelerator outer cable is secured to the accelerator pedal bracket rather than to the toe-
board . Securing the outer cable in this way has a merit of making the ratio of throttle valve move-
ment to cable stroke less variable . This arrangement is also effective to prevent unsmooth cable
return movement that may result from deformation of the toeboard or improper installation of the
accelerator pedal and, therefore, to improve safety.
Accelerator cable
Grommet
Toeboard
Accelerator pedal
B2H4134A
SP-2
GENERAL
Speed Control System
1 . General
Thl, n~~ i, li,rn+r,r .+ .-,r .~,hll, .-..-1 .~, + h l. + .-. .J,~,I + ..
I I IG QlrIr G IGI 0
.W1 outer cable Is secured 'Lo 11 IG accele rator p edal bracket rathe r than lV the
11 IC to e-
board . Securing the outer cable in this way has a merit of making the ratio of throttle valve move-
ment to cable stroke less variable . This arrangement is also effective to prevent unsmooth cable
return movement that may result from deformation of the toeboard or improper installation of the
accelerator pedal and, therefore, to improve safety.
In addition, the floating type casing cap through which the cable is attached to the bracket re-
duces vibration of the pedal, thus improving quietness .
Casing cap (floating type)
Accelerator c
Gromm
Accelerator pedal
;ket
B2H4139A
SP-2
SUNROOF
Sun roof/T-top/Convertible Top
1 . Sunroof
A: SEDAN
1 . DESCRIPTION
The sunroof has both tilting and sliding mechanisms . The tilting mechanism raises or lowers the
rear of the glass lid when the tilt switch is operated ; the sliding mechanism moves the lid backward
to open or forward to close when the OPEN/CLOSE switch is operated .
The sunroof has the following features :
* Reduced thickness of the sunroof provides extra overhead clearance in the passenger
compartment .
" Extensive use of aluminium die castings for sunroof components contributes to reduction in
weight .
2. FUNCTION
SUNROOF TILTING AND SLIDING OPERATION
" With the sunroof fully closed, pushing the rear side of the tilt switch causes the rear end of the
sunroof lid to rise by 50 mm (1 .97 in) . Pushing then the front side of the switch causes the lid
to lower to the original position .
" Pushing the OPEN/CLOSE switch rearward causes the sunroof lid to slide rearward and open .
Pushing the switch forward causes the glass lid to move forward and stop at a point 150 mm
(5 .91 in) before the fully closed position . Pushing the switch again closes the lid completely.
" SUN SHADE OPERATION

" The sun shade can be opened or closed manually when the sunroof is closed .
" The sun shade, if closed, moves rearward together with the glass lid when the open side of
the OPEN/CLOSE switch is pushed .
SR-2
SUNROOF
Sunroof/T-top/Convertible Top
3. SLIDING AND TILTING MECHANISMS

The motor installed at the front of the sunroof frame rotates a pinion gear to move the drive wire.
This opens, closes, tilts up or tilts down the glass lid by way of the rear guide connected to the drive
wire .
Fully closed condition Tilt-up condition
(4)
B5H0839B
(1) Front guide

(2) Rear guide
(3) Lid bracket
(4) Link
SR-3
SUNROOF
Sunroof/T-top/Convertible Top
B : WAGON
1 . DESCRIPTION
B5H0629A
(1) Front glass lid

(2) Rear glass lid
(3) Motor
(4) Rear frame
(5) Front frame
" The front sunroof is a tilting type . The rear end of the glass lid can rise by 50 mm (1 .97 in) .
" The rear sunroof is a sliding type . When the sunroof is fully opened, the opening area is 340 mm
(13 .39 in) long and 632 mm (24.88 in) wide .
" Each sunroof uses a 4 mm (0.16 in) thick glass lid and a sunshade .
SR-4
SUNROOF
Sun roof/T-top/Convertible Top
2. FUNCTION
" OPEN AND CLOSE OPERATIONS
" With the front sunroof fully lowered, holding the OPEN side of the sunroof switch pressed
causes the rear end of the front glass lid to tilt up by 50 mm (1 .97 in) and then come to a stop .
If the switch is released and its OPEN side pressed again, the rear glass lid now opens, sliding
rearward by 200 mm (7 .87 in) and stops there . The glass lid further goes to the fully open position
if the OPEN side of the sunroof switch is pressed again .
" With the rear sunroof fully open, holding the CLOSE side of the sunroof switch pressed causes
the glass lid to move forward until its front edge reaches a point 150 mm (5.91 in) away from the
fully closed position . The rear glass lid moves to the fully closed position if the CLOSE side of
the sunroof switch is released and then pressed again .
Pressing the same side of the switch after complete closure of the rear sunroof causes the front
glass lid to tilt down completely .
" SUNSHADE OPERATION

" The front sunshade can be manually opened or closed regardless of the position of the front
glass lid .
" The rear sunshade is automatically opened or closed together with the glass lid . In addition,
when the glass lid is fully closed, the sunshade can be opened or closed manually.
SR-5
VEHICLE DYNAMICS CONTROL (VDC) SYSTEM
VDC
1 . Vehicle Dynamics Control (VDC) System

A: OUTLINE
The vehicle dynamics control (VDC) system is a driver assist system which enhances vehicle's
running stability by utilizing the anti-lock brake system (ABS) and traction control system (TCS)
functions in combination with its own function which reduces sudden changes in vehicle behavior
that are likely to occur when travelling on a slippery road or quickly avoiding an obstacle on the
road.
(12) (13) ,. . .
1 -1
(14)
B4H2340A
(1) VDC hydraulic control unit (7) VDC warning light (13) Tone wheel
(2) Proportioning valve (8) VDC operating indicator light (14) Wheel cylinder
(3) Engine control module (9) VDC OFF indicator light (15) Yaw-rate and lateral G sensor
(4) Master cylinder (10) Steering angle sensor (16) Automatic transmission
control module
(5) Diagnosis connector (11) Data link connector (for SUBARU (17) VDC control module
select monitor)
(6) ABS warning light (12) ABS sensor (18) Pressure sensor
VDC-2
VDC
B: OPERATION PRINCIPLE OF VDC

1 . OVERSTEER SUPPRESSION
When the vehicle starts to spin during cornering, the VDC control module (VDCCM) actuates the
brakes on the front and rear outer wheels . As a result, a force that counteracts the oversteer-caus-
ing yaw moment is generated so that the vehicle's behavior is stabilized.
B4H1634B
(1) Braking force

(2) Oversteer-causing yaw moment
2 . UNDERSTEER SUPPRESSION
When the vehicle starts to drift outward during cornering, the VDCCM causes the rear inner wheel
to be braked . As a result, a force that counteracts the understeer-causing yaw moment is gener-
ated so that the vehicle's behavior is stabilized .
B4H1635B
(1) Braking force

(2) Understeer-causing yaw moment
VDC-3
VDC
C: FUNCTIONS USED IN VEHICLE'S BEHAVIOR STABILIZATION CONTROL

VDC function The VDC control module (VDCCM) determines the driver's intention from the data provided by the
steering angle sensor, braking pressure sensor, engine-related sensors and other relevant sources
and recognizes the result as the target vehicle behavior . At the same time, it determines the vehicle's
actual behavior from the data provided by the yaw-rate sensor, lateral G sensor, ABS sensor and
other relevant sources. Then, the module compares the target and actual vehicle behaviors to esti-
mate how the vehicle is running (whether it understeers, oversteers, slips or is in other condition),
and based on the result, performs braking control of individual wheels, engine output control and
AWD control as necessary to correct the vehicle's running condition .
TCS function The TCS constantly receives signals from the relevant sensors to monitor the vehicle speed. When
the running wheels slip exceeding a certain limit, it performs braking control of individual wheels, en-
gine output control and AWD control as required to maintain optimal traction and adequate side force.
ABS function The ABS constantly receives signals from the relevant sensors to monitor the vehicle speed. When
the slip of wheels during braking exceeds a certain limit, it performs braking control of individual
wheels and AWD control as required to maintain optimal traction and adequate side force.
NOTE:
" "Braking control" is effected by the VDCCM as follows :
The VDCCM calculates the required braking force for each wheel and sends signals to the VDC
hydraulic unit . The hydraulic unit's motor pump is then operated to generate the required hydraulic
pressure . Further, it controls the hydraulic unit's solenoid valves to increase, maintain or decrease
the hydraulic pressure applied to the brake wheel cylinder as required .
When the brakes are applied by the driver, however, the braking force is controlled by the hydraulic
pressure resulting from the driver's action .
" "Engine output control" is effected by the VDCCM as follows :
The VDCCM calculates the target engine output for each condition, and compares it with the cur-
rent engine output . Based on the result of comparison, it determines the number of cylinders for
which fuel injection is to be stopped and sends a command to the engine control module. The tar-
geted engine output is then achieved .
" "AWD control" is effected by the VDCCM as follows :
When necessary, the VDCCM sends a command to the automatic transmission control module.
According to the command, the transmission control module controls the transfer clutch so that
the torque is distributed between the front and rear axles optimally.
VDC-4
VDC
D : SYSTEM COMPONENTS AND FUNCTIONS

VDCCM 0 Determines the vehicle's running condition from various sensor signals and, based on the result, con-
trols the VDC hydraulic control unit, ABS and TCS as required .
Performs CAN communication with the automatictransmission control module and the steering angle
sensor.
Causes the system to stop and the warning lightto illuminate if a faultoccurs in a circuit of the electrical
system . Stores the code that indicates the location of the fault.
VDC Hydraulic Control Actuates the pump motor in response to a command from the VDCCM and changes fluid passages
Unit (VDCH/U) using solenoid valves to control the hydraulic pressures applied to the wheel cylinders.
Steering angle sensor Detects the steering direction and angle when the steering wheel is operated by the driver and out-
puts signals corresponding to them to the VDCCM.
Yaw-rate and lateral G Detects the yaw-rate and lateral G of the vehicle and outputs it to the VDCCM .
sensor
Pressure sensor Detects the hydraulic pressure resulting from driver's brake pedal operation and outputs it to the
VDCCM .
ABS sensor (wheel Detects the speed of each wheel and outputs it to the VDCCM.
speed sensor)
Tone wheel Causes changes in magnetic flux density as its teeth move to enable the ABS sensor to detect the
wheel speed.
Engine Control Module Controls the engine output in response to commands from the VDCCM. Further, it transmits current
(ECM) engine output and engine speed signals to the VDCCM .
Automatic transmission Controls the transfer clutch in response to commands from the VDCCM during VDC control, ABS
control module control or TCS control so that torque is distributed optimally between the front and rear axles.
ABS warning light Alerts the driver to an ABS fault.
VDC warning light Alerts the driver to a VDC or TCS fault.
VDC operating indica- Blinks when the VDC is operating or lights steadily when the TCS is operating.
for light
VDC OFF indicator Illuminates to tell the driver that the VDC and TCS are inactive (not due to a system failure) .
light
NOTE:
CAN (Controller Area Network) communication refers to bidirectional multiplex high-speed com-
munication .
VDC-5
VDC
_J
B4H2341A
(1) VDC control module (14) Primary suction solenoid valve (27) BATTERY
(2) Relay box (15) Primary cut solenoid valve (28) Front left ABS sensor
(3) Valve relay (16) Secondary suction solenoid valve (29) Front right ABS sensor
(4) Motor relay (17) Secondary cut solenoid valve (30) Rear left ABS sensor
(5) Hydraulic control unit (18) Pump motor (31) Rear right ABS sensor
(6) Front left inlet solenoid valve (19) Primary pressure sensor (32) Yaw-rate and lateral G sensor
(7) Front left outlet solenoid valve (20) Secondary pressure sensor (33) Engine control module
(8) Front right inlet solenoid valve (21) VDC OFF switch (34) Automatic transmission control
module
(9) Front right outlet solenoid valve (22) ABS warning light (35) Steering angle sensor
(10) Rear left inlet solenoid valve (23) VDC warning light (36) Diagnosis connector
(11) Rear left outlet solenoid valve (24) VDC operating indicator light (37) Data link connector
(12) Rear right inlet solenoid valve (25) VDC OFF indicator light
(13) Rear right outlet solenoid valve (26) Ignition relay
VDC-6
VDC
E : OPERATION OF VDC HYDRAULIC CONTROL UNIT (VDCH/U)

1 . DURING NORMAL BRAKING
No solenoid valves are energized . The ports of the inlet solenoid valve and cut solenoid valve are
open, while the ports of the outlet solenoid valve and suction solenoid valve are closed .
In this state, the fluid pressure generated by the master cylinder can be applied to the wheel cylin-
der through the open ports of the cut solenoid valve and inlet solenoid valve.
NOTE :
For simplicity of explanation, operation of the hydraulic control unit is represented by operation
of a single wheel circuit.
VDC-8
VDC
(20]
1341-1163713
(1) Reservoir tank (9) De-energized (17) Motor
(2) Master cylinder (10) De-energized (18) Wheel cylinder

(3) Pressure sensor (11) Damper chamber (19) Outlet solenoid valve
(4) Port open (12) Port open (20) Port closed
(5) Port closed (13) Inlet solenoid valve (21) De-energized
(6) Suction solenoid valve (14) Pump (22) Reservoir
(7) Cut solenoid valve (15) Check valve

(8) Check valve (16) De-energized
VDC-9
VDC
2. PRESSURE "DECREASE" CONTROL WITH BRAKE PEDAL DEPRESSED

The inlet solenoid valve and outlet solenoid valve are energized ; while the other solenoid valves
are not energized . This means that the ports of the inlet solenoid valve and suction solenoid valve
are closed, while those of the outlet solenoid valve and cut solenoid valve are open .
Although the fluid pressure generated by the master cylinder can reach the inlet solenoid valve
through the open port of the cut solenoid valve, the pressurized fluid cannot go further since the
passage is blocked there . On the other hand, since the port of the outlet solenoid valve is open,
the brake fluid in the wheel cylinder can flow out into the reservoir. The fluid pressure in the wheel
cylinder decreases as a result . The brake fluid in the reservoir is pumped back into the master
cylinder .
NOTE :
of a single wheel circuit .
VDC-10
VDC
X20;
(22)
B4H1638B

(4) Port open (12) Port closed (20) Port open
(5) Port closed (13) Inlet solenoid valve (21) Energized

(8) Check valve (16) Energized
VDC-11
VDC
3. PRESSURE "HOLD" CONTROL WITH BRAKE PEDAL DEPRESSED

Only the inlet solenoid valve is energized . This means that the ports of the inlet solenoid valve, out-
et soienoia waive an -a' suction soienoia waive are all ciosea except tF-1at of the cut soienoiU waive .
In this state, the fluid pressure generated by the master cylinder is transmitted through the open
port of the cut solenoid valve to the inlet solenoid valve but not beyond the inlet solenoid valve
since the passage is blocked there. As the port of the outlet solenoid valve is also closed, the fluid
pressure in the wheel cylinder is held unreleased .
The pump is always operated whenever commanded by the VDCCM.
NOTE :
VDC-12
VDC
X20;
(22)
B4H1639B

(4) Port open (12) Port closed (20) Port closed
Cut solenoid valve (15) Check valve
Check valve (16) Energized
VDC-13
VDC
4. PRESSURE "INCREASE" CONTROL WITH BRAKE PEDAL DEPRESSED

No solenoid valves are energized . This means that the ports of the inlet solenoid valve and cut
solenoid valve are open, while those of the outlet solenoid valve and suction solenoid valve are
closed .
In this state, the fluid pressure generated by the master cylinder is transmitted to the wheel cylinder
through the open ports of the cut solenoid valve and inlet solenoid valve, applying the brake with
an increased force . The pump is always operated whenever commanded by the VDCCM .
NOTE :
VDC-14
VDC
X20;
(22)
B4H1640B
Reservoir tank (9) De-energized (17) Motor
Master cylinder (10) De-energized (18) Wheel cylinder

(4) Port open (12) Port open (20) Port closed
Cut solenoid valve (15) Check valve
Check valve (16) De-energized
VDC-15
VDC
5 . PRESSURE "INCREASE" CONTROL WITH BRAKE PEDAL NOT DEPRESSED

The cut solenoid valve and suction solenoid valve are energized while the other solenoid valves
are not ener~ienergized . Thi smeans that the ports of the cut solenoid valve and outlet sc~ie~~uiu valve
are closed, while those of the inlet solenoid valve and suction solenoid valve are open .
In this state, the pump is activated, forcing the brake fluid in the master cylinder reservoir tank into
the wheel cylinder through the open port of the suction solenoid valve and then through the open
port of the inlet solenoid valve. The brake is then applied with an increased force .
NOTE :
VDC-16
VDC
X20;
(22)
B4H 1641 B
(1) Reservoir tank (9) Energized (17) Motor

(2) Master cylinder (10) Energized (18) Wheel cylinder
(4) Port closed (12) Port open (20) Port closed
(5) Port open (13) Inlet solenoid valve (21) De-energized
VDC-17
VDC
6. PRESSURE "HOLD" CONTROL WITH BRAKE PEDAL NOT DEPRESSED

The cut solenoid valve, suction solenoid valve and inlet solenoid valve are all energized, while the
outlet solenoid valve is de-energized . This means that the ports of the cut solenoid valve, inlet sole-
noid valve and outlet solenoid valve are closed, while the port of the suction solenoid valve is open .
In this state, the pump is activated, forcing the brake fluid in the master cylinder reservoir tank
through the open port of the suction solenoid valve . The fluid passage is, however, blocked by the
closed inlet solenoid valve . Since the port of the outlet solenoid valve is also closed, the fluid pres-
sure in the wheel cylinder is held unreleased .
The fluid pressure generated by the pump becomes higher and higher because the port of the
inlet solenoid valve is closed . When it reaches a certain level, the built-in relief valve of the cut sole-
noid valve opens and allows the brake fluid to return into the master cylinder reservoir tank .
NOTE :
VDC-18
VDC
(10)
(21 :
(23)
B4H1642B
(1) Reservoir tank (9) Energized (17) Energized

(2) Master cylinder (10) Relief valve (18) Motor
(3) Pressure sensor (11) Energized (19) Wheel cylinder
(4) Port closed (12) Damper chamber (20) Outlet solenoid valve
(5) Port open (13) Port closed (21) Port closed
(6) Suction solenoid valve (14) Inlet solenoid valve (22) De-energized
(7) Cut solenoid valve (15) Pump (23) Reservoir
(8) Check valve (16) Check valve
VDC-19
VDC
7. PRESSURE "DECREASE" CONTROL WITH BRAKE PEDAL NOT DEPRESSED

The cut solenoid valve, suction solenoid valve, inlet solenoid valve and outlet solenoid valve are
all energized . This means that the ports of the cut solenoid valve and inlet solenoid valve are
closed, while those of the suction and outlet solenoid valves are open .
In this state, the pump is activated drawing the brake fluid from the reservoir and forcing it toward
the master cylinder through the open port of the suction solenoid valve. The fluid passage is
blocked by the inlet solenoid valve, so the fluid cannot flow toward the wheel cylinder. Since the
port of the outlet solenoid valve is open, on the other hand, the brake fluid in the wheel cylinder
is allowed to be drawn into the reservoir, so the fluid pressure in the wheel cylinder decreases . The
brake fluid drawn into the reservoir is raised from it and forced into the master cylinder reservoir
tank through the suction solenoid valve .
The pressure of the fluid in the passage toward the cut solenoid valve becomes higher and higher
as the pump operates since the valve is closed . When the pressure reaches a certain level, the
build-in relief valve of the cut solenoid valve opens, releasing the brake fluid into the master cylin-
der reservoir tank .
NOTE:
VDC-20
VDC
(10)
(23) 1341-1164313
Reservoir tank (9) Energized (17) Energized

(2) Master cylinder (10) Relief valve (18) Motor
(3) Pressure sensor (11) Energized (19) Wheel cylinder
(4) Port closed (12) Damper chamber (20) Outlet solenoid valve
(5) Port open (13) Port closed (21) Port open
(6) Suction solenoid valve (14) Inlet solenoid valve (22) Energized
Cut solenoid valve (15) Pump (23) Reservoir
Check valve (16) Check valve
VDC-21
FRONT WIPER AND WASHER
1 . Front Wiper and Washer

A: DESCRIPTION
1 . FRONT WIPER
1) The front wiper is of a tandem type featuring wide wiping area . The blade is installed to the arm
by means of U-hook joint to improve serviceability.
2) The front wiper operates in the HI and LOW speed modes and the INTERMITTENT mode.
The operation modes can be selected by turning the wiper switch incorporated in the combination
switch .
3) In the INTERMITTENT mode, the intermittent unit installed behind the combination switch con-
trols the front wiper operation interval .
4) The front wiper system uses a modular construction in which the wiper motor forms an integral
part of the linkage. The motor is installed on the body through rubber mounting .
B6H 1164
2. FRONT WASHER SYSTEM

1) The washer system consists of a washer tank, a motor and pump unit and a pair of nozzles .
2) The washer tank is installed at the front of the strut mount on the left side of the engine compart-
ment.
3) The washer motor and pump unit is installed at the bottom of the washer tank.
4) The washer nozzles are installed on the hood . Each nozzle has two spray holes .
5) Each washer nozzle is provided with a check valve which is located just below it.
WW-2
FRONT WIPER AND WASHER
3. SPECIFICATIONS
Washer Tank Capacity 4.0 liters (4 .2 US qt, 3.5 Imp

. qt)
. . i
Wiper Motor I Rated voltage I 12 V
No-load current 4 A or less
Speed HIGH 65±5rpm
[at 2.0 N~m (20 kg-cm, 17 in-Ib)]
LOW 45 ± 5 rpm
Locked rotor charac- HIGH Torque 29 .4 N~m (300 kg-cm, 2.2 ft-Ib)
teristics
Current 31 .5 A or less
LOW Torque 34 .3 N~m (350 kg-cm, 2.5 ft-Ib)
Current 36 .0 A or less
Wiper Blade I Length I Driver side 550 mm (21 .65 in)
Passenger side 500 mm (19 .69 in)
WW-3
REAR WIPER AND WASHER
2 . Rear Wiper and Washer

A: DESCRIPTION
1 . REAR WIPER
1) The rear wiper operates intermittently at a 10-second interval .
2) The rear wiper operates over a 168-degree angle .
1361-11165
3) The wiper blade is attached to the arm by means of a U-hook joint in the same way as with the
front wipers .
2. REAR WASHER SYSTEM

1) The same washer tank is shared by the front and rear washer systems .
2) The washer motor and pump unit is installed at the bottom of the washer tank, adjacent to the
front washer's unit.
3) The washer nozzle is installed on the upper portion of rear gate panel . The nozzle has two spray
holes .
4) The washer nozzle is provided with a check valve which is located just below it .
3. SPECIFICATIONS
Wiper Motor Rated voltage 12 V

No-load current 2 A or less
Speed [at 0.5 N~m (5 kg-cm, 4.3 in-Ib)] 30 ± 5 rpm or more
Locked rotor current 13 A or less
Wiper Blade Length 375 mm (14.76 in)
WW-4
WINDSHIELD WIPER DEICER
3 . Windshield Wiper Deicer

A: CONSTRUCTION
The wiper deicer system is activated when the wiper deicer switch is pressed with the ignition
switch turned ON . It heats the lower part of the windshield with a heater wire to melt the ice that
blocks the wiper blades .
The system turns off automatically in 15 minutes after the wiper deicer switch is turned ON .
Windshield
icer
re
Printedceramic
Heating area of wiper deicer Section A
B6H0857C
B : CIRCUIT DIAGRAM
B6H0858
WW-5
AIRBAG SYSTEM
Airbag System
1 . Airbag System
A: INSTALLATION
(4)
14)
7)
(3)
(3)
B5H0840B
(1) Front sub sensor (8) 4-pin connector (Yellow)
(2) 7-pin connector (Yellow) (9) Airbag control module
(3) 2-pin connector (Yellow) (10) 28-pin connector (Yellow)
(4) Airbag module (Driver) (11) 2-pin connector (Blue)
(5) 12-pin connector (Yellow) (12) Airbag module (Side)
(6) Airbag module (Passenger) (13) 2-pin connector (Yellow) (To seat belt pretensioner)
(7) Side airbag sensor (14) 4-pin connector (Yellow)
AB-2
AIRBAG SYSTEM
Airbag System
B : FUNCTION
FRONT AIRBAGS
The airbag system is provided as a driver and front passenger restraint system supplementary
to the seat belts . When an impact greater than a set level is applied to the front of the vehicle, the
sensors generate an electrical pulse to inflate the airbags in the airbag modules, thus preventing
the driver's and passenger's upper bodies from directly hitting against the steering wheel, instru-
ment panel and/or windshield .
Driver side Passenger side
Safety sensor and rInflator

electric sensor -\
Front sub sensor
Collision
Front sub sensor,

electric sensor and
safety sensor detect
an impact greater
than the set level .
" Inflators are ignited .
" Gas is generated .
Airbag inflation com-

pletes .
" Gas is discharged .
Airbags deflate .
1351-1050413
AB-3
AIRBAG SYSTEM
Airbag System
2. SIDE AIRBAGS
The side airbags provide the driver and front passenger with a restraint supplementary to that by
the seat belts in the event of a side-on collision . When an impact greater than the set level is applied
to either side of the vehicle, the relevant side airbag sensor sends an ignition signal to the corre-
sponding airbag control module . The side airbag module operates to inflate the airbag, thus re-
ducing the shock inflicted in the outside upper body (chest) of the driver or front passenger.
Collision
Side airbag sensor detects

an impact greater than the
set level .
" Inflator is ignited .
" Gas is generated .
" Airbag inflation completes .
" Gas is discharged .
Airbag deflates .
B5H0505B
AB-4
CONSTRUCTION
Airbag System
2. Construction
A: GENERAL
" The airbag system consists of an airbag control module, left and right front sub sensors, an elec-
tric sensor and safety sensor built into the control module, driver's and passenger's airbag mod-
ules each containing an inflator and airbag, and side airbag sensors and modules each contain-
ing an inflator and airbag (Side airbag equipped model) .
FRONT AIRBAG SYSTEM :
A frontal impact exceeding the set level causes the safety sensor, electric sensor and one or both
front sub sensors to input impact signals to the CPU . The CPU determines whether the airbags
should be inflated or not based on these signals .
SIDE AIRBAG SYSTEM :
Input of a side impact signal showing shock energy greater than the set level causes the airbag
on the corresponding side to inflate .
Safety sensor
ront sub
ensor (RH)
Side airbag
Side sensor (RN)
sensc
B5H0552A
AB-5
CONSTRUCTION
Airbag System
B : AIRBAG CONTROL MODULE

The airbag control module is installed in front of the front floor tunnel . It detects the vehicle's decel-
eration by receiving electrical signals from its inside safety and electric sensors as well as one front
sub sensors and judges whether to inflate the airbags . This control module has a built-in self-diag-
nosis function . If a fault occurs inside the system, it lights up the airbag warning light in the com-
bination meter. The fault data is stored in the module . A back-up power supply is provided for pos-
sible damage to the battery during an accident, and a boosting circuit is built into the module in
case of a battery voltage drop.
S5H0010
C : FRONT SUB SENSOR

One front sub sensor is installed on each side, in front of the front wheel apron wall . The front sub
sensor is a pendulum type sensor. If the sensor receives a frontal impact exceeding a certain limit,
the mass in the sensor rotates forward to turn the switch ON .
Iss
Switch contacts
r
B5H0507B
AB-6
CONSTRUCTION
Airbag System
D : AIRBAG SENSOR
The safety sensor and electric sensor are incorporated into the airbag control module and the side
airbag sensors .
The safety sensor is also a pendulum type sensor. If the sensor receives a frontal or side impact
exceeding a certain limit, the mass in the sensor moves in the direction opposite to the impact
direction to turn the switch ON.
The electric sensor consists of a semiconductor type sensor which senses the deceleration
caused by collision in terms of change in the electrical resistance of the impact sensing circuit.
SAFETY SENSOR
ss
Switch contacts
ELECTRIC SENSOR
ical resistance
Semiconductor
H5H0685B
AB-7
CONSTRUCTION
Airbag System
E : AIRBAG MODULE
1 . FRONT AIRBAG
The driver's airbag module is located at the center of the steering wheel and the passenger's air-
bag module is located at upper portion of instrument panel . Each module contains an airbag and
an inflator. If a collision occurs, the inflator produces a large volume of gas to inflate the airbag in
a very short time . Contained in the passenger's airbag module is a dual-stage inflator which can
inflate the airbag in different timings depending on the severity of impact.
Driver's module Passenger's module
(3)
(1)
(5)
B5H0823B
(1) Airbag (4) Dual-stage inflator (Passenger)

(2) Inflator (Driver) (5) Steering support beam
(3) Airbag module lid
2 . SIDE AIRBAG
A side airbag module is located at the outer side of each front seat backrest, and it contains an
airbag and an inflator.
If a side-on collision occurs, the inflator produces a large volume of gas to inflate the airbag in a
very short time .
Inflator Section A
B5H0508A
AB-8
CONSTRUCTION
Airbag System
F : AIRBAG CONNECTORS
1 . DESCRIPTION
The airbag system uses connectors with a double lock mechanism and an incomplete coupling
detection mechanism for enhanced reliability . If coupling is incomplete, the airbag warning light
comes on in the combination meter.
2. AIRBAG HARNESS-TO-AIRBAG HARNESS CONNECTOR

Slide lock
Disconnection : Step 1 :
Push
Step 2 : 123
Slide and hold
(1)
Step 3 :
Release
(2)
Step 2 :
Hold
Step 4 :
Disconnect
Connection :
Insert the male side connector half into the other until a "click" is heard . S5H0012B
AB-9
CONSTRUCTION
Airbag System
3. AIRBAG HARNESS-TO-BODY HARNESS CONNECTOR

Disconnection :
Press the lever (A) to let the green lever (B) pop out . This unlocks the double lock mechanism . Then
separate the connector halves by pulling them apart while pressing the lever (A) .
Connection :
Insert the male side connector half into the other until a "click" is heard, then push in the green lever
(B) until a "click" is heard . This engages the double lock mechanism .
(A)
B5H0841A
AB-10
CONSTRUCTION
Airbag System
4. FRONT SUB SENSOR AND SIDE AIRBAG SENSOR CONNECTORS

Housing A
Outer cover
B5H1130A
Disconnection :
Step 1 : Pull housing A in direction of arrow
while pulling down outer cover.
Outer cover
How
,ing A
Step 3 : Separate housing A and housing B .
I I,,//" I I
1
B5H 1131 A
Connection :
Insert housing B into housing A until a "click" is heard .
AB-11
CONSTRUCTION
Airbag System
5. PASSENGER'S AIRBAG MODULE CONNECTOR

Disconnection :
Hold t h e pin insulator Wltfl one fidrld and the cover insulator with the other hand . Pull the cover
insulator in the direction of the arrow in the drawing .
NOTE :
Do not hold the socket insulator when disconnecting the connector.
Pin insulator
Cover insulator
B5H1094A
Connection:
Step 1 : Insert the socket insulator into the pin insulator such that the pin insulator's claw is pressed
against the cover insulator .
NOTE :
Do not hold the cover insulator.
Step 2 : Push the socket insulator forcibly toward the pin insulator. The cover insulator will move
riding over the claw to complete engagement of the connector.
r1 ami
B5H1095A
AB-12
CONSTRUCTION
Airbag System
G : STEERING ROLL CONNECTOR

The steering roll connector is located between the steering column and steering wheel . The con-
nector contains a spirally wound flat cable . The cable can follow rotational movements of the steer-
ing wheel and ensures connection between the airbag module in the steering wheel and the air-
bag harness through which electrical signals are transmitted from the airbag control module.
S5H0013A
H : AIRBAG WARNING LIGHT

The airbag warning light is located inside the combination meter. It illuminates if a poor connection
in the airbag circuit occurs, or if the airbag control module detects an abnormal condition . When
the airbag system is normal, this light comes on when the ignition switch is turned ON and then
goes out about 7 seconds later.
AIR BAG
4 o I' D
O D
O O C
B5H0633
I : WIRE HARNESS
The wire harness of the airbag is entirely covered with a yellow protective tube, and can easily be
distinguished from the other systems' harnesses .
AB-13
CONSTRUCTION
Airbag System
J : LOCATIONS OF WARNING AND CAUTION LABELS
View A View B View C
B5H0842A
AB-14
ANTI-LOCK BRAKE SYSTEM (ABS)
ABS
1 . Anti-lock Brake System (ABS)

A: FEATURE
" The 5 .3i type ABS used in the 2001 Legacy has a hydraulic control unit, an ABS control module,
a valve relay and a motor relay integrated into a single unit (called "ABSCM & H/U") for circuit sim-
plicity and reduced weight.
" The ABS electrically controls the brake fluid pressure to each wheel to prevent the wheel from
locking during braking on slippery road surfaces, thereby enabling the driver to maintain the
directional control .
" If the ABS becomes inoperative, a fail-safe system is activated to ensure same level of braking
performance as with a conventional brake system . In that case, the warning light comes on to indi-
cate that the ABS is malfunctioning .
" The ABS is a 4-sensor, 4-channel system ; the front wheel system is an independent control de-
sign*1, while the rear wheel system is a select-low control design*2 .
*1 : A system which controls the front wheel brakes individually.
*2 : A system which applies the same fluid pressure to both the rear wheels if either wheel starts
to lock . The pressure is determined based on the lower of the frictional coefficients of both wheels .
, ., lr;~~ (a) (9)
9)
lal 1y) (12) ($) (7)
B4H2196A
(1) ABS control module and hydraulic (5) G sensor (9) Wheel cylinder
control unit (ABSCM & H/U)
(2) Proportioning valve (6) ABS warning light (10) Automatic transmission control
module
(3) Diagnosis connector (7) Tone wheel (11) Brake switch
(4) Data link connector (8) ABS sensor (12) Master cylinder
(for SUBARU select monitor)
ABS-2
ABS
B : FUNCTIONS OF SENSORS AND ACTUATORS

Names Fi inrtinn
ABS control module and ABSCM section e It determines the conditions of the wheels and the vehicle body from the
hydraulic control unit wheel speed data and controls the hydraulic unit depending on the re-
(ABSCM & H/U) sult .
When the ABS is active, the ABSCM provides the automatic transmis-
sion control module with control signals which are used by the module
for cooperative control of the vehicle with the ABSCM.
Whenever the ignition switch is placed at ON, the module performs a
self diagnosis sequence . If anything wrong is detected, the module cuts
off the system .
It communicates with the SUBARU select monitor.
H/U section * When the ABS is active, the H/U changes fluid passages to the wheel cylin-
ders in response to commands from the ABSCM.
It constitutes the brake fluid passage from the master cylinder to the wheel
cylinders together with the piping .
Valve relay section It serves as a power switch for the solenoid valves and motor relay coil . It
operates in response to a command from the ABSCM.
Motor relay section It serves as a power switch for the pump motor. It operates in response to
a command from the ABSCM .
ABS sensors (wheel speed sensors) They detect the wheel speed in terms of a change in the density of the
magnetic flux passing through them and convert it into an electrical signal .
The electrical signal is sent to the ABSCM.
Tone wheels They give a change in the magnetic flux density by the teeth around them-
selves to let the ABS sensors generate electrical signals.
G sensor It detects a change in acceleration in the longitudinal direction of the ve-
hicle and outputs it to the ABSCM as a voltage signal .
Stop light switch It provides information on whether the brake pedal is depressed or not to
the ABSCM . The ABSCM uses it to determine ABS operation .
ABS warning light It alerts the driver to an ABS fault. When the diagnosis connector and diag-
nosis terminal are connected, the light flashes to indicate a trouble code
stored in the ABSCM.
Automatic transmission control module It provides gear controls (fixing the speed at 3rd or changing power trans-
mission to front and rear wheels) in response to control signals from the
ABSCM.
ABS-3
ABS
(1)
BATTERY
S4H0019A
(1) ABS control module and hydraulic (9) Front right outlet solenoid valve (17) ABS warning light
control unit
(2) ABS control module section (10) Rear left inlet solenoid valve (18) Stop light switch
(3) Valve relay (11) Rear left outlet solenoid valve (19) Stop light
(4) Motor relay (12) Rear right inlet solenoid valve (20) G sensor
(5) Motor (13) Rear right outlet solenoid valve (21) Front left ABS sensor
(6) Front left inlet solenoid valve (14) Automatic transmission control (22) Front right ABS sensor
module
(7) Front left outlet solenoid valve (15) Diagnosis connector (23) Rear left ABS sensor
(8) Front right inlet solenoid valve (16) Data link connector (24) Rear right ABS sensor
ABS-4
ABS
C: PRINCIPLE OF ABS CONTROL

When the brake pedal is depressed during driving, the wheel speed decreases and the vehicle
speed does as well . The decrease in the vehicle speed, however, is not always proportional to the
decrease in the wheel speed . The non-correspondence between the wheel speed and vehicle
speed is called "slip" and the magnitude of the slip is expressed by the "slip ratio" which is defined
as follows :
Slip ratio = Vehicle speed - Wheel speed/Vehicle speed x 100%
When the slip ratio is 0%, the vehicle speed corresponds exactly to the wheel speed ; when it is
100%, the wheels are completely locking (rotating at a zero speed) while the vehicle is moving .
The braking effectiveness is represented by the "coefficient of friction" between the tire and road
surface . The larger the coefficient, the higher the braking effectiveness . The diagram below shows
the relationship between the coefficient of friction and the slip ratio for two different road surface
conditions (asphalt-paved road and icy road), assuming that the same tires are used for both the
conditions and the vehicles are moving forward . Although the braking effectiveness (coefficient
of friction) depends on the road surface condition as shown and also on the type of the tire, its peak
range generally corresponds to the 8 - 30% range of the slip ratio .
The ABS controls the fluid pressure to each wheel so that a coefficient of friction corresponding
to this slip ratio range is maintained .
~Control range by ABS
Asphalt-pavedroad
3
c
0
.V U
ca JJ
_~ Icy road
i
O I
N
U~
100(%)
Slip ratio
G4H0064A
ABS-5
ABS
D: ABS SENSORS
Each of the ABS sensors detects the speed of the corresponding wheel . The sensor consists of
a permanent magnet, coil and tone wheel . The magnetic flux produced by the permanent magnet
changes as each tooth of the tone wheel (which rotates together with the wheel) passes in front
of the magnet's pole piece . The changing magnetic flux induces voltages at a frequency corre-
sponding to the wheel speed .
(1)
(4)
0 S N
VV
(5) (6)
B4H2197B
(1) Sensor body (4) Full speed

(2) Pole piece (5) Low speed
(3) Tone wheel (6) Permanent magnet
ABS-s
ABS
E : ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM & H/U)
" ABS CONTROL MODULE SECTION (ABSCM)
The ABSCM contains two microcontrol modules (MCMs) : master and slave . Both the MCMs pro-
cess the same program and each MCM monitors the other's outputs . If a mismatch occurs be-
tween their outputs, the ABSCM cuts off the system and activate the fail-safe function .
The ABSCM can store a maximum of 3 trouble codes in an EEP ROM . If more than 3 faults have
occurred, only the 3 most recent failures are stored and others are erased. Trouble codes remain
stored until they are internally or externally erased .
The ABSCM has a test routine (sequence control pattern) which facilitates checking of the hydrau-
lic control unit.
" ABS control
Using primarily the wheel speed data from each ABS sensor and secondarily the vehicle decelera-
tion rate data from the G sensor as parameters, the ABSCM generates a simulated vehicle speed
when there is a risk of wheel lock-up . Using the simulated vehicle speed (called "dummy" vehicle
speed) as a reference, the ABSCM determines the state of the wheel in terms of the tendency to-
ward lock-up . If the result shows that the wheels are about to lock, the ABSCM issues commands
to energize or de-energize the solenoid valves and activate the motor pump of the H/U to modulate
the brake fluid pressures that act on the wheel cylinders, thereby preventing the wheels from lock-
ing .
The ABSCM controls the right and left front wheel fluid pressures independently and the rear wheel
fluid pressures based on the wheel which is the most likely to lock (select-low control) .
" Functions available using SUBARU select monitor
When the SUBARU select monitor is connected, the ABSCM allows it
" To read out analog data
" To read out ON/OFF data
" To read out or erase trouble code
" To read out status information in the event of a fault (Freeze frame data)
" To initiate ABS sequence control pattern
" Indication functions
Under the control of the ABSCM, the ABS warning light provides the following three indication func-
tion :
" ABS fault alerting
" Trouble code indication (by flashing in the diagnosis mode)
" Valve ON/OFF indication (when sequence control pattern is initiated)
ABS-7
ABS
" HYDRAULIC CONTROL UNIT SECTION (H/U)

The H/U is a fluid pressure controller consisting of, among others, a motor, solenoid valves, a hous-
ing and relays . It also constitutes passage of the two diagonally split brake circuits .
* The pump motor drives an eccentric cam which in turn moves the plunger pump to generate
hydraulic pressure .
" The housing accommodates the pump motor, solenoid valve and reservoir. It also constitutes
a brake fluid passage .
" The plunger pump, when operated, draws the brake fluid from the reservoir, lets the fluid in a
wheel cylinder drain into the reservoir, and/or forces the fluid into the master cylinder.
" The outlet solenoid valve is a 2-position type . It opens or closes the brake fluid passage between
a wheel cylinder and the reservoir according to commands from the ABSCM .
" The inlet solenoid valve is duty-controlled to reduce brake fluid pulsation for minimum ABS op-
eration noise .
" The reservoir temporarily stores the brake fluid drained from a wheel cylinder when pressure
"decrease" control is performed .
" The damper chamber suppresses brake fluid pulsation which would occur during pressure "de-
crease" control in the fluid discharged from the plunger pump to minimize kickbacks of the brake
pedal .
o The valve relay controls power supply to the solenoid valves and motor relay in response to a
command from the ABSCM . In normal (1G ON) condition, the relay is closed to supply power to
the solenoid valves and motor relay. When an error occurs in the system, the valve relay is turned
OFF to keep the fluid pressure circuit in the normal mode (non-ABS mode) .
" The motor relay closes and supplies power to the pump motor in response to a command from
the ABSCM during the ABS drive mode operations .
The H/U has four operating modes ; normal mode (non-ABS mode), and three ABS active modes,
i .e ., "increase", "hold" and "decrease" modes .
ABS-8
ABS
1 . DURING NORMAL BRAKING (ABS NOT ACTIVE)

Both the inlet and outlet solenoid valves are not energized .
This means that the inlet port of the inlet solenoid valve is open, whereas the outlet port of the outlet
solenoid valve is closed . So the fluid pressure generated in the master cylinder is transmitted to
the wheel cylinder, producing a brake force .
NOTE:
ABS-10
ABS
(1)
N~
(13) B4H0989A
(1) From master cylinder (8) Wheel cylinder

(2) Damper chamber (9) Outlet solenoid valve
(3) Inlet port open (10) Motor
(4) Inlet solenoid valve (11) Outlet port closed
(6) De-energized (13) Reservoir
(7) Pump
ABS-11
ABS
2. PRESSURE "DECREASE" CONTROL (ABS ACTIVE)

Both the inlet and outlet solenoid valves are energized, which means that the inlet port is closed
and the outlet port is open .
In this state, the wheel cylinder is isolated from the master cylinder but open to the reservoir, so
the brake fluid in it can be drained into the reservoir, decreasing its pressure and reducing the
braking force of the wheel .
The brake fluid collected in the reservoir is forced into the master cylinder by the pump.
During this phase of ABS operation, the pump motor continues operating .
NOTE :
ABS-12
ABS
N~
(1)
(13)
B4H0990A

(3) Inlet port closed (10) Motor
(4) Inlet solenoid valve (11) Outlet port open
(5) Check valve (12) Energized
(6) Energized (13) Reservoir
(7) Pump
ABS-13
ABS
3. PRESSURE "HOLD" CONTROL (ABS ACTIVE)

The inlet solenoid valve is energized, so the inlet port is closed .
VI 1 flhe other I ICII IU, U ie outlet solenoid valve is de-energize U-1 , so the output port is also closed . in
this state, all the passages connecting the wheel cylinder, master cylinder and reservoir are
blocked . As a result, the fluid pressure in the wheel cylinder is held unchanged .
NOTE :
ABS-14
ABS
(13) B4H0991A

(3) Inlet port closed (10) Motor
(6) Energized (13) Reservoir
(7) Pump
ABS-15
ABS
4. PRESSURE "INCREASE" CONTROL (ABS ACTIVE)

Both the inlet and outlet solenoid valves are de-energized, which means that the inlet port of the
inlet solenoid valve is open, whereas the outlet port of the outlet solenoid valve is closed . So the
fluid pressure generated in the master cylinder is transmitted to the wheel cylinder and increased
fluid pressure in the wheel cylinder applies the brake with a larger force .
NOTE :
ABS-16
ABS
(1)
~7
(13) B4H0992B

(3) Inlet port open (10) Motor
(6) De-energized (13) Reservoir

(7) Pump
ABS-17
ABS
F : ABS CONTROL CYCLE CURVES

Depressing the brake pedal increases the brake fluid pressure in each wheel cylinder, which in
h,gg~ speed (or incr eases <<"le -heel ucCEiErativ~l
turn decreases the wheel rate) . When. arc brake ifluid
pressure is increased to a level of point "A" of the brake fluid pressure curve in the diagram below
(at which the wheel deceleration rate exceeds threshold "-bo"), the ABSCM makes a pressure
"hold" control . At the same time, the ABSCM calculates a "dummy" vehicle speed which is a refer-
ence speed it uses in the next stage of control .
When the wheel speed then drops below the slip ratio setting, i .e., a speed lower than the "dummy"
vehicle speed by the predetermined value (at point "B" of the pressure curve), the ABSCM makes
a control to prevent the wheel from locking, or a pressure "decrease" control .
As the wheel cylinder pressure decreases, the wheel speed starts increasing (or the wheel accel-
eration rate starts rising) . When the wheel acceleration rate exceeds threshold "+b1o" (at point "C"
of the pressure curve), the ABSCM makes a pressure "hold" control . When the wheel acceleration
rate exceeds threshold "+b2o" (at point "D" of the pressure curve), the ABSCM recognizes that
wheel lock-up will not occur and then makes a pressure "increase" control .
When the wheel acceleration rate drops below threshold "+b2o", (at point "E" of the pressure
curve), the ABSCM starts pressure "hold" and "increase" control cycles at a given interval .
When the wheel deceleration rate then exceeds threshold "-bo" (at point "F" of the pressure curve),
the ABSCM immediately makes a pressure "decrease" control .
vehicle speed
Speed
Wheel
acceleration
/deceleration
Brake fluid
pressure
Outlet ON
valve
OFF
Inlet ON
valve
OFF
Time
B4H2239B
Brake fluid
Inlet valve Outlet valve
Pressure
Increase OFF I OFF
Hold
Decrease __T__
ON
ON
-
OFF
ON
ABS-18
ABS
G : ABS WARNING LIGHT

When a fault occurs in the signal transmission system or the ABSCM, the ABS warning light in the
combination meter comes on . At the same time, the current to the hydraulic control unit is inter-
rupted. The brake system then functions in the same manner as a system without ABS. The warn-
ing light utilizes a dual circuit design .
If the warning light comes on, one or more trouble codes should be stored in the control module.
They must be identified using the warning light's code indicating function .
U.S. spec. vehicle Canada spec. vehicle
0) a
5060 70 80
,°° ,
W
AIRBAG VDC ,~ ~ ~ ~ ~O AIRBAG VDC
140
VOID (~)
\~ F
J
X400 I ' O"~~'RJO \ OFF 0100-iR7O
~
- 00
0 F ~~ ~ ~~ o J ~~110 O F ~~ ~ -- , 180
MPH
QT 10 kmR,
- MPH 120 Q km/h
~1 /u
O TRIP ODO
888888 0 `~ ~ 888888
0
B4H2339A
(1) ABS warning light
ABS-19
ABS
H : G SENSOR
The G sensor detects changes in the vehicle's acceleration/deceleration rate in the longitudinal
direction .
The moving electrode of a capacitor in the sensor moves away from or close to the fixed electrode
as the vehicle accelerates or decelerates and the resulting change in the capacitance of the ca-
pacitor is outputs to the ABSCM as a change in the voltage .
Front
When vehicle is accelerated (A) When vehicle is cruising (B) When vehicle is decelerated (C)
Ceramic board
Fixarl ala~trnria
Moving electrode
-1 G : Accelerated OG : Cruising +1G : Decelerated
A B C
G Sensor Output Characteristics

134H0988
ABS-20
HEATER SYSTEM
1 . Heater System
The heater control unit is located in the middle portion of the instrument panel .
The heater unit has mode doors and an air mix door. The intake unit has an intake door and a blow-
er motor. The heater unit and the intake unit are regulated by their control units .
Fresh outside air is introduced into the cabin through the center and side ventilators when the
blower fan is operated .
All models are equipped with front side window defrosters .
An optional filter is provided in front of the evaporator inlet .
(2) r A`
~1 I .I 1" I
($)~ ($)
~~ (11)
L-
JL.
6)
~1~~~/> \v(14)~~' \~ UK
(4) (4)
(5)~ V (5)
Fn- n
(6) (6)
B4H2189A
(1) Front defroster outlet (7) Fresh air (13) Intake door
(2) Side defroster outlet (8) Recirculated air (14) Heater core
(3) Center ventilator outlet (9) Ventilator door (15) Evaporator (A/C model)
(4) Side ventilator outlet (10) Heater door (16) Blower fan
(5) Front heater outlet (11) Defroster door (17) Filter (Option)
(6) Rear heater outlet (12) Air mix door A/C: Air conditioner
AC-2
SWITCH FUNCTIONS
2 . Switch Functions
(3)
(2) (1) (5)
Indicator 'ON OFF
Compressor ON OFF
(1) Air conditioner switch
' : When the fan switch is turned ON, the indicator and compressor
also turn ON .
Indicator ON OFF
(2) Recirculation switch Intake door Recirc Fresh
position
Switch
1 2 3 4
(3) Fan switch position
Fan speed 1 st (slow) 2nd 3rd 4th (fast)
(4) Temperature control switch Any temperature can be selected between COLD and HOT.
Switch
position IJ ~ ~ pI
(5) Mode selector switch
Ventilator Defroster
Air outlet Ventilator and Heater and Defroster
heater heater
1341-1150313
AC-3
MODE SELECTOR SWITCH AND AIR FLOW
3 . Mode Selector Switch and Air Flow

Q: _AIR FLOW
Mode selector Air flow
switch position
11 ~inli ~11
DEF ~,
r
DEF/HEAT
IIII I
u
H EAT
IIII I
ILI
I'~ u u
BI-LEVEL
FF1 F1
u
.. ~~ n~' ~
u u
VENT
IIII IIII
B4H2241A
AC-4
MODE SELECTOR SWITCH AND AIR FLOW
HVAC System (Heater, Ventilato r and A/C)
B : AIR DISTRIBUTION RATIO

The following diagram shows air distribution for each position of the mode selector switch .
N
100
~ (qo)
\/GAIT i
80 80
i i i
i i i 70
i i i
60
FOOT
- - ~ - 45
40 40
- - ;- - - ; -- 25
20 DEF
VENT BI-LEVEL HEAT DEF/HEAT DEF
Mode selector switch position
B4H1513C
C: SYSTEM CONTROL FLOW
Ventilator door ---

Mode door motor ~ I
Mode selector
switch
Heater door ---
Defroster door ---

Recirculation switch '
___ Fresh air introduction or

L 111d Intake door motor Intake door inside air recirculation
(Cable) Outlet air

Temperature control - -------------------------- Air mix door --- temperature
switch
1341-1004613
AC-5
MODE DOOR CONTROL
4 . Mode Door Control

The servo motor for driving the mode door is installed on the siege facing the ei .rive .r'q Pat nf th.e
heater unit . Operating the mode selector switch sends a signal to the servo motor. In response to
the signal, the motor makes a clockwise or counterclockwise rotation to drive the mode door
through a link .
B4H1505A
(1) DEF position

(2) DEF/HEAT position
(3) HEAT position
(4) VENT/HEAT position
(5) VENT position
AC-6
INTAKE DOOR CONTROL
5. Intake Door Control

The intake door motor is located on the upper part of the intake unit. It opens and closes the intake
doors through a rod and a link . When the recirculation switch is pressed (the indicator comes on),
the ground circuit of the intake door motor is formed through terminal 2 of the moving contact
instead of through terminal 1 . This causes the motor to make a rotation to close the intake doors.
Since the moving contact is built into the motor and rotates together with it, the ground circuit of
the motor opens when the contact's slot reaches terminal 2 . The motor then stops .
When the recirculation switch is pressed again (the indicator goes out), the ground circuit is
formed through terminal 1 rather than terminal 2 . The motor makes a rotation in the same direction
as when the switch is first pressed - but now opening the intake doors - until the moving contact's
slot reaches terminal 1 .
Intake door motor

-- Recirc switch _-
To IG M Recirc
Switch
moving p I
contact
I I Recirc I Indicator
I
i
i
Fresh
2 1
Recirc Fresh ~J Y
G4H0741 A
AC-7
BLOWER SYSTEM
6 . Blower System
The blower relay is ready to be activated when the ignition switch is in the ON position . With the
ignition switch ON, placing the fan switch in any position other than OFF activates the relay, allow-
ing electric current to flow from the battery to the ground through the blower motor, the resistor,
and the selected fan switch contacts . The connected resistor(s) vary depending on the selected
position of the fan switch and cause the blower motor speed to change .
H4H1097A
AC-8
FILTER (OPTION)
HVA C System (Heater, Ventilator and A/C)
7. Filter (Option)
The optional filter is located in front of the cooling unit's evaporator inlet.
The air conditioner may fail to exhibit its lull perrormance it the niter is exces5ively, witn
dust and dirt. It is essential to replace the filter with a new one at the specified interval .
(2)
B4H2191 A
(1) Filter
(2) Cooling unit
AC-9
AIR CONDITIONING CYCLE
8. Air Conditioning Cycle

A: GENERAL
The refrigerant recirculates in the air conditioning system, flowing out of the compressor, passing
through the condenser, receiver drier and evaporator, and returning to the compressor.
The flow of refrigerant to the evaporator is controlled by an expansion valve located inside the
evaporator.
The compressor operates and stops repeatedly to maintain the evaporator temperature within a
specified range . When the evaporator temperature falls below the specified temperature, the ther-
mo-control amplifier stops the compressor operation . When the evaporator temperature rises
above the temperature, the thermo-control amplifier puts back the compressor into operation .
The refrigerant system is protected against excessively high or low pressures by a pressure
switch . If the system pressure rises or drops excessively, the pressure switch is activated to pre-
vent the compressor from operating .
Compressor
Condenser
Evaporator
High-pressure gas
Low-pressure gas
E> E>
High-pressure liquid
Expansion valve
IL : Low-pressure liquid
L Receiver drier
C] : Refrigerant flow
S4H0003B
AC-10
COMPRESSOR
9. Compressor
A: GENERAL
The compressor is a rotary type that has a rotor fitted with five radially movable vanes . The rotor
rotates together with the vanes in an elliptical cylinder. As the rotor rotates, the volume of each
closed space formed between two adjacent vanes (referred to as "cylinder chamber" in the follow-
ing description) decreases, so that the pressure of the refrigerant gas confined in the cylinder
chamber increases . In this way, the rotary compressor performs its function as a pump . The pump-
ing cycle consisting of suction, compression and discharge takes place 10 times during every
rotation of the rotor .
On the discharge side of the cylinder, a roll valve is provided that opens at a predetermined high
pressure . Air tightness between the rotor shaft and front head is ensured by the shaft seal . The
trigger valve incorporated in the front side block provides the function of applying back pressure
to the vanes . The compressor contains necessary quantity of compressor oil . The oil is distributed
to all the parts requiring lubrication and sealing by utilizing the discharge pressure of the refriger-
ant .
(3)
4)
S4H0307A
(1) Front head (6) Vane (11) Shaft seal

(2) Side block (7) Rotor (12) Magnet clutch
(3) Rear head (8) Roll valve (13) Trigger valve
(4) Check valve (9) Cylinder
(5) Rear bearing (10) Front bearing
AC-11
COMPRESSOR
B : FUNCTIONS
As the rotor rotates, the volume of each cylinder chamber changes . This creates the compressor's
suction, compression and discharge functions as explained in the following :
1) Suction :
Low-pressure gaseous refrigerant is forced out from the evaporator by rotation of the compressor.
It enters the low-pressure chamber in the rear head through the check valve . The refrigerant is then
drawn into the cylinder by rotation of the vane-fitted rotor through the two suction ports provided
in the rear side block . Air tightness of the cylinder chambers is maintained by the compressor oil .
(9)
4)
,(5)
B4H0745A
(1) Rotor (4) Rear head (7) Vane

(2) Refrigerant (5) Low-pressure chamber (8) Drive shaft
(3) Check valve (6) Rear side block
2) Compression :
Further rotation of the rotor after suction makes the volume of each cylinder chamber smaller, thus
compression occurs.
B4H0746A
(1) Drive shaft (2) Refrigerant
AC-12
COMPRESSOR
3) Discharge :
When the pressure of refrigerant in the cylinder chamber exceeds a predetermined pressure, the
roll valve opens to discharge the refrigerant through a pipe-shaped passage built in the front side
block into the high-pressure chamber in the front head . The gaseous refrigerant in the high-pres-
sure chamber is led to a baffle, which separates the compressor oil contained in the refrigerant
before it flows into the high-pressure piping .
B4H0747A
(1) Front head (4) Roll valve (7) High-pressure chamber

(2) Refrigerant (Discharging) (5) Front side block
(3) Refrigerant (High-pressure) (6) Pipe
AC-13
COMPRESSOR
C: TRIGGER VALVE
This valve has a function of maintaining a proper level of pressure behind the vanes (vane back
pressure) such that they can~
- move easily upon start ui iie compressor. The trigger valve is incor-
porated in the front side block and its end opens to a cavity called "K-ditch" that is provided in the
rotor side end of the side block . The valve consists of a check ball and a spring .
The vanes are prone to chatter if there is only small difference between the high- and low-pressur-
es. This condition typically occurs when the compressor is started . In such a condition, the spring
raises the ball to open the valve and allows the back pressure to act on the vanes, thereby ensuring
smooth operation .
S4H0308A
(1) K-ditch (3) Front head

(2) Check ball (4) Spring
1) When compressor starts or when load is low :

When the compressor starts or when the load is low (the high-pressure level is low), the spring can
raise the check ball clear of its seat, so the trigger valve is opened . The pressure of the high-pres-
sure chamber then acts on the back end surface of each vane to prevent it from chattering .
(1
3)
(4)
B4H0749A
(1) High-pressure chamber (3) Vane

(2) Trigger valve (Open) (4) Rotor
AC-14
COMPRESSOR
2) When compressor is in regular operation :

When the pressure in the high-pressure chamber of the compressor increases, the pressure over-
VVIrIIGJ 11IG JPI11I~j
. lGIiJIVII QiIU rIUJIIGJ IIIG &Glr'rR IhJQII Ql~~.allIJL its Seat, SO the LIIygGI VQIVG VIVJGJ .
The oil port pressure coming through the side block is applied to the end surface of vane to main-
tain proper back pressure .
3)
(4)
B4H0750A
(1) High-pressure chamber (3) Vane

(2) Trigger valve (Closed) (4) Rotor
AC-15
COMPRESSOR
D: CHECK VALVE
A check valve consisting of a spherical plate and spring is provided at the suction port of the rear
head . Immediately after the compressor has stopped, there is large difference between the high-
and low-pressures . This would cause reverse rotation of the compressor and consequent reverse
flow of refrigerant to the evaporator if no check valve is provided . Immediately after the compres-
sor has stopped, the high-pressure refrigerant forces the check valve plate upward and closes
the suction port to prevent flow of refrigerant from the high-pressure side to the low-pressure side.
(2)
(3)
(4)
(5)
B4H0751A
(1) Refrigerant suction port (3) Spring (5) Refrigerant

(2) Plate (4) Check valve
AC-16
COMPRESSOR
E : LUBRICATION
The lubrication oil is collected at the bottom of the high-pressure chamber. The high-refrigerant
pressure in the chamber forces the oil upward through the oil passages in the front sine block to
lubricate the front end of the rotor. The high-chamber pressure also forces the oil through the pas-
sages in the bottom of the cylinder to lubricate the rear end of the rotor. The oil that has lubricated
each end of the rotor enters the low-pressure chamber by the internal pressure of the compressor.
The oil contained in the gaseous refrigerant from the evaporator passes through the low-pressure
chamber and lubricates the rear bearing . The oil also passes through the passage in the drive
shaft and lubricates the front bearing and shaft seal before entering the suction port of the cylinder.
Since the pressure in the suction port of the cylinder is slightly lower than that in the low-pressure
chamber, the oil that has lubricated all the parts enters the suction port and is finally brought by
the refrigerant back to the high-pressure chamber.
(2)
V~ ~ (6)
B4H0752A
(1) Front bearing (4) Low-pressure chamber (7) High-pressure chamber

(2) Vane (5) Rotor (8) Shaft seal
(3) Rear bearing (6) Oil port
AC-17
COMPRESSOR
F : MAGNET CLUTCH
The magnet clutch serve to transmit engine power to the compressor module . It is built into the
compressor shaft . When current flow through the magnet clutch coil, the drive plate is attracted
so that the pulley and compressor shaft rotate as a module . When the compressor is not in use,
the pulley alone rotates freely .
The compressor used with the six-cylinder engine has a lock sensor. If the sensor detects locking
of the compressor resulting from a fault, it causes disengagement of the magnet clutch to protect
the engine and the power steering drive .
4)
(5)
B4H0169B
(1) Bearing (4) Drive shaft
(2) Magnet clutch coil (5) Clutch pulley
(3) Compressor (6) Drive plate
AC-18
CONDENSER
10 . Condenser
A : MECHANISM
The high-temperature and high-pressure gaseous refrigerant discharged from the compressor is
cooled down and converted into liquid by the condenser .
The condenser consists of tubes and radiating fins .
The heat of the refrigerant flowing through the condenser tubes is released into to the ambient air
which is caused to flow across the fins by the cooling fan.
B4H1508A
(1) Refrigerant inlet (High-pressure gaseous refrigerant)

(2) Refrigerant outlet (High-pressure liquid refrigerant)
AC-19
RECEIVER DRIER
11 . Receiver Drier
A: MECHANISM
The amount of refrigerant necessary to circulate in the system varies with change in the heat load .
The receiver drier stores part of the liquid refrigerant until an increased heat load requires its use
again . The receiver drier also has the following functions :
1) It removes bubbles from the liquid refrigerant . (If bubbles are present, the refrigerant passing
through the expansion valve varies in quantity, temperature, and pressure, resulting in insufficient
cooling .)
2) It removes moisture from the refrigerant .
3) It removes foreign substance from the refrigerant .
The receiver drier contains a strainer to remove foreign substance and desiccant to absorb mois-
ture from refrigerant .
(4)
(5)
B4H0171 D
(1) Head block (6) Pressure switch

(2) Inlet (7) Strainer
(3) Outlet (8) Strainer cushion
(4) Inside pipe (9) Desiccant
(5) Body
AC-20
PRESSURE SWITCH
12. Pressure Switch

The pressure switch is located on the high-pressure line to the receiver drier. When an abnormally
high or low pressure occurs in the nigh-pressure line, the pressure switch turns OFF to stop -opera-
tion of the compressor.
" When the pressure is abnormally low [177 kPa (1 .8 kg/cm2, 26 psi) or less]
The pressure switch turns OFF assuming that the refrigerant is lost due to leakage .
" When the pressure is abnormally high [2,940 kPa (30 kg/cm2, 427 psi) or more]
The pressure switch turns OFF to prevent the system from being damaged .
3)
(4)
(5)
177 f 20 2,940 - 200

(1 .8 t 0.2, (30 +_ 2,
26 ± 3) 427 t 28)
ON-------
I- L-- Unit : kPa (kg/cm2, psi)

OFF
186 t 29 590 ± 200
(1 .9 t 0.3, (6 - 2,
27 t 4) 85 - 28)
(Low pressure) (High pressure)
B4H0172C
(1) Point terminal (4) Pressure guide

(2) Contact point (5) High-pressure disc spring
(3) Guide pin (6) Low-pressure disc spring
AC-21
EVAPORATOR
13 . Evaporator
A: MECHANISM
Air pushed by the blower passes through the cooling fins and tubes of the evaporator. Since the
air is warmer than the refrigerant, the heat of air moves to the refrigerant through the fins and tubes .
As the low-pressure refrigerant moves through the evaporator, heat from the air causes the refrig-
erant to boil. By the time the refrigerant has passed through the evaporator, it becomes vapor.
Moisture in the air condenses to water drops as it moves around the tubes and fins of the evapora-
tor. Water and dirt are then discharged outside the vehicle through a drain hose .
The evaporator is a laminated type and consists of thin, rectangular aluminum plates arranged
in multiple layers and fins that are attached between them . During flow through the evaporator, the
state of the refrigerant changes as follows :
Misty refrigerant (very close to liquid form) from the expansion valve at a low-pressure, enters the
lower tube of the evaporator, where it soaks up heat from the compartment . The refrigerant boils
and vaporizes quickly due to the rapid heat exchange . Then the refrigerant is pushed upward by
the force of the bubble generated during the heat exchange and enter the upper tube . When it
reaches the upper tank, the refrigerant is in a thoroughly vaporized state .
The evaporator has a single tank, and its surface has been given the following treatments
" Rustproof treatment
" Waterproof treatment
" Moldproof treatment
(2) E
B4H 1511 A
(1) From receiver drier

(2) To compressor
(3) Misty refrigerant
(4) Vapor
(5) Expansion valve
A C-22
EXPANSION VALVE
14. Expansion Valve

A: MECHANISM
The expansion valve is connected to both the evaporator inlet and outlet pipes . It converts high-
pressure liquid refrigerant which comes from the receiver drier to misty, low-pressure refrigerant
which is delivered to the evaporator . Being at low pressure and low temperature, this refrigerant
can easily evaporate in the evaporator and remove heat from the cabin air. The valve performs this
conversion by automatically controlling the flow rate of refrigerant according to the cooling ability
required by the heat load .
The refrigerant temperature is sensed by the temperature sensing element located in the low-
pressure refrigerant passage of the expansion valve, and the flow rate of the refrigerant is con-
trolled by changing the lift of the valve ball located in the high-pressure passage .
Temperature
sensing element
Diaphragm
From evap To compressor
(Low-press
Orifice
To evaporator
(Low-pressure) =rom
deceiver
drier
Valve ball
H4H1123C
AC-23
EXPANSION VALVE
B : FUNCTION
When the heat load to the air conditioning system increases, the refrigerant temperature at the
evaporator outlet rises and therefore the pressure r1 around the temperature sensing area in-
creases . As this pressure P1 becomes higher than the sum of the evaporator outlet (low-pressure
side) pressure P2 and the spring force F (P1 > P2 + F), the diaphragm is pressed down, moving
the valve ball connected to the diaphragm clear of its seat . This increases the flow of the refriger-
ant .
When the heat load is small, the action of the valve's inner elements is contrary to the above ; the
valve ball closes and the flow of the refrigerant decreases .
H4H1124
AC-24
COMPRESSOR CLUTCH "ON" DELAY SYSTEM
15 . Compressor Clutch "ON" Delay System

When the A/C switch and fan switch are turned ON, a signal is sent to the engine control module .
The engine control module then judges whetner the engine is in operation . II if1e engine IS operat-
ing, the engine control module activates the A/C relay. The maximum clutch "ON" delay times is
0 .8 seconds after the A/C relay is activated .
Pressure switch A/C relay

I~~ 0
I GN o-~..c~ + F-o o~ 10 ; 0+
Fan switch Thermostat

A/C switch Fj o Compressor
Engine
control
module
B4H1832B
AC-25
COMPRESSOR CONTROL SYSTEM
16 . Compressor Control System

A : GENERAL
1) When the A/C switch and fan switch are turned ON, the A/C relay is activated . The compressor
starts operating, and then the main and sub fans also operate .
2) The thermo control amplifier, when activated, disengages the compressor clutch and the main
and sub fans .
3) When the pressure switch turns on, the compressor clutch is disengaged and the main and
sub fans also stop .
B : THERMO CONTROL AMPLIFIER

The thermo control amplifier disconnects the magnet clutch circuit to prevent the evaporator from
becoming frosted when the temperature of the evaporator fin drops close to 3°C (37°F) . When the
limit temperature is reached, the thermistor (located on the evaporator fin) interrupts the base cur-
rent of the amplifier. This deactivates the A/C relay, which in turn disconnects the magnet clutch
circuit.
rressure sw A/C relay
IGN i
+12V E~~~-+ Engine
Thermo control amp .

Compressor operation °C (°F)
1 .5±0 .5(35±0 .9)
ON
OFF
- - ----- - - ----- 3.0±0.5(37±0.9)
i
Thermistor
I__________
Evaporator Comparator
Thermo control amplifier
Fan sw . A/C sw .
1341-1224213
AC-26
C : ACCELERATION CUT SYSTEM

The A/C switch turns the air conditioning system ON and OFF. The on-off signals from the switch
are transmitted to the engine control module (ECM) .
When the ECM receives a full-throttle signal from the throttle sensor during compressor operation,
it deactivates the A/C relay to interrupt electric current to the compressor magnet clutch . This pre-
vents the degradation of acceleration performance. The A/C relay is in the main fuse box located
on the left side of the engine compartment .
Pressure sw
+12V
-- -.
A/C
relay
- --'
Throttle sensor
To magnet
clutch
Accelerator pedal Engine control module

B4H1834B
D : IDLE SPEED CONTROL

The idle air control solenoid valve increases the engine idling speed when the compressor is in
operation .
The engine control module activates the idle air control solenoid valve when it receives an A/C
switch ON signal so that necessary by-pass air is introduced into the throttle body to ensure proper
idling speed for an increased engine load .
Idle air control

solenoidvalve
Input signal
Engine
A/C switch control
module
r' Air
B4H0181 A
AC-27
E : FAN CONTROL
The main fan and sub fan are switched ON and OFF according to the operating modes as shown
in the following table .
Engine coolant temperature

Lower than 95°C Between 95 and 99°C Higher than 100°C
A/C com- (203°F) (203 and 210°F) (212°F)
Vehicle speed
pressor
Operation of radiator fan I Operation of radiator fan Operation of radiator fan
Main Sub Main Sub Main Sub
Lower than 19 km/h OFF I OFF OFF ON OFF ON ON
(12 MPH)
ON ON ON ON ON ON ON
Between 20 and 69 km/h I OFF OFF OFF ON OFF ON ON
(12 and 43 MPH)
ON ON ON ON ON ON ON
Between 70 and 105 km/h OFF OFF OFF OFF OFF ON ON
(43 and 65 MPH) ON
ON ON OFF ON ON ON
Higher than 106 km/h OFF OFF OFF OFF OFF ON I ON
(66 MPH) OFF ON ON
ON OFF OFF ON
AC-28
AUTOMATIC AIR CONDITIONING
17. Automatic Air Conditioning

A: SWITCH FUNCTIONS
(3) (4)
(5) (6) (7) (8) (9) (10)
B4H1512A
(1) AUTO switch (6) OFF switch

(2) Ambient temperature display switch (7) Fresh/Recirc switch
(3) Defroster switch (8) Mode selector switch
(4) Rear deffoger switch (9) A/C switch
(5) Temperature set switch (10) Blower fan switch
AC-29
1 . AUTOMATIC CONTROL OPERATION

" AUTO switch : When this switch is pressed (ON), the air outlet selection, blower fan speed, air
tPl"YIYIPYatI IYP
, .. . . P ..~ ...~- .., frAeh/rArirr-i i 1a tinn. eXniitr-
. . .... . . ., ~ -~ --- v~~ ~w~hinrr anrj
~~~ ~, w u nnmnrooo~r
vvi ~ iFri .. .vi nrorotinn urn
vNci uuvi i CL i c ~i i+rmntinnlhi
auwi i iau~aiiy nr,r,
Uvi r
trolled .
When the AUTO switch is pressed second time, the compressor operates in the ECON mode . In
the ECON mode, the ECM controls compressor operation based on inputs from the intake air tem-
perature sensor. Compressor operating time in the ECON mode is shorter than in the AUTO mode .
" Temperature set switch : A desired cabin temperature can be set in 0.5°C increments .
" OFF switch : When this switch is pressed, the blower fan and compressor stop and all the indica-
tors go out.
2. MANUAL CONTROL OPERATION

" A/C switch : The air-conditioner turns on when this switch is pressed first and turns off when it
is pressed second time .
" Blower fan switch : Fan speed changes in the order of Lo, M1, M2 and Hi, every time it is pressed .
" Ambient temperature display switch : When this switch is pressed momentarily, the ambient tem-
perature is indicated on the display for 5 seconds . When this switch is depressed for more than
1 seconds, the ambient temperature is continuously indicated .
" Defroster switch : Air is directed to the windshield for defrosting when this switch is pressed .
" Rear deffoger switch : Pressing this switch causes the rear deffoger to operate for 15 minutes .
" Fresh/Recirc switch : Every time this switch is pressed, switching takes place between outside
air introduction and inside air recirculation alternately.
" Mode selector switch : Pressing this switch changes the outlets to which the air is directed in the
order shown below.
Jet lid 144

1
-40 -00 0 We
1
lid
B4H1314B
AC-30
B : CABIN TEMPERATURE SENSOR

The cabin temperature sensor sends signals to the ECM .
This sensor consists of an aspirator and a thermistor, the resistance of which changes in inverse
proportion to the temperature . The aspirator uses the vacuum created by the heater unit to direct
cabin air to the thermistor . (The cabin temperature sensor, therefore, functions only while the blow-
er fan is in operation .)
Heater unit
Aspirator
~- _ -
Thermistor
Cabin temperature sensor

B4H1315B
C : AMBIENT TEMPERATURE SENSOR

This sensor uses a thermistor to detect the ambient temperature and sends signals the ECM .
The thermistor can detect only an average temperature of the outside air but cannot respond to
sharp changes in the temperature because its exterior is made of a plastic to increase the thermal
capacity .
The ambient temperature sensor is located on the radiator stay behind the front grille for efficient
exposure to the outside air.
4.0
3.5
3.0
N
U
C
«1 2.5
.N
N
2.0
1.5
1.0
0 10 20 30 40
Temperature (°C)
B4H1316B
AC-31
D: SUNLOAD SENSOR
A photodiode is used in the sunload sensor. The photodiode detects changes in the sunbeam in-
tensity and converts the results into current signals to send to the ECM .
The sunload sensor is built into the front defroster grille .
(mA)
_±20%
0.4
660
0 Boo Kcal/hr - M2
n 200 400 600
(LX)
17,359
Sunbeam intensity
Sunbeam intensity and output current
B4H1317B
AC-32
E : AIR MIX SERVO MOTOR

According to signals from the ECM, the servo motor forming integral part of the air mix damper
rotates in one or the other direction to change the opening of the damper via a link .
The motor has a built-in potentiometer which detects the opening of the air mix damper and sends
the result to the ECM .
F/HOT
COL
1 2 3
4 . 5
100 -
-------- /i
0 95+5
m
0
rd line
O
55
±~
V 1-2
V(1-3)
-- - -- -- -- -- -- --
0 105'
Rotation angle
F/COOL F/HOT
(DEG .)
B4H1318B
AC-33
F : AIR OUTLET SWITCHING SERVO MOTORS

According to signals from the ECM, the servo motor incorporated into each air outlet switching
damper rotates in one or the other direction to open or close the damper via a link to control the
air from the corresponding outlet(s) .
Each motor has a built-in potentiometer which detects the position of its damper and send the re-
sult to the ECM .
1 2 3 4 5 6 7 8 9
G VENT'~DEF
DEF VENT
- - - - - ----
- --- --- -- - -- - -
Brush
VENT B/LHEAT D/H DEF
AT' - PIZ - 7 IRI IJC~'
10 9 1 2 6 5
ECM
B4H1319B
G : FRESH/RECIRC SWITCHING SERVO MOTOR

According to signals from the ECM, the servo motor incorporated into the fresh/recirc switching
damper rotates in one or the other direction to perform switching between the outside air introduc-
tion and inside air recirculation modes via a link .
FRE REC
L_
B4H1320B
AC-34
H : BLOWER SPEED CONTROL POWER TRANSISTOR

The base voltage of the power transistor changes according to blower drive signals from the ECM .
The blower speed changes steplessly in accordance with the change in the power transistor's
base voltage.
Should an over-current occur, the thermal fuse connected to the circuit (rated to blow at 144°C
(291 °F)) cuts off the current to the blower.
I : EVAPORATOR SENSOR
The evaporator sensor detects the temperature at the evaporator outlet and sends the result to
the ECM .
is
Y 6
a>
5
ro
N 4
N
-5 0 5 10 15 20 25 30 35 40
Temperature (°C)
B4H1321B
AC-35
J : CONTROL SYSTEM
1 . CALCULATION OF REQUIRED BLOW-OUT AIR TEMPERATURE (TAO)
1) REQUIRED BLOW-OUT AIR TEMPERATURE (TAO):
Upon reception of temperature set switch signals in addition to cabin temperature, ambient tem-
perature and sunload sensor signals, the ECM calculates the TAO first and then, based on the cal-
culated temperature, it determines the outlets from which the air is to be blown out.
Cabin temperature (Cabin temp. sensor)

Ambient temperature (Ambient temp . sensor)
Intensity of sunload (Sunload sensor)
Inlet air temperature (Intake sensor)
(Sensor transmitted data) Determination of air

temperature and outlets
Set temperature (18 .0 to 32 .0°C) (TAO)
(Driver input data)
B4H1323B
2) CALCULATION OF REQUIRED TAO:

" When the set temperature is 18 .0°C, the TAO is fixed at the MAX COOL .
" When the set temperature is 32 .0°C, the TAO is fixed at the MAX HOT.
" When the set temperature is 18 .5°C to 31 .5°C, an optimum TAO is calculated based on the set
temperature, as well as the cabin temperature, ambient temperature and sunload data at that time .
AC-36
2 . TEMPERATURE CONTROL
The temperature control is made based on the driver's inputs from the temperature set switch and
+hn r4~~+n frnm ~iorin~ ic+ tomnorati irk cnncnYC~
u ~c uc~~cA ~~ v. ~ ~ V U~ w~ . I F '-I ULUI lr Jlrl IJVI V~
th
LI IV
o Finn H nt orminAe
LV~v~ -t- i i 1 . .' iw
thA Tin I wvn
a iv ii v y thPCP
ICIt'1r'1 , .. Hata all("
operates the air mix motor so that the TAO can be attained .
The ECM compares the air mix damper opening it has received from the air mix damper potentiom-
eter with the target opening it has calculated and, if necessary, operates the motor to move the
damper to the HOT or COLD side and hold the damper in an appropriate position .
The target damper opening is corrected using the sunlight intensity data .
The air mix damper is moved fully to the HOT side and held there when the temperature set switch
is placed at the FULL HOT position (32°C), while it is moved fully to the COLD side and held there
when the switch is placed at the FULL COLD position (18°C) .
Measurement condition : inlet air temperature OoC
10Full dull
Air mix damper opening (%) Cabin temperature (°C)
hot cold
B4H1324B
(1) If the vehicle is exposed to sunbeam, the air mix damper opening is set to 60% when the cabin temperature is 25°C and the
ambient temperature is 30°C .
(2) The air mix damper opening is set to 0% (maximum cool position) when the cabin temperature is 40°C and ambient tempera-
ture is 30°C .
AC-37
3. AIR FLOW CONTROL

" Normal air flow control :
When the air conditioning system is in the automatic control mode, the airflow is determined based
on the TAO calculated by the ECM . The blower fan speed is controlled accordingly .
In the automatic control mode, the minimum air flow is different between DEF mode and the other
modes . For the minimum air flow in BI-LEVEL, HEAT and DEF/HEAT modes, a voltage of 5 .5V is
applied to the blower motor, while for the DEF mode a voltage of 9.0V is applied .
The minimum air flow is corrected by the sunbeam intensity if the VENT or BI-LEVEL mode is se-
lected .
:When exposed Measurement condition : set temperature 25°C

to sunbeam
------ :When not exposed
to sunbeam
;t -
.;
r= :
o;
S
N, 0
30~
(?)--------------------- ------------------------------------------- -------------------- A\
---
12 10 8 6 4 5 10 15 20 25 30 35 40 45
Voltage applied to blower motor (v)
Cabin temperature (oC)
B4H1326B
(1) If the vehicle is not exposed to sunbeam, a voltage of approx . 5V is applied to the blower motor when the cabin temperature
is 25°C and the ambient temperature is 40°C .
(2) The system (battery) voltage is applied to the blower motor when the cabin temperature is 40°C and the ambienttemperature
is 40°C .
AC-38
" Blower fan starting speed control :

When the blower motor is turned ON in the automatic control mode, the fan speed is initially low
and then gradually increases (applied voltage increases by 1 V every second until an appropriate
voltage is reached) to prevent air from blowing out in a gust .
" Blower fan control at low coolant temperatures :
Even when the blower motor is automatically turned ON, the blower fan is kept stopped or allowed
to rotate at the minimum speed for a maximum of 150 seconds depending on the cabin tempera-
ture and the ambient temperature, if the engine coolant temperature is below 49°C with the air out-
lets for the VENT or DEF mode selected .
After the conditions for prohibiting blower fan operation or limiting its speed are removed, the volt-
age applied to the blower motor is increased gradually (by 0.34V every minute) such that a large
amount of cold air does not blow out toward the leg area .
Once the coolant temperature exceeds 49°C, the normal blower fan control is performed including
the starting speed control .
" Blower fan stop control with compressor ON :
The blower fan is stopped for 3 seconds if the compressor is turned ON with the intake sensor-de-
tected temperature is higher than 35°C .
AC-39
4. AIR INLET CONTROL SYSTEM

The air inlet control system determines whether the air inlet damper is to be opened depending
GII the Tl11V calculated U~% LIIG LV VI, LIIUJ selecting GILIIGI II JIUC Clll ICUll IiUICLIIVII VI I I GJII dll IIILIVUUU-
tion .
The damper is generally opened for fresh air introduction when the compressor is turned OFF.
It is also opened generally when the DEF position is selected .
U/han evnneefl to ci inheam
5 10 15 20 25 30 35 40 45
Cabin temperature (°C)
1341-11331 13
(1) The air inlet damper is opened for fresh air introduction when the cabin temperature is 25°C and the ambient temperature
is 20°C .
(2) The air inlet damper is closed for inside air recirculation when the cabin temperature is 35°C and the ambient temperature
is 30°C .
AC-40
5. AIR OUTLET CONTROL SYSTEM

The air outlet control system automatically selects the most appropriate air outlet combination de-
nA,n,rli,n,y nn, the ECM-ral,riil,atgrl TA,C) h\i arti\iatinn -,P.rvn-.m..ntn .r-. fn .r t.hP VF_NT; 13I-LEVEL Or HEAT
modes .
When the OFF switch is pressed position, the air outlet control system is held in the HEAT mode .
5°C
5 10 15 20 25 30 35 40 45
Cabin temperature (°C)
1341-1133413
(1) The air outlets for the VENT mode are selected when the cabin temperature is 30°C and the ambient temperature is 30°C .
AC-41
6. COMPRESSOR CONTROL SYSTEM

In the automatic air-conditioning mode, the A/C relay is activated or deactivated depending on
+"
u ie T/^-\O (required blow-outy air temperature), TAM (ambient temperature) and i INT (suction air
temperature) to operate or stop the compressor.
The compressor operation circuit supplies current to the magnet clutch as the ECM activates the
A/C relay by connecting its coil to the ground .
A/C relay
ECM ~99J
_ MCR
Compressor control
" Control by TAO

and TAM
----------------
B4H1338C
" Control by TAO and TAM
MCR ON
(A/C)
c
0
OFF
(EGO)
36 43
TAO-TAM
B4H1340A
" Control by T I NT
COMP
ON
COMP
OFF
Def
2 .5±0.5°C
A/C 2 .5t0 .5°C 5t1°C
ECON 6 .510 .5°C 911°C
B4H1341B
AC-42
GENERAL
1 . General
A: OUTLINE
The automatic transmission comes in two types ; one is for the models without a variable torque
distribution (VTD) system (called "MPT models" - standing for multi-plate transfer models - in the
following description), and the other for the models with a VTD system (called "VTD models" in the
following description) . Both the types are of a full-time all-wheel drive design, combining the
torque converter/clutch section, final reduction section, automatic transmission section, and
transfer section into a single unit (see "C : CROSS SECTIONAL VIEW") .
These transmissions are controlled electronically by the transmission control module (TCM). The
TCM is a microprocessor-based unit that controls operation of various solenoid valves and other
electric devices depending on many variables (throttle opening, vehicle speed, engine speed,
selected gear range, etc .) to select the optimum gear and the most appropriate way of power
transmission (including engine braking and lock-up clutch engagement) for a particular condi-
tion .
The TCM has an additional function of automatically selecting either of the two control patterns
("Base" and "Power") in accordance with the driving type which it identifies from the rate of move-
ment of the accelerator pedal . It uses the Base pattern typically for cruising on a flat road and the
Power pattern during acceleration or up-hill driving .
1 . MPT MODELS
" The automatic transmission for the MPT models has a transfer hydraulic pressure control unit .
This unit is located at the rear of the automatic transmission section and consists of a duty-cycle-
controlled solenoid valve which adjusts the hydraulic pressure applied to the wet multi-plate type
transfer clutch .
" The TCM has in its memory a set of duty ratio data, each defining at what ratio the transfer clutch
should transmit the torque for a particular driving condition . Based on the driving condition in-
formation it receives from the corresponding sensors (vehicle speed, throttle opening, gear range,
slip of wheels, etc .), the TCM selects an appropriate duty ratio from the memory and uses it to con-
trol the solenoid valve . The solenoid valve then regulates the hydraulic pressure to the transfer
clutch and the clutch is engaged to a degree determined by the hydraulic pressure .
2. VTD MODELS
" Electronically controlled and fully automatic, the four-speed transmission for the VTD models
is called "E-4AT" . The center differential of this AWD transmission features the SUBARU drive pow-
er distribution system which combines a newly developed compound planetary gear set and an
electronically controlled differential action limiting mechanism (limited slip differential or LSD) . The
system provides the vehicle with easy handling and stable operation features .
" The center differential distributes the drive torque to the front and rear wheels at a ratio of 45 .5
54.5 through the torque dividing function of the compound planetary gear set . This ratio has been
determined with emphasis on maximizing cornering smoothness (that requires optimizing dis-
tribution of the cornering forces generated between tires and road surface) rather than maximizing
traction performance (that requires optimizing distribution of the dynamic loads) . This front-rear
torque distribution ratio (and, consequently, the cornering force distribution ratio) is variable due
to the function of the electronically controlled differential action limiting mechanism . The range of
the variation in the torque distribution ratio is from the ratio originally set for the compound plane-
tary gears to the ratio attained when the differential gear set performs no differential action . This
system capable of varying the torque distribution properly according to conditions enables the
AT-2
GENERAL
driver to handle the vehicle easily even in a marginal condition and the vehicle to show improved
driveability and stability in all road conditions .
B: FEATURES
1 . MPT MODELS
" The transmission uses both structural and control means to reduce gearshift and engagement
shocks ; a one-way clutch and three accumulators effectively absorb shock loads, while fully elec-
tronic gear-shift control (1st through 4th), hydraulic pressure (line pressure) control and lock-up
clutch control minimize chances of shock occurring .
" Both power transmission efficiency and fuel economy are improved by the use of a torque con-
verter with hydraulically operated lock-up clutch and a gear train creating four forward and one
reverse speeds with two sets of simple planetary gears .
" Apart from a highly rigid transmission case, the use of a push-pull cable for the selector lever
mechanism improves quietness as the cable conveys vibration only slightly to the driver's control
mechanism .
* The TCM has an on-board diagnosis function to facilitate servicing and a fail-safe control func-
tion to ensure minimum level of operation should an important problem occur in the system .
" The degree of engagement of the transfer clutch is accurately controlled by the TCM . This is
especially effective to prevent undesirable tight corner braking which would occur when making
a sharp turn at a low speed .
" Distribution of torque to the rear wheels is optimally controlled according to the engine output
torque and selected gear. This improves fuel efficiency and directional stability.
" When the ABS is in operation, the TCM performs special control for the most effective braking
by properly adjusting the degree of engagement of the transfer clutch and fixing the speed to a
certain gear.
" The manual range feature enables the driver to hold the transmission in a desired gear. If used
properly, it can improve driveability and ride comfort .
2 . VTD MODELS
" The gearshift feeling is improved by optimally controlling the gearshift timing and the engine
torque during gearshifts .
" Both power transmission efficiency and fuel economy are improved by the use of a torque con-
verter with hydraulically operated lock-up clutch and a gear train creating four forward and one
reverse speeds with two sets of simple planetary gears.
* The center differential combining compound planetary gears with an electronically controlled
and hydraulically operated multi-plate differential action limiting device (limited slip differential)
is a vehicle controllability enhancement feature that enables the vehicle to be handled easily even
in a marginal condition .
" When the ABS is in operation, the TCM controls the differential action limiting device in such a
way that the ABS can be controlled most appropriately in accordance with signals from the ABS
system .
" The manual range feature enables the driver to hold the transmission in a desired gear . If used
properly, it can improve driveability and ride comfort .
" The TCM has an on-board diagnosis function to facilitate servicing and a fail-safe control func-
tion to ensure minimum level of operation should an important problem occur in the system .
AT-3
GENERAL
C: CROSS SECTIONAL VIEW

1 . MPT MODELS
L -i L~l L131 141
B3H0884A
(1) Lock-up damper (9) Torque converter (17) Reduction drive (25) One-way clutch [1] Torque converter
turbine speed shaft clutch section
sensor
(2) Torque converter (10) High clutch (i8) Parking gear (26) Hydraulic control
clutch valve
(3) Input shaft (11) Reverse clutch (19) Reduction drive (27) Oil pan [2] Final reduction
gear section
(4) Oil pump drive (12) 2-4 brake (20) Rear vehicle (28) Drive pinion shaft
shaft speed sensor
(5) Torque converter (13) Front planetary (21) Rear drive shaft (29) Hypoid drive [3] Automatic
clutch case gear gear transmission
section
(6) Oil pump (14) Low clutch (22) Extension case (30) Impeller
(7) Oil pump housing (15) Rear planetary (23) Transfer clutch (31) Stator [4] Transfer section
gear
(8) Transmission (16) Low & reverse (24) Reduction driven (32) Turbine
case brake gear
AT-4
GENERAL
Automatic Transmissio n
2. VTD MODELS
[1l l21 131 141 H3H0743A
(1) Lock-up damper (10) High clutch (19) Reduction drive (28) Oil pan [1] Torque converter
gear clutch section
(2) Torque converter (11) Reverse clutch (20) Rear vehicle (29) Drive pinion shaft
clutch speed sensor
(3) Input shaft (12) 2-4 brake (21) Rear drive shaft (30) Hypoid drive [2] Final reduction
gear section
(a) Oil pump drive (13) Front planetary (22) Extension case (31) Impeller
shaft gear
(5) Torque converter (14) Low clutch (23) Center (32) Stator [3] Automatic
clutch case differential transmission
section
(6) Oil pump (15) Rear planetary (24) Multi-plate clutch (33) Turbine
gear (LSD)
(7) Oil pump housing (16) Low & reverse (25) Reduction driven [a] Transfer section
brake gear
(8) Transmission (17) Intermediate (26) One-way clutch
case shaft
(s) Torque converter (18) Parking gear (27) Hydraulic control
turbine speed valve
sensor
AT-5
ELECTROHYDRAULIC CONTROL SYSTEM
2 . Electrohydraulic Control System

A: GENERAL
1 . MPT MODELS
The electrohydraulic control system for the transmission and transfer consists of various sensors
and switches, a transmission control module (TCM) and the hydraulic controlling units including
solenoid valves. The system controls the automatic transmission operation, including gear shift-
ing, lock-up clutch operation, line pressure, automatic control pattern selection ("Base" and "Pow-
er"), and gear-shift timing . It also controls the operation of the transfer clutch . The TCM determines
vehicle operating conditions from various input signals and controls a total of eight solenoids (shift
solenoids 1 and 2, low clutch timing solenoid, 2-4 brake timing solenoid, line pressure duty sole-
noid, lock-up duty solenoid, transfer duty solenoid, and 2-4 brake duty solenoid) by sending ap-
propriate signals to them .
INPUT OUTPUT
ON-OFF
Throttle position sensor Shift solenoid 1
ON-OFF
Shift solenoid 2
Rear vehicle speed sensor
Line pressure duty solenoid

ECM Dropping resistor A

Engine speed signal
Lock-up duty solenoid
ATF temperature sensor
Transfer duty solenoid
Inhibitor switch
2-4 brake duty solenoid
ECM
Intake manifold pressure signal Dropping resistor B
TCM
FWD switch 2-4 brake timing solenoid
Low clutch timing solenoid

Battery voltage
ECM
Torque control signal 1
ABS signal ECM
Torque control signal 2
Brake switch ECM
AT diagnosis signal
- - - - - - - - - - - - - - - - - - - - - - - - - - - - --
Torque converter turbine speed sensor
FWD indicator light i Combination meter
ECM
Torque control cut signal AT OIL TEMP light
Cruise control signal Speedometer circuit

'---- -
H3H1940B
AT-6
2. VTD MODELS
The electrohydraulic control system for the transmission and transfer consists of various sensors
and switches, a transmission control module (TCM) and the hydraulic controlling units including
solenoid valves. The system controls the automatic transmission operation, including gear shift-
ing, lock-up clutch operation, line pressure, automatic control pattern selection ("Base" and "Pow-
er"), and gear-shift timing . It also controls operation of the transfer multi-plate clutch (LSD) . The
TCM determines vehicle operating conditions from various input signals and controls a total of
eight solenoids (shift solenoids 1 and 2, low clutch timing solenoid, 2-4 brake timing solenoid, line
pressure duty solenoid, lock-up duty solenoid, transfer duty solenoid, and 2-4 brake duty sole-
noid) by sending appropriate signals to them.
INPUT OUTPUT
ON-OFF
Throttle position sensor Shift solenoid 1
ON-OFF
Rear vehicle speed sensor Shift solenoid 2
Front vehicle speed sensor Line pressure duty solenoid
ECM
Engine speed signal Dropping resistor A
ATF temperature sensor Lock-up duty solenoid
Inhibitor switch Transfer duty solenoid
ECM
Intake manifold pressure signal 2-4 brake duty solenoid
Battery voltage Dropping resistor B

TCIVI
VDC communication
"ABS signal
F2-4 brake timing solenoid
"TCS signal
"VDC signal Low clutch timing solenoid
-Steering angle
-Yaw-rate and lateral G signal ECM
etc . Torque control signal 1
ECM
I Brake switch I Torque control signal 2
ECM
Torque converter turbine speed sensor AT diagnosis signal
I
Torque control cut signal AT OIL TEMP light i Combination meter
I
I
I
Cruise control signal ~ Speedometer circuit
----
B3H2076A
AT-7
B : INPUT SIGNALS
Signal name Major function
Indicates the throttle valve position . This signal is used to determine shift point, line
pressure, and lock-up engaging vehicle speed, which vary with engine load .
Front vehicle speed sensor Indicates the vehicle speed. This signal is used for control of gear shifting, lock-up
(located on transmission case) engaging, line pressure, and transfer clutch operation.
Rear vehicle speed sensor Used to control transfer clutch, and also as backup signal in case of failure of front
(located on extension case) vehicle speed sensor.
Indicates the engine speed. This signal is used for control of lock-up clutch to ensure
Engine speed signal
smooth engagement .
Used to determine gears and line pressures in each of ranges "P", "R", "N", "D", "3", "2"
Inhibitor switch and "1 ".
Indicates the ATF temperature . This signal is used for inhibition of lock-up, release of
OD and determination of ATF temperature .
Used to change the mode from AWD to FWD. Also used to adapt the vehicle to FWD
FWD switch (MPT models) tester roller. Changeover from AWD to FWD can be made by inserting a fuse into the
fuse holder.
Used when ABS is operating to optimize ABS control. In this control, transfer clutch
ABS signal torque load capacity is adjusted to eliminate the influence of engine braking and re-
duce the degree of coupling between front and rear wheels .
Indicates operation of cruise control system . It is used to expand "4th" operating
Cruise control signal
range.
Torque converter turbine speed Tells the rotation speed of the input shaft. The proportion of this speed to the vehicle
sensor speed determines whether shifting should be made or not.
Torque control cut signal Sent from engine control module (ECM) to TCM to inhibit the torque control.
Intake manifold pressure signal Used to determine line pressure of gear shifting .
Used when TCS is operating to optimize TCS control. In this control, transfer clutch
TCS signal (VTD models) torque is controlled to eliminate the influence of engine braking and reduce the degree
of coupling between front and rear wheels .
Used when VDC is operating to optimize VDC control. In this control, transfer clutch
VDC signal (VTD models) torque is controlled to eliminate the influence of engine braking and reduce the degree
of coupling between front and rear wheels .
Steering angle sensor (VTD models) Used to monitor the vehicle behavior and send signals for transfer control.
Yaw-rate and lateral G sensor Used to monitor the vehicle behavior and send signals for transfer control.
(VTD models)
If this signal is issued during downhill driving, TCM makes shift down control, causing
Brake switch the vehicle speed to be reduced.
~
AT-8
C: OUTPUT SIGNALS
Signal name Function
Each of these signals controls shift step by turning the corresponding solenoid ON/
I Shift solenoid 1, 2
OFF. Activating timing is controlled for each solenoid to reduce shift shock.
Line pressure duty solenoid Regulates the line pressure according to driving conditions .
Lock-up duty solenoid Regulates the hydraulic pressure of the lock-up clutch to operate it in three modes
(open, smooth and lock-up) .
Transfer duty solenoid Regulates the hydraulic pressure of the transfer clutch to control the driving force to
the rear drive shaft.
AT OIL TEMP light Causes the light to illuminate when ATF becomes excessively hot (exceeds a set tem-
perature level) . This light is also used for on-board diagnostics .
2-4 brake duty solenoid Regulates 2-4 brake operating pressure to reduce shifting shocks .
2-4 brake timing solenoid Switches on or off the pressure acting on 2-4 brake timing valve B to control the re-
lease timing of the 2-4 brake.
Switches on or off the pressure acting on the low clutch timing valve B to control the
Low clutch timing solenoid release timing of the low clutch .
Also switches on or off the pressure acting on the reverse inhibit valve to control the
reverse inhibit function .
Torque control signal 1 Reduces engine torque during range selection and gear change .
Torque control signal 2 Reduces engine torque du ring range selection and gear change .
AT-9
D : CONTROL ITEMS
1 . MPT MODELS
Control item Description of control
Base shift control
Upshifting and downshifting are set for each range, gear
Base pattern
and pattern according to throttle position and vehicle speed.
Power pattern
Gear shift control Gear is locked in 3rd when ABS signal enters .
ABS-in-operation control
ATF-low-temperature con- Shifting into 4th gear is prevented when ATF temperature is
trot below the preset value.
Power pattern is selected when throttle opening is changed
Power pattern control
Automatic pattern at a speed exceeding the preset value.
select control When throttle opening is changed at a speed less than the
Base pattern control
preset value, Base pattern is resumed.
Lock-up ON is set for D-range 4th gear ; ON/OFF is set for
all gears (except D-range 4th) and patterns . Lock-up control
Base lock-up control is performed according to throttle position and vehicle
Transmission Lock-up control
control speed. (Basically lock-up is OFF during gear shifting .)
Smooth control I Smooth lock-up is performed when lock-up is switched on .
Line pressure is regulated according to throttle position,
Ordinary control
vehicle speed and range signals.
Line pressure con- Line pressure is regulated when shifting to lessen shifting
Shifting control
trot shock.
Line pressure is lowered to a minimum so as to reduce en-
Starting control
gine cranking load .
Shift step control ON/OFF timing for shift solenoid is controlled .
Lock-up control When shifting, the lock-up clutch is temporarily released .
Shift timing control
When shifting, line pressure is controlled to the optimum
Line pressure control
level so as to reduce shifting shock.
Transfer clutch pressure is regulated according to the
Ordinary transfer control
throttle valve angle and vehicle speed.
1 range control Transfer clutch pressure is increased .
Immediately after detecting a slip, transfer clutch pressure is
AWD transfer controlled to tie same pressure as 1 range. (This control is
Slip control
clutch control canceled if V - 60 km/h (37 MPH), or when throttle valve is
closed fully.)
Control in turns Transfer clutch pressure is reduced after detecting a turn .
Transfer clutch pressure is adjusted to a set level immedi-
ately after reception of ABS signal .
AT-1 0
2 . VTD MODELS
Control item Description of control
Base shit control
Upshifting and downshifting are set for each range, gear
Base pattern
and pattern according to throttle position and vehicle speed.
Power pattern
Gear shift control
ABS-in-operation control Gear is locked in 3rd when ABS signal enters .
ATF low temperature con- Shifting into 4th gear is prevented when ATF temperature is
trot below the preset value.
Power pattern is selected when throttle opening is changed
Power pattern control
Automatic pattern at a speed exceeding the preset value .
select control When throttle opening is changed at a speed less than the
Base pattern control preset value, Base pattern is resumed.
Lock-up ON is set for D-range 4th gear; ON/OFF is set for
all gears (except D-range 4th) and patterns . Lock-up control
Base lock-up control is performed according to throttle position and vehicle
Transmission Lock-up control
control speed . (Basically lock-up is OFF during gear shifting .)
Smooth control Smooth lock-up is performed when lock-up is switched on .
Line pressure is regulated according to throttle position,
Ordinary control
vehicle speed and range signals.
e pressure con- is regulated when shifting to lessen shifting
Shifting control
to1 shock.
Line pressure is lowered to a minimum so as to reduce en-
Starting control
gine cranking load .
Shift step control ON/OFF timing for shift solenoid is controlled .
Lock-up control When shifting, the lock-up clutch is temporarily released .
Shift timing control
When shifting, line pressure is controlled to the optimum
Line pressure control
level so as to reduce shifting shock.
Multi-plate clutch (LSD) pressure is regulated according to
Ordinary transfer control
the torque input to the transfer and the driving condition .
When starting, the LSD pressure is adjusted proportionately
Start control
to the throttle value angle.
When the front and rear wheel speed ratio is less than the
Control in turns set value for a vehicle speed, the LSD pressure is de-
AWD mult- creased .
plate clutch
When a front or rear wheel starts slipping, the LSD pressure
control (LSD) Slip control is decreased .
The LSD pressure is adjusted to the set level immediately
after reception of ABS signal .
When the brake switch is ON and throttle valve is fully
Base brake control
closed, the LSD pressure is lowered.
1 range control The LSD pressure is increased to improve driveability.
AT-1 1
E : THROTTLE POSITION SENSOR

The throttle position sensor provides electrical signals corresponding to throttle valve positions .
The throttle valve angular position and accelerator depressing speed are detected by this throttle
position sensor.
F : REAR VEHICLE SPEED SENSOR

1 . MPT MODELS
This vehicle speed sensor (output shaft speed sensor) is externally mounted on the extension
case . It detects the rear wheel speed in terms of the peripheral speed of the transfer clutch drum
and sends sine wave signals (30 pulses per rotation) to the TCM .
B3H0915C
(1) Rear vehicle speed sensor
2. VTD MODELS
This vehicle speed sensor (output shaft speed sensor) is externally mounted on the extension
case . It detects the rear wheel speed in terms of the peripheral speed of the rear drive shaft and
sends sine wave signals (22 pulses per rotation) to the TCM .
/i\
H3H1818C
(1) Rear vehicle speed sensor
AT-1 2
G : FRONT VEHICLE SPEED SENSOR

This vehicle speed sensor (output shaft speed sensor) is externally mounted on the transmission
case . It detects the front wheel speed and sends sine wave signals (16 pulses per rotation) to the
TCM .
The TCM converts the signals into 4-pulse signals and outputs them to both the engine control
module (ECM) and the combination meter.
9 MPT MODELS
lil
1531-10915D
(1) Front vehicle speed sensor
" VTD MODELS
H3H1818D
(1) Front vehicle speed sensor
AT-13
H : ATF TEMPERATURE SENSOR

This sensor is located in the hydraulic control valve of the transmission . It detects the temperature
of ATF and outputs it as an electrical resistance signal . The output characteristics of the sensor
are shown below.
t
U
C
ro
Temperature
B3H0916B
(1) ATF temperature sensor
I : TORQUE CONVERTER TURBINE SPEED SENSOR

The torque converter turbine speed sensor (output shaft speed sensor) is externally mounted on
the transmission case .
The sensor detects the torque converter turbine speed in terms of the rotation speed of the periph-
ery of the high clutch drum coupled to the input shaft, and sends sine wave signals (32 pulses per
rotation) to the TCM . The TCM calculates the proportion of the input shaft speed to the vehicle
speed and determines whether the shifting is to be made or not .
U
QI
G
%-
---
B3H0999B
(1) Torque converter turbine speed sensor
AT-14
J : INHIBITOR SWITCH
The inhibitor switch assures safety when starting the engine . This switch is mounted on the right
side of the Lfc11551U(1 (~c15C, C1IIU 15 Uf.JCICIICU !Jy Lilt-, JCICULUI If VGI .
When the selector lever is set to P or N, the electrical circuit in the inhibitor switch is closed and
the starter circuit is completed for cranking the engine .
When the selector lever is in the R, D, 3, 2 or 1 range, the electrical circuit in the inhibitor switch
is open. Hence engine cranking is disabled . In the R range, the backup light circuit is completed
in the switch, and the backup lights come on .
In addition to the above function, the inhibitor switch incorporates a circuit for detecting the se-
lected range position and sending the range signal to the TICK
Inhibitor switch side connector
1331-1001613
Range position Pin No .

(4)-(3)
(12)-(11)
R
(10) -(9)
(4)-(1)
(12)-(11)
D (4)-(8)
3 (4)-(7)
2 (4)-(6)
AT-15
K : SHIFT SOLENOIDS 1 AND 2

These solenoids are located in the transmission hydraulic control valve . They are turned ON or
OFF according to signals from the TCM . The gear positions are changed according to the ON and
OFF condition of these solenoids .
(2)
B3H0994J
(1) Shift solenoid 2

(2) Shift solenoid 1
L: LOW CLUTCH TIMING SOLENOID

This solenoid is located in the transmission hydraulic control valve . It is turned ON or OFF accord-
ing to signals from the TCM . It then controls the low clutch timing valve B and reverse inhibitor
valve.
B3H0994K
(1) Low clutch timing solenoid
AT-1 6
M :2-4 BRAKE TIMING SOLENOID

This solenoid is located in the transmission hydraulic control valve . It is turned ON or OFF accord-
ing to signals from the TCM . It then controls the 2-4 brake timing valve B to decrease the change
gear shock .
B3H0994L
(1) 2-4 brake timing solenoid
N : LINE PRESSURE DUTY SOLENOID

This solenoid is located in the transmission hydraulic control valve . Its duty ratio is controlled by
signals from the TCM . This solenoid then controls the pressure modifier valve and accumulator
control valve A to adjust the line pressure to an optimum pressure level suitable for operating
conditions .
(1)
B3H0994M
(1) Line pressure duty solenoid
AT-1 7
O : LOCK-UP DUTY SOLENOID

This solenoid is located in the transmission hydraulic control valve . Its duty ratio is controlled by
signals from the TCM . It then controls the lock-up control valve to provide smooth engagement and
disengagement of the lock-up clutch .
(1)
B3H0994N
(1) Lock-up duty solenoid
P : 2-4 BRAKE DUTY SOLENOID

This solenoid is located in the transmission hydraulic control valve. Its duty ratio is controlled by
signals from the TCM . It modulates the 2-4 brake pressure when the 2-4 brake is operated, reduc-
ing shifting shocks.
B3H09940
(1) 2-4 brake duty solenoid
AT-18
Q : TRANSFER DUTY SOLENOID

This solenoid is located in the transfer hydraulic pressure control unit on the rear end of transmis-
sion case . I
n rn+ i n
duty ratio
in
V IJ controll
by frnm
ned ~y signals from
fh
i i th
o
e -r~nn
TCM . it th
t hivi
eni contro
ls the
wa .v t ransfer clutch/
control valve to control the pressure applied to the transfer clutch .
" MPT MODELS
(1)
B3H0995C
* VTD MODELS
(1)
H3H1929C
AT-19
TRANSMISSION CONTROL MODULE (TCM)
3. Transmission Control Module (TCM)

The TCM receives various sensor signals and determines the running conditions of the vehicle .
it then sends control signals to each solenoid accord ing to the preset gearshift characteristic data,
lock-up operation data, and transfer clutch torque data (duty ratios) / multi-plate clutch (LSD)
torque data (duty ratios) .
A: CONTROL SYSTEM
1 . MPT MODELS
Control item Input signal
Shift control Ordinary shift control Throttle position sensor
Engine speed
Inhibitor switch
ABS-in-operation control ABS signal
Brake switch
Hydraulic oil temperature control ATF temperature sensor
Reverse inhibiting control Throttle position sensor
Inhibitor switch
Shift pattern (Base/Power) select control Throttle position sensor
Inhibitor switch
Grade control Throttle position sensor
Brake switch
Inhibitor switch
Engine speed
Intake manifold pressure
Lock-up control Ordinary lock-up control Throttle position sensor
Engine speed
Inhibitor switch
Smooth control Throttle position sensor
AT20
Oil pressure control Ordinary pressure control Throttle position sensor

Engine speed
Inhibitor switch
Shifting control Throttle position sensor
Engine speed
Inhibitor switch
Starting control Engine speed
Inhibitor switch
Learning control Shift solenoid A
Shift solenoid B
AWD transfer clutch control Ordinary transfer control Throttle position sensor
Inhibitor switch
FWD switch
1 range control Throttle position sensor
Inhibitor switch
Slip detection control Throttle position sensor
Steering control Throttle position sensor
Brake switch
AT21
2. VTD MODELS
Shift control Ordinary shift control Throttle position sensor
Engine speed
Inhibitor switch
Brake switch
Reverse inhibiting control Throttle position sensor
Inhibitor switch
Shift pattern (Base/Power) select control Throttle position sensor
Inhibitor switch
Grade control Throttle position sensor
Brake switch
Inhibitor switch
Engine speed
Intake manifold pressure
Lock-up control Ordinary lock-up control Throttle position sensor
Engine speed
Inhibitor switch
Smooth control Throttle position sensor
Oil pressure control Ordinary pressure control Throttle position sensor
Engine speed
Inhibitor switch
Shifting control Throttle position sensor
Engine speed
Inhibitor switch
Starting control Engine speed
Inhibitor switch
Learning control Shift solenoid A
Shift solenoid B
AT22

AWD multi-plate clutch (LSD) Ordinary transfer control Throttle position sensor
control Rear vehicle speed sensor
Inhibitor switch
Steering angle sensor
Yaw-rate and lateral G sensor
1 range control Throttle position sensor
Inhibitor switch
Slip detection control Throttle position sensor
Steering control Throttle position sensor
Brake switch
Base brake operating control Throttle position sensor
Brake switch
TCS-in-operation control TCS signal (VDC communication signal)
VDC-in-operation control VDC signal (VDC communication signal)
AT-23
B : SYSTEM DIAGRAM
ABS signal -------------- . ------------- Speedometer circuit
FWD switch (MPT models) ------------- ----------

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GENERAL DESCRIPTION

1 . General Description 55,0.0,

1 . DRIVE PLATE AND DRIVEN PLATE S570007E4901

2. AUTOMATIC TRANSMISSION FLUID

1 . TORQUE CONVERTER CLUTCH AND

l1) (2) (4)

2. OIL PUMP 5510001A0502

(1) Oil pump rotor (12) O-ring

3. TRANSMISSION CASE AND CONTROL

(1) Oil level gauge (24) Magnet (47) Gasket

4. CONTROL VALVE AND HARNESS

(1) Stay (12) Accumulator spring (24) ATF temperature sensor

5. HIGH CLUTCH AND REVERSE CLUTCH

6. PLANETARY GEAR AND 2-4 BRAKE

(1) Thrust needle bearing (10) Washer (19) Snap ring

(1) Retaining plate (12) Needle bearing (23) Snap ring

8. REDUCTION GEAR WITHOUT VTD

(1) Seal ring (7) Ball bearing (13) Ball bearing

9. REDUCTION GEAR WITH VTD 5510001A0509

10. DIFFERENTIAL GEAR 5510007A0510

(1) Crown gear (8) O-ring (15) Differential bevel gear

11 . TRANSFER AND EXTENSION CASE

12. TRANSFER AND EXTENSION CASE

C : PRECAUTION 5570001F59 of washing rubber parts, perform the job quickly

D : PREPARATION TOOL 55,~,A,~

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499267300 STOPPER PIN Used for installing inhibitor switch .

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

2. GENERAL PURPOSE TOOLS 55,~,A,~oz

E : PROCEDURE S570001E45 Therefore, in this section, to conduct the particular

For removal and installation procedures of auto-

(A) Transmission harness

(A) Air breather hose (Transmission case)

(A) Air breather hose (Transmission case)

4. Oil Charger Pipe 5510203

(A) Oil level gauge

(A) Oil level gauge

5 . Oil Cooler Pipes 55,020.9 Except 3.0 L model

3.0 L model (A) Outlet pipe

4) Install oil charger pipe with O-ring . <Ref . to

(A) Outlet pipe

1) Insert oil cooler outlet ball and spring .

Torque Converter Turbine

1) Extract the torque converter clutch assembly .

2) Disconnect transmission harness connector

(A) Transmission harness

1) Install and route the transmission harness.

3) Apply proper amount of liquid gasket to the A

(A) Front vehicle speed sensor

7) Install the rear vehicle speed sensor.

4) Install the oil pan to the transmission case

5) Turn over the transmission case to its original

on 2.0 L TURBO, 2.5 L and 3.0 L models; 2.7

3) Extract the oil pump shaft from torque converter

1) Install the clip to torque converter clutch . C : INSPECTION 55,

8. Transmission Cover 55,~~ NOTE :

2) Measure the distance "E" from the transmission

Extension Case 55,0587 3) Tighten bolts to secure the case.

4) Install the rear vehicle speed sensor .

10. Transfer Clutch s5,o588 B : INSTALLATION 55,058